How AODD Pumps Can Satisfy All Demands in Mining Operations

Mining is amongst the world’s oldest industries, tracing its roots back to those prehistoric days when somebody grabbed a digging instrument and began burrowing into the ground. In the various millennia since, mining has grown into one of the world’s most necessary and widespread business enterprises, with operations spread across the globe while tasked with recovering an almost inexhaustible listing of useful commodities.
In fact, according to the World Mining Congress’s World Mining Data 2020 report, 17.7 billion metric tons of mined merchandise were recovered in 2018, up from eleven.3 billion metric tons in 2000 and practically double the 9.6 billion metric tons in 1985. Asian international locations accounted for 58 % of the 2018 manufacturing, with North America second at 15.1 %, adopted by Europe (8 percent), Oceania (6.eight percent), Latin America (6.3 percent), and Africa (5.3 percent). Individually, China (23 percent), the United States (12.1 percent), Russia (9.2 percent), and Australia (7.2 percent) were essentially the most prolific producers, with their whole fifty one.1 percent of manufacturing more than the remainder of the world combined.
This implies that the mining trade is a powerful one, with solid growth expected to proceed in the coming years in plenty of regions of the world. It also signifies that mining operations will proceed to rely on pumping technologies that offer sturdy, dependable, and secure service in a variety of crucial liquid-handling operations. This white paper will illustrate why optimistic displacement air-operated double-diaphragm (AODD) pumps can be the greatest choice for many of these purposes.
THE CHALLENGE
While mining might look like nothing more than a rough-and-tumble operation—holes are dug by heavy equipment or with explosives, opening the hidden ode to access from above—there are, actually, many complicated and typically delicate operations that must be performed properly if the mining operation is to carry out at its highest degree of effectivity.
From a macro standpoint, this requires a pumping technology that can operate reliably in harsh and distant locations, even when submerged, or when tasked with dealing with particulate-laden liquids or toxic/corrosive products, and also one which is in a position to be maintained and repaired just so downtime is lessened. The pumps must even be light sufficient to be manually moved from location to location inside the mine itself.
For many years, a popular selection to be used in these conditions was centrifugal pumps. While centrifugal pumps are able to create the high flow charges which are required, they’ve numerous operational “pain points” that hamper their use in mining purposes: an lack of ability to self-prime or run dry; special seals wanted to stop leaks; particular linings wanted to deal with solids; excessive motor speeds of as much as 1,800 rpm; and comparatively excessive upkeep requirements and costs, especially when charged with transferring solid-heavy liquids.
Another popular choice has been the progressive cavity pump, however, like centrifugal pumps, they have a selection of operational shortcomings. These embody an lack of ability to persistently handle liquids with high ranges of abrasives, which results in elevated maintenance prices, put on on costly stators and rotors that can eventually need to be changed, and general greater purchase, working, and repair/replacement costs.
Here are some of the specific liquid-transfer operations that happen in a mine and the ways that some pump applied sciences can fall brief in satisfying them:
Mine dewatering: Removing excess produced water from the mine is a important 24/7/365 operation and the water that’s recovered is commonly stuffed with particulates that may be as massive as zero.12 to zero.16 inches in measurement. If used on this application, centrifugal pumps require special supplies of building, which could be value prohibitive, to protect towards impeller put on brought on by the abrasive particles. Centrifugal pumps are additionally not dry-run succesful, which adversely affects their level of efficiency in this software.
General service: For frequent liquid-handling applications, you need an easy-to-operate pump that reliably can run dry, strip lines, operate at low speeds whereas nonetheless delivering high circulate charges, and be simple to hold up and repair. Centrifugal pumps simply don’t possess these capabilities.
Corrosive liquids: Much like solid-laden liquids, corrosive ones can wreak havoc on the wetted elements of centrifugal and progressive cavity pumps. This usually demands a necessity to use special mechanical seals, which can result in exorbitant maintenance, restore, and replacement costs.
Press filter: Press filters are used to clean the liquids which are produced within the mines and, again, centrifugal pumps can fall quick on this software as a end result of the solid-laden liquid can harm the pump’s internals until special, dearer materials of development or linings are used. Also, the nature of press-filter operation creates a robust discharge-pressure variation that can drive the centrifugal pump to function away from its best effectivity point (BEP), resulting in high vibration and radial hundreds that may result in shortened service life. A solution to that is the incorporation of variable frequency drives (VFDs) and controllers, but these are expensive and might negatively affect the cost-effectiveness of the operation.
Product transfer: This is out there in all forms in a mining operation, from loading and unloading from transport vans with new and used oil for the heavy equipment, fresh and fouled water, and any chemical compounds which are required. In each instance, there’s the chance that the pump might be pressured to run dry because the truck or storage vessel is emptied, while discharge-pressure variation can also generate high vibration and radial loads. As previously illustrated, centrifugal pumps can’t run dry, so they need protection from this condition or the addition of special seals. However, เกจวัดแรงดันpsi of those upgrades nonetheless can not completely protect in opposition to a catastrophic failure.
THE SOLUTION
While centrifugal pumps—despite their popularity—have confirmed to not be the simplest answer in many liquid-handling functions in mining, one pump expertise that has proven to be an optimum selection is AODD—in phrases of maximizing reliability, cost-effectiveness, ease of operation and upkeep, and security for mining personnel and the environment.
AODD pumps are in a place to carry out successfully in mining functions because their methodology of operation allows them to simply deal with variable circulate charges and pressures, while being dry-run and line-stripping capable, and nimble sufficient to transfer liquids which may be shear-sensitive or high-viscosity, as properly as slurries laden with rocks, pebbles, and different particulates.
The simple design of the AODD pump options few transferring components and comparably lower speeds than other pump applied sciences, which improves reliability and simplifies maintenance, whereas the pump’s seal-less building leads to fewer leaks, which is a critical consideration when handling the many hard-to-seal, corrosive, or hazardous liquids that are prevalent in a mining operation. AODD pumps can be found in both steel (most generally aluminum, ductile iron and forged iron) and plastic (polypropylene and PVDF) housing constructions, whereas a wide array of elastomers can be utilized within the diaphragms, which eliminates many chemical-compatibility concerns.
A wide variety of AODD pump configurations present operational flexibility that can also result in optimized efficiency at many levels. The capacity to function AODD pumps in a wide range of purposes, from primary general use to delicate chemical-handling processes, permits operators to more cost-effectively outfit their mines. AODD pumps can additionally be less expensive to operate, especially those models which might be outfitted with a next-generation mechanically actuated air distribution system (ADS). At their most basic, AODD pumps excel within the typical rugged and harsh operating conditions found within the world’s mines, which reduces breakdown incidents along with corresponding downtime and repair costs.
Specifically, Wilden, whose founder, Jim Wilden, conceived the AODD pumping precept sixty-five years ago, has been devoted to growing applied sciences that meet the wants of mining operations. Today, Wilden presents three AODD pump models which would possibly be built to excel in mining purposes, out there in ductile iron, cast iron, aluminum, polypropylene and Kynar supplies of construction:
Brahma® Series: The Brahma pumps, which function a bolted configuration, have been constructed to be used in applications that require the dealing with of liquids featuring large solids. The Brahma pumps have a novel top-inlet/bottom-discharge flow orientation and flap valves that enable the passage of large solids with no risk that injury will occur because of product entrapment or the settling of solids inside the pump’s inside move paths. Brahma pumps can be found in two models—PS810 (2-inch) and PS1510 (3-inch)—that are outfitted with the revolutionary Pro-Flo® SHIFT ADS, which has been designed to minimize back air consumption by up to 60 %. The T810 and T1510 models are powered by the Turbo-Flo™ ADS, the industry’s first air motor for AODD pumps. The flow-rate vary for the four Brahma pumps is 166 to 258 gallons per minute at pressures as much as a hundred twenty five psi with solids-handling capability starting from 2 to 3 inches.
Stallion® Series: The Stallion pumps characteristic a clamped design with carrying handles for light-weight portability. Their design options giant inner clearances and flow-through paths for simple passage of large solids with no probability for clogging. An altered ball/seat check-valve meeting additional enables solids passage, whereas a polyurethane display screen base at the inlet increases the pump’s sturdiness. The PS4, PS8, and PS15 (1.5-, 2-, and 3-inch) fashions are powered by a Pro-Flo SHIFT ADS, with the T4, T8, and T15 (1.5-, 2-, and 3-inch) pumps featuring the Turbo-Flo ADS, Wilden’s most robust ADS design for the hardest environments. Flow rates amongst the six models vary from fifty seven gallons per minute to 232 gallons per minute at working pressures up to one hundred twenty five psi. Solids sizes that can be handled vary from half to 1 inch.
Pro-Flo SHIFT Series: Pro-Flo SHIFT pumps feature clamped or bolted configuration. Their design options different chamber supplies, including metallic and plastics, even Kynar, which is able to dealing with excessive ranges of abrasive supplies. The Pro-Flo SHIFT can be essentially the most efficient AODD pump in the market, able to decreasing up to 60 percent air consumption. This makes it the greatest choice for dealing with corrosive and abrasive products in mining processes. The pumps have a product vary that goes from 1.5 to three inches and flows from 2 to 271 gallons per minute.
All of the Brahma, Stallion, and Pro-Flo SHIFT pumps are capable of be outfitted with a extensive array of diaphragm styles—including the newer Chem-Fuse, EZ-Install, and Reduced-Stroke models—in a varying array of materials, such as Wil-Flex™ (Santoprene®), Geolast®, Polyurethane, Buna-N®, EPDM, Neoprene, FKM, and PTFE. This diaphragm vary gives users the widest choice of diaphragms on the market, all of that are capable of offering prolonged imply time between failure (MTBF) for optimized uptime with lowered upkeep, repair, and replacement costs.
All of those capabilities make AODD pumps the perfect selection for the aforementioned widespread liquid-handling purposes in mining: dewatering, common service, corrosive-handling, filter press, and every day product transfer.
CONCLUSION
In summary, Wilden AODD pumps are the most fitted choice for mining functions as a end result of they provide considerable operational advantages, like comparable low-speed operation, dry-run, line-stripping, self-priming, and deadhead capability, along with increased operational security and a reduction in maintenance/repair prices that can be incurred by pumps that are not designed to handle abrasive/corrosive or solid-laden liquids.
Wilden AODD pumps additionally outperform different AODD applied sciences in other significant ways: simple design with the lowest variety of elements for faster, less complicated, and safer repairs and the bottom number of spare components to stock; recent improvements in supplies of building that enhance the pump’s MTBF; and improved effectivity through using the Pro-Flo SHIFT ADS, which in the end ends in sooner product transfer with decrease air consumption. Wilden also continues to innovate through the event of the next-generation Chem-Fuse and EZ-Install diaphragms, each of which improve service life and safety whereas not compromising the dealing with of challenging liquids.
FOR MORE INFORMATION
Fernando Meneses is the regional supervisor North Latin America for Wilden, a leading producer of air-operated double-diaphragm (AODD) pumps. He may be reached at fernando.meneses@psgdover.com. Wilden is a product brand of PSG®, a Dover company. PSG is comprised of a quantity of main pump firms, together with Abaque®, All-Flo™, Almatec®, Blackmer®, Ebsray, em-tec®, Griswold®, Hydro™, Mouvex®, Neptune®, Quantex™, Quattroflow®, RedScrew™, and Wilden®. For extra data, go to www.wildenpump.com or www.psgdover.com.
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