How AODD Pumps Can Satisfy All Demands in Mining Operations

Mining is probably certainly one of the world’s oldest industries, tracing its roots again to these prehistoric days when somebody grabbed a digging instrument and started burrowing into the ground. In the numerous millennia since, mining has grown into one of the world’s most essential and widespread commercial enterprises, with operations unfold across the globe whereas tasked with recovering an nearly inexhaustible record of useful 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 eleven.three billion metric tons in 2000 and nearly double the 9.6 billion metric tons in 1985. Asian countries accounted for 58 % of the 2018 manufacturing, with North America second at 15.1 p.c, adopted by Europe (8 percent), Oceania (6.8 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) had been the most prolific producers, with their whole 51.1 percent of production greater than the remainder of the world combined.
This signifies that the mining industry is a robust one, with strong development anticipated to continue within 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, reliable, and secure service in numerous important liquid-handling operations. This white paper will illustrate why optimistic displacement air-operated double-diaphragm (AODD) pumps could be the solely option for lots of of these applications.
THE CHALLENGE
While mining might appear to be 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 advanced and sometimes delicate operations that must be performed properly if the mining operation is to perform at its highest level of efficiency.
From a macro standpoint, this requires a pumping know-how that can function reliably in harsh and remote locations, even when submerged, or when tasked with handling particulate-laden liquids or toxic/corrosive merchandise, and likewise one which is ready 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 well-liked alternative for use in these conditions was centrifugal pumps. While centrifugal pumps are able to create the excessive circulate rates which might be required, they have a variety of operational “pain points” that hamper their use in mining functions: an lack of ability to self-prime or run dry; special seals wanted to forestall leaks; particular linings wanted to handle solids; excessive motor speeds of as a lot as 1,800 rpm; and comparatively excessive maintenance requirements and prices, particularly when charged with transferring solid-heavy liquids.
Another in style selection has been the progressive cavity pump, however, like centrifugal pumps, they’ve numerous operational shortcomings. These embrace an lack of ability to persistently deal with liquids with excessive levels of abrasives, which outcomes in increased maintenance prices, put on on expensive stators and rotors that can ultimately must be replaced, and overall greater purchase, working, and repair/replacement prices.
Here are a few of the particular liquid-transfer operations that happen in a mine and the ways in which some pump technologies can fall quick 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 stuffed with particulates that can be as large as 0.12 to zero.16 inches in measurement. If used in this software, centrifugal pumps require particular supplies of building, which could be value prohibitive, to guard in opposition to impeller put on caused by the abrasive particles. Centrifugal pumps are additionally not dry-run succesful, which adversely affects their degree of performance on this utility.
General service: For frequent liquid-handling purposes, you need an easy-to-operate pump that reliably can run dry, strip strains, operate at low speeds whereas nonetheless delivering high flow charges, and be simple to hold up and restore. Centrifugal pumps merely don’t possess these capabilities.
Corrosive liquids: Much like solid-laden liquids, corrosive ones can wreak havoc on the wetted parts of centrifugal and progressive cavity pumps. This usually demands a need to use special mechanical seals, which can result in exorbitant upkeep, repair, and replacement prices.
Press filter: Press filters are used to scrub the liquids which might be produced in the mines and, again, centrifugal pumps can fall brief in this software as a result of the solid-laden liquid can harm the pump’s internals except particular, costlier supplies of development or linings are used. Also, the character of press-filter operation creates a robust discharge-pressure variation that can force the centrifugal pump to operate away from its best efficiency level (BEP), resulting in high vibration and radial masses that may lead to shortened service life. A answer to that is the incorporation of variable frequency drives (VFDs) and controllers, however these are expensive and may negatively affect the cost-effectiveness of the operation.
Product transfer: This is available in all varieties in a mining operation, from loading and unloading from transport vehicles with new and used oil for the heavy machinery, recent and fouled water, and any chemicals that are required. In every instance, there is the risk that the pump shall be forced to run dry as the truck or storage vessel is emptied, while discharge-pressure variation can also generate high vibration and radial loads. As beforehand illustrated, centrifugal pumps can not run dry, in order that they want protection from this situation or the addition of particular seals. However, เกจแรงดัน of those upgrades still can’t completely shield in opposition to a catastrophic failure.
THE SOLUTION
While centrifugal pumps—despite their popularity—have proven to not be the most effective answer in many liquid-handling purposes in mining, one pump know-how that has proven to be an optimum choice is AODD—in phrases of maximizing reliability, cost-effectiveness, ease of operation and maintenance, and security for mining personnel and the setting.
AODD pumps are capable of carry out successfully in mining functions because their technique of operation permits them to simply deal with variable circulate rates and pressures, while being dry-run and line-stripping capable, and nimble enough to transfer liquids which are shear-sensitive or high-viscosity, as properly as slurries laden with rocks, pebbles, and other particulates.
The easy design of the AODD pump features few shifting components and comparably lower speeds than other pump technologies, which improves reliability and simplifies upkeep, while the pump’s seal-less development results in fewer leaks, which is a crucial consideration when handling the many hard-to-seal, corrosive, or hazardous liquids which might be prevalent in a mining operation. AODD pumps can be found in both metal (most generally aluminum, ductile iron and solid iron) and plastic (polypropylene and PVDF) housing constructions, whereas a broad selection of elastomers can be used within the diaphragms, which eliminates many chemical-compatibility concerns.
A extensive number of AODD pump configurations present operational flexibility that may additionally end in optimized efficiency at many levels. The ability to feature AODD pumps in a broad range of purposes, from fundamental common use to delicate chemical-handling processes, allows operators to extra cost-effectively outfit their mines. AODD pumps can be less expensive to function, especially these fashions that are outfitted with a next-generation mechanically actuated air distribution system (ADS). At their most simple, AODD pumps excel in the typical rugged and harsh operating circumstances discovered within the world’s mines, which reduces breakdown incidents along with corresponding downtime and restore costs.
Specifically, Wilden, whose founder, Jim Wilden, conceived the AODD pumping precept sixty-five years ago, has been devoted to developing technologies that meet the wants of mining operations. Today, Wilden presents three AODD pump models which are constructed to excel in mining purposes, available in ductile iron, cast iron, aluminum, polypropylene and Kynar supplies of building:
Brahma® Series: The Brahma pumps, which characteristic a bolted configuration, have been built for use in functions that require the dealing with of liquids featuring massive solids. The Brahma pumps have a singular top-inlet/bottom-discharge move orientation and flap valves that allow the passage of enormous solids with no danger that injury will happen because of product entrapment or the settling of solids throughout the pump’s inner flow paths. Brahma pumps are available 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 percent. 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 up to one hundred twenty five psi with solids-handling capability ranging from 2 to three inches.
Stallion® Series: The Stallion pumps feature a clamped design with carrying handles for lightweight portability. Their design options large internal clearances and flow-through paths for straightforward passage of enormous solids with no probability for clogging. An altered ball/seat check-valve meeting further permits solids passage, whereas a polyurethane display screen base at the inlet will increase the pump’s durability. 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 featuring the Turbo-Flo ADS, Wilden’s most robust ADS design for the toughest environments. Flow charges amongst the six fashions vary from 57 gallons per minute to 232 gallons per minute at working pressures as a lot as one hundred twenty five psi. Solids sizes that might be handled range from half to 1 inch.
Pro-Flo SHIFT Series: Pro-Flo SHIFT pumps function clamped or bolted configuration. Their design options totally different chamber supplies, together with metal and plastics, even Kynar, which is able to handling excessive levels of abrasive materials. The Pro-Flo SHIFT can also be probably the most efficient AODD pump out there, able to lowering as a lot as 60 % air consumption. This makes it the best choice for dealing with corrosive and abrasive products in mining processes. The pumps have a product vary that goes from 1.5 to 3 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 huge selection of diaphragm styles—including the newer Chem-Fuse, EZ-Install, and Reduced-Stroke models—in a various array of materials, corresponding to Wil-Flex™ (Santoprene®), Geolast®, Polyurethane, Buna-N®, EPDM, Neoprene, FKM, and PTFE. This diaphragm range provides users the widest selection of diaphragms in the marketplace, all of that are able to providing prolonged mean time between failure (MTBF) for optimized uptime with reduced maintenance, restore, and replacement prices.
All of these capabilities make AODD pumps the ideal selection for the aforementioned frequent liquid-handling functions in mining: dewatering, common service, corrosive-handling, filter press, and day by day product switch.
CONCLUSION
In abstract, Wilden AODD pumps are the finest choice for mining purposes because they provide considerable operational advantages, like comparable low-speed operation, dry-run, line-stripping, self-priming, and deadhead capability, together with increased operational safety and a reduction in maintenance/repair prices that might be incurred by pumps that aren’t designed to deal with abrasive/corrosive or solid-laden liquids.
Wilden AODD pumps also outperform different AODD technologies in different vital methods: simple design with the bottom variety of components for faster, simpler, and safer repairs and the bottom variety of spare elements to inventory; latest enhancements in supplies of construction that improve the pump’s MTBF; and improved efficiency through using the Pro-Flo SHIFT ADS, which in the end leads to faster product switch with decrease air consumption. Wilden also continues to innovate through the development of the next-generation Chem-Fuse and EZ-Install diaphragms, each of which increase service life and safety whereas not compromising the handling 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 model of PSG®, a Dover company. PSG is comprised of a number of main pump corporations, together with Abaque®, All-Flo™, Almatec®, Blackmer®, Ebsray, em-tec®, Griswold®, Hydro™, Mouvex®, Neptune®, Quantex™, Quattroflow®, RedScrew™, and Wilden®. For extra data, visit www.wildenpump.com or www.psgdover.com.
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