How AODD Pumps Can Satisfy All Demands in Mining Operations

Mining is one of the world’s oldest industries, tracing its roots back to these prehistoric days when someone grabbed a digging instrument and started burrowing into the bottom. In the numerous millennia since, mining has grown into one of many world’s most important and widespread business enterprises, with operations spread throughout the globe while tasked with recovering an almost inexhaustible record of useful commodities.
In fact, in accordance with the World Mining Congress’s World Mining Data 2020 report, 17.7 billion metric tons of mined merchandise were recovered in 2018, up from 11.3 billion metric tons in 2000 and practically double the 9.6 billion metric tons in 1985. Asian nations accounted for 58 % of the 2018 production, with North America second at 15.1 p.c, adopted by Europe (8 percent), Oceania (6.eight percent), Latin America (6.three 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) have been probably the most prolific producers, with their whole fifty one.1 % of production greater than the rest of the world mixed.
This signifies that the mining industry is a strong one, with strong growth anticipated to proceed in the coming years in many regions of the world. It also signifies that mining operations will continue to rely on pumping applied sciences that supply robust, reliable, and protected service in a variety of important 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 would possibly seem like nothing more than a rough-and-tumble operation—holes are dug by heavy machinery or with explosives, opening the hidden ode to entry from above—there are, in fact, many complicated and generally delicate operations that must be carried out properly if the mining operation is to perform at its highest degree of efficiency.
From a macro standpoint, this requires a pumping technology that can function reliably in harsh and distant places, even when submerged, or when tasked with dealing with particulate-laden liquids or toxic/corrosive merchandise, and also one which is in a position to be maintained and repaired simply so downtime is lessened. The pumps should even be mild enough to be manually moved from location to location inside the mine itself.
For a few years, a preferred selection to be used in these situations was centrifugal pumps. While centrifugal pumps are in a position to create the excessive circulate rates which are required, they’ve a variety of operational “pain points” that hamper their use in mining purposes: an inability to self-prime or run dry; particular seals wanted to forestall leaks; special linings wanted to handle solids; excessive motor speeds of as much as 1,800 rpm; and relatively excessive maintenance requirements and costs, especially when charged with transferring solid-heavy liquids.
Another well-liked choice has been the progressive cavity pump, however, like centrifugal pumps, they have numerous operational shortcomings. These embody an incapability to constantly handle liquids with high ranges of abrasives, which finally ends up in increased maintenance costs, put on on expensive stators and rotors that will finally need to be replaced, and total larger purchase, working, and repair/replacement prices.
Here are a number of the particular liquid-transfer operations that take place 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 critical 24/7/365 operation and the water that is recovered is usually full of particulates that could be as large as 0.12 to 0.16 inches in size. If used in this application, centrifugal pumps require particular materials of building, which may be value prohibitive, to protect against impeller put on brought on by the abrasive particles. Centrifugal pumps are additionally not dry-run succesful, which adversely affects their stage of efficiency on this application.
General service: For frequent liquid-handling functions, you need an easy-to-operate pump that reliably can run dry, strip traces, operate at low speeds whereas nonetheless delivering excessive flow rates, and be simple to take care of and repair. Centrifugal pumps merely 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 lead to exorbitant upkeep, restore, and alternative prices.
Press filter: Press filters are used to clean the liquids which are produced within the mines and, again, centrifugal pumps can fall short on this application as a end result of the solid-laden liquid can harm the pump’s internals until particular, dearer supplies of construction or linings are used. Also, the character of press-filter operation creates a robust discharge-pressure variation that may drive the centrifugal pump to operate away from its greatest efficiency point (BEP), resulting in excessive vibration and radial loads that may lead to shortened service life. A answer to this is the incorporation of variable frequency drives (VFDs) and controllers, however these are costly and may negatively affect the cost-effectiveness of the operation.
Product transfer: This comes in all forms in a mining operation, from loading and unloading from transport trucks with new and used oil for the heavy machinery, recent and fouled water, and any chemical substances which are required. In each instance, there is the danger that the pump shall be compelled to run dry because the truck or storage vessel is emptied, whereas discharge-pressure variation can even generate excessive vibration and radial loads. As previously illustrated, centrifugal pumps can’t run dry, so that they want protection from this situation or the addition of particular seals. However, all of those upgrades still can’t completely protect against a catastrophic failure.
THE SOLUTION
While centrifugal pumps—despite their popularity—have confirmed to not be the best solution in lots of liquid-handling purposes in mining, one pump expertise 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 surroundings.
AODD pumps are capable of carry out successfully in mining purposes as a end result of their methodology of operation permits them to easily deal with variable move rates and pressures, whereas being dry-run and line-stripping succesful, and nimble sufficient to switch liquids which are shear-sensitive or high-viscosity, in addition to slurries laden with rocks, pebbles, and other particulates.
The easy design of the AODD pump features few moving elements and comparably lower speeds than other pump applied sciences, which improves reliability and simplifies maintenance, while the pump’s seal-less construction results in fewer leaks, which is a crucial consideration when handling the many hard-to-seal, corrosive, or hazardous liquids which are prevalent in a mining operation. AODD pumps can be found in both metallic (most commonly aluminum, ductile iron and cast iron) and plastic (polypropylene and PVDF) housing constructions, whereas a broad array of elastomers can be used in the diaphragms, which eliminates many chemical-compatibility considerations.
A wide number of AODD pump configurations present operational flexibility that may additionally lead to optimized efficiency at many levels. The capability to feature AODD pumps in a extensive range of functions, from primary general use to delicate chemical-handling processes, allows operators to more cost-effectively outfit their mines. AODD pumps can be less costly to operate, particularly those fashions which would possibly be outfitted with a next-generation mechanically actuated air distribution system (ADS). At their most elementary, AODD pumps excel in the typical rugged and harsh operating circumstances found in 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 creating applied sciences that meet the needs of mining operations. Today, Wilden offers three AODD pump fashions which are built to excel in mining purposes, out there in ductile iron, forged iron, aluminum, polypropylene and Kynar materials of development:
Brahma® Series: The Brahma pumps, which feature a bolted configuration, have been constructed to be used in functions that require the handling of liquids that includes massive solids. The Brahma pumps have a unique top-inlet/bottom-discharge move orientation and flap valves that allow the passage of huge solids with no threat that damage will occur as a result of product entrapment or the settling of solids inside the pump’s inside circulate 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 reduce air consumption by as much as 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 range for the 4 Brahma pumps is 166 to 258 gallons per minute at pressures up to 125 psi with solids-handling capability ranging from 2 to three inches.
Stallion® Series: The Stallion pumps function a clamped design with carrying handles for lightweight portability. Their design options massive inner clearances and flow-through paths for straightforward passage of huge solids with no chance for clogging. An altered ball/seat check-valve assembly 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 that includes the Turbo-Flo ADS, Wilden’s most sturdy ADS design for the hardest environments. Flow rates amongst the six fashions range from 57 gallons per minute to 232 gallons per minute at working pressures up to a hundred twenty five psi. ราคาเพรสเชอร์เกจ that may be handled range from half of 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 metallic and plastics, even Kynar, which is capable of dealing with excessive ranges of abrasive supplies. The Pro-Flo SHIFT is also essentially the most environment friendly AODD pump available within the market, capable of decreasing up to 60 p.c air consumption. This makes it the best option 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 capable of be outfitted with a broad 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 vary offers users the widest selection of diaphragms on the market, all of which are able to offering extended mean time between failure (MTBF) for optimized uptime with lowered upkeep, repair, and replacement prices.
All of these capabilities make AODD pumps the ideal choice for the aforementioned widespread liquid-handling purposes in mining: dewatering, basic service, corrosive-handling, filter press, and daily product transfer.
CONCLUSION
In summary, Wilden AODD pumps are the finest option for mining applications as a result of 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 can be incurred by pumps that are not designed to deal with abrasive/corrosive or solid-laden liquids.
Wilden AODD pumps additionally outperform different AODD applied sciences in different important ways: simple design with the lowest number of elements for quicker, less complicated, and safer repairs and the lowest number of spare components to stock; latest enhancements in materials of building that enhance the pump’s MTBF; and improved effectivity through using the Pro-Flo SHIFT ADS, which finally ends in faster product switch with decrease air consumption. Wilden additionally continues to innovate through the event of the next-generation Chem-Fuse and EZ-Install diaphragms, each of which increase service life and safety whereas 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 manufacturer 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 firm. PSG is comprised of a quantity of main pump corporations, together with Abaque®, All-Flo™, Almatec®, Blackmer®, Ebsray, em-tec®, Griswold®, Hydro™, Mouvex®, Neptune®, Quantex™, Quattroflow®, RedScrew™, and Wilden®. For more data, visit www.wildenpump.com or www.psgdover.com.
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