How AODD Pumps Can Satisfy All Demands in Mining Operations

Mining is certainly one of the world’s oldest industries, tracing its roots back to these prehistoric days when someone grabbed a digging instrument and commenced burrowing into the bottom. In the many millennia since, mining has grown into one of the world’s most essential and widespread industrial enterprises, with operations spread across the globe whereas tasked with recovering an nearly inexhaustible listing of valuable commodities.
In reality, in accordance with the World Mining Congress’s World Mining Data 2020 report, 17.7 billion metric tons of mined products have been recovered in 2018, up from 11.three billion metric tons in 2000 and nearly double the 9.6 billion metric tons in 1985. Asian countries accounted for fifty eight % of the 2018 manufacturing, with North America second at 15.1 percent, followed by Europe (8 percent), Oceania (6.eight percent), Latin America (6.3 percent), and Africa (5.three percent). Individually, China (23 percent), the United States (12.1 percent), Russia (9.2 percent), and Australia (7.2 percent) were probably the most prolific producers, with their total fifty one.1 percent of production greater than the relaxation of the world combined.
This implies that the mining industry is a robust one, with solid development anticipated to proceed in the coming years in lots of areas of the world. It also signifies that mining operations will proceed to depend on pumping technologies that provide sturdy, dependable, and safe service in numerous critical liquid-handling operations. This white paper will illustrate why optimistic displacement air-operated double-diaphragm (AODD) pumps could be the only option for lots of of those functions.
THE CHALLENGE
While mining might seem like nothing greater than a rough-and-tumble operation—holes are dug by heavy machinery or with explosives, opening the hidden ode to access from above—there are, in fact, many complex and generally delicate operations that have to be performed correctly if the mining operation is to perform at its highest level of efficiency.
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 that is ready to be maintained and repaired in order that downtime is lessened. The pumps should even be mild sufficient to be manually moved from location to location throughout the mine itself.
For many years, a well-liked choice for use in these situations was centrifugal pumps. While centrifugal pumps are able to create the high move rates which are required, they’ve a variety of operational “pain points” that hamper their use in mining purposes: an incapability to self-prime or run dry; special seals wanted to prevent leaks; special linings needed to handle solids; excessive motor speeds of up to 1,800 rpm; and comparatively high maintenance requirements and costs, especially when charged with transferring solid-heavy liquids.
Another popular selection has been the progressive cavity pump, but, like centrifugal pumps, they have a number of operational shortcomings. These embrace an incapability to persistently deal with liquids with excessive ranges of abrasives, which leads to elevated upkeep costs, wear on expensive stators and rotors that can ultimately must be changed, and overall larger purchase, operating, and repair/replacement costs.
Here are a few of the specific liquid-transfer operations that take place in a mine and the ways in which some pump applied sciences can fall brief in satisfying them:
Mine dewatering: Removing extra produced water from the mine is a important 24/7/365 operation and the water that is recovered is usually filled with particulates that can be as large as zero.12 to zero.16 inches in size. If used in this software, centrifugal pumps require special supplies of construction, which can be value prohibitive, to guard against impeller wear attributable to the abrasive particles. Centrifugal pumps are additionally not dry-run capable, which adversely affects their level of performance on this application.
General service: For frequent liquid-handling functions, you want an easy-to-operate pump that reliably can run dry, strip strains, operate at low speeds while still delivering high move charges, and be simple to maintain and restore. 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 typically demands a necessity to make use of particular mechanical seals, which may result in exorbitant maintenance, restore, and substitute prices.
Press filter: Press filters are used to wash the liquids which are produced in the mines and, again, centrifugal pumps can fall short in this utility as a outcome of the solid-laden liquid can harm the pump’s internals except special, more expensive supplies of development or linings are used. Also, the character of press-filter operation creates a strong discharge-pressure variation that can drive the centrifugal pump to operate away from its finest efficiency level (BEP), resulting in high vibration and radial hundreds that can result in shortened service life. A resolution to that is the incorporation of variable frequency drives (VFDs) and controllers, but these are costly and might negatively have an effect on the cost-effectiveness of the operation.
Product switch: This comes in all types in a mining operation, from loading and unloading from transport vans with new and used oil for the heavy machinery, recent and fouled water, and any chemical compounds which might be required. In every instance, there’s the danger that the pump will be pressured to run dry as the truck or storage vessel is emptied, while discharge-pressure variation can also generate excessive vibration and radial masses. As beforehand illustrated, centrifugal pumps can’t run dry, in order that they want protection from this situation or the addition of special seals. However, all of those upgrades still can not totally defend towards a catastrophic failure.
THE SOLUTION
While centrifugal pumps—despite their popularity—have proven to not be the best resolution in lots of liquid-handling purposes in mining, one pump technology that has proven to be an optimum alternative is AODD—in terms of maximizing reliability, cost-effectiveness, ease of operation and upkeep, and safety for mining personnel and the setting.
AODD pumps are capable of carry out effectively in mining applications as a outcome of their methodology of operation allows them to simply handle variable circulate charges and pressures, while being dry-run and line-stripping succesful, and nimble sufficient to transfer liquids that are shear-sensitive or high-viscosity, as nicely as slurries laden with rocks, pebbles, and other particulates.
The easy design of the AODD pump features few moving elements and comparably lower speeds than different pump applied sciences, which improves reliability and simplifies maintenance, while the pump’s seal-less building results in fewer leaks, which is a crucial consideration when handling the numerous hard-to-seal, corrosive, or hazardous liquids which may be prevalent in a mining operation. AODD pumps can be found in each metal (most commonly aluminum, ductile iron and forged iron) and plastic (polypropylene and PVDF) housing constructions, while a extensive array of elastomers can be used within the diaphragms, which eliminates many chemical-compatibility issues.
A extensive variety of AODD pump configurations present operational flexibility that may additionally result in optimized performance at many ranges. The capacity to characteristic AODD pumps in a broad range of functions, from fundamental basic use to delicate chemical-handling processes, permits operators to extra cost-effectively outfit their mines. AODD pumps can be less expensive to operate, particularly these fashions that are 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 circumstances found in the world’s mines, which reduces breakdown incidents along with corresponding downtime and repair prices.
Specifically, Wilden, whose founder, Jim Wilden, conceived the AODD pumping principle sixty-five years in the past, has been dedicated to creating technologies that meet the needs of mining operations. Today, Wilden provides three AODD pump models that are built to excel in mining applications, obtainable in ductile iron, cast iron, aluminum, polypropylene and Kynar supplies of development:
Brahma® Series: The Brahma pumps, which function a bolted configuration, have been constructed to be used in functions that require the handling of liquids featuring giant solids. The Brahma pumps have a unique top-inlet/bottom-discharge move orientation and flap valves that allow the passage of enormous solids with no threat that damage will happen on account of product entrapment or the settling of solids inside the pump’s inside flow 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 cut back air consumption by up to 60 p.c. 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 4 Brahma pumps is 166 to 258 gallons per minute at pressures as a lot as one hundred twenty five psi with solids-handling functionality ranging from 2 to three inches.
Stallion® Series: The Stallion pumps feature a clamped design with carrying handles for light-weight portability. Their design options massive inner clearances and flow-through paths for simple passage of huge solids with no likelihood for clogging. An altered ball/seat check-valve meeting additional allows solids passage, while a polyurethane display screen base on the inlet increases the pump’s sturdiness. The PS4, PS8, and PS15 (1.5-, 2-, and 3-inch) models are powered by a Pro-Flo SHIFT ADS, with the T4, T8, and T15 (1.5-, 2-, and 3-inch) pumps that includes the Turbo-Flo ADS, Wilden’s most sturdy ADS design for the toughest environments. Flow rates amongst the six fashions vary from fifty seven gallons per minute to 232 gallons per minute at working pressures as a lot as a hundred twenty five psi. Solids sizes that could be dealt with vary from half of to 1 inch.
Pro-Flo SHIFT Series: Pro-Flo SHIFT pumps characteristic clamped or bolted configuration. Their design options completely different chamber materials, together with metal and plastics, even Kynar, which is capable of handling high levels of abrasive supplies. The Pro-Flo SHIFT is also probably the most environment friendly AODD pump out there, capable of reducing as much as 60 % air consumption. This makes it the finest choice for dealing with corrosive and abrasive products in mining processes. The pumps have a product range 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 able to be outfitted with a extensive selection of diaphragm styles—including the newer Chem-Fuse, EZ-Install, and Reduced-Stroke models—in a varying array of materials, similar to Wil-Flex™ (Santoprene®), Geolast®, Polyurethane, Buna-N®, EPDM, Neoprene, FKM, and PTFE. This diaphragm range provides users the widest choice of diaphragms in the marketplace, all of which are able to providing prolonged imply time between failure (MTBF) for optimized uptime with lowered upkeep, restore, and alternative costs.
All of those capabilities make AODD pumps the best choice for the aforementioned widespread liquid-handling functions in mining: dewatering, common service, corrosive-handling, filter press, and daily product switch.
CONCLUSION
In abstract, Wilden AODD pumps are the most suitable choice for mining functions as a end result of they provide appreciable operational benefits, like comparable low-speed operation, dry-run, line-stripping, self-priming, and deadhead functionality, along with increased operational safety and a reduction in maintenance/repair costs that can be incurred by pumps that are not designed to handle abrasive/corrosive or solid-laden liquids.
Wilden AODD pumps additionally outperform other AODD applied sciences in other important ways: easy design with the bottom number of elements for faster, less complicated, and safer repairs and the lowest variety of spare elements to inventory; latest improvements in supplies of building that increase the pump’s MTBF; and improved effectivity by way of the use of the Pro-Flo SHIFT ADS, which finally results in quicker product transfer with decrease air consumption. หลักการทำงานของเกจ์วัดแก๊ส continues to innovate by way of the event of the next-generation Chem-Fuse and EZ-Install diaphragms, each of which increase service life and safety while not compromising the dealing with of difficult liquids.
FOR MORE INFORMATION
Fernando Meneses is the regional supervisor North Latin America for Wilden, a quantity one producer of air-operated double-diaphragm (AODD) pumps. He can be reached at fernando.meneses@psgdover.com. Wilden is a product model of PSG®, a Dover company. PSG is comprised of several leading pump companies, including Abaque®, All-Flo™, Almatec®, Blackmer®, Ebsray, em-tec®, Griswold®, Hydro™, Mouvex®, Neptune®, Quantex™, Quattroflow®, RedScrew™, and Wilden®. For extra info, visit www.wildenpump.com or www.psgdover.com.
Share

Leave a Comment