How AODD Pumps Can Satisfy All Demands in Mining Operations

Mining is among the world’s oldest industries, tracing its roots again to these prehistoric days when someone grabbed a digging instrument and commenced burrowing into the ground. In the numerous millennia since, mining has grown into one of the world’s most important and widespread commercial enterprises, with operations spread throughout the globe whereas tasked with recovering an almost inexhaustible listing of valuable commodities.
In truth, according to the World Mining Congress’s World Mining Data 2020 report, 17.7 billion metric tons of mined products were recovered in 2018, up from 11.3 billion metric tons in 2000 and nearly 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 percent, followed 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) have been essentially the most prolific producers, with their total 51.1 percent of production more than the rest of the world combined.
This signifies that the mining industry is a strong one, with solid growth anticipated to continue in the coming years in many regions of the world. It additionally implies that mining operations will proceed to rely on pumping applied sciences that offer strong, dependable, and safe service in a quantity of critical liquid-handling operations. This white paper will illustrate why constructive displacement air-operated double-diaphragm (AODD) pumps could be the only option for many of these functions.
THE CHALLENGE
While mining may look 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, actually, many advanced and generally delicate operations that must be performed properly if the mining operation is to carry out at its highest degree of efficiency.
From a macro standpoint, this requires a pumping technology that may operate reliably in harsh and remote areas, even when submerged, or when tasked with handling particulate-laden liquids or toxic/corrosive products, and also one that is ready to be maintained and repaired simply so downtime is lessened. The pumps must also be mild sufficient to be manually moved from location to location within the mine itself.
For many years, a popular selection to be used in these conditions was centrifugal pumps. While centrifugal pumps are in a place to create the excessive circulate charges that are required, they have a selection of operational “pain points” that hamper their use in mining purposes: an inability to self-prime or run dry; special seals needed to stop leaks; special linings needed to deal with solids; excessive motor speeds of up to 1,800 rpm; and comparatively high maintenance necessities and prices, particularly when charged with transferring solid-heavy liquids.
Another well-liked alternative has been the progressive cavity pump, however, like centrifugal pumps, they have a quantity of operational shortcomings. These include an incapability to persistently handle liquids with high ranges of abrasives, which ends up in increased upkeep prices, wear on costly stators and rotors that can eventually need to be replaced, and total higher purchase, operating, and repair/replacement prices.
Here are a number of the specific liquid-transfer operations that happen in a mine and the ways in which some pump applied sciences can fall quick in satisfying them:
Mine dewatering: Removing extra produced water from the mine is a crucial 24/7/365 operation and the water that is recovered is often full of particulates that can be as large as zero.12 to 0.sixteen inches in measurement. If used on this application, centrifugal pumps require special materials of construction, which can be price prohibitive, to guard against impeller put on caused by the abrasive particles. Centrifugal pumps are additionally not dry-run succesful, which adversely impacts their stage of efficiency on this application.
เกจ์วัดแก๊สหุงต้ม : For common liquid-handling purposes, you need 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 keep up and repair. Centrifugal pumps merely do not 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 need to use special mechanical seals, which may result in exorbitant upkeep, repair, and alternative costs.
Press filter: Press filters are used to clean the liquids that are produced within the mines and, again, centrifugal pumps can fall brief on this application as a result of the solid-laden liquid can injury the pump’s internals unless special, costlier materials of building or linings are used. Also, the character of press-filter operation creates a powerful discharge-pressure variation that can drive the centrifugal pump to function away from its greatest effectivity point (BEP), leading to high vibration and radial loads that may lead to shortened service life. A answer to that is the incorporation of variable frequency drives (VFDs) and controllers, but these are costly and may negatively affect the cost-effectiveness of the operation.
Product transfer: This is obtainable in all types in a mining operation, from loading and unloading from transport vans with new and used oil for the heavy equipment, contemporary and fouled water, and any chemical substances which are required. In every occasion, there might be the danger that the pump shall be forced to run dry because the truck or storage vessel is emptied, while discharge-pressure variation can also generate excessive vibration and radial loads. As beforehand illustrated, centrifugal pumps can not run dry, so that they want safety from this condition or the addition of particular seals. However, all of these upgrades nonetheless can not completely defend towards a catastrophic failure.
THE SOLUTION
While centrifugal pumps—despite their popularity—have confirmed to not be the simplest solution in many liquid-handling functions in mining, one pump technology that has confirmed to be an optimum selection is AODD—in terms 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 as a outcome of their technique of operation permits them to easily deal with variable circulate rates and pressures, while being dry-run and line-stripping capable, and nimble enough to switch liquids which may be shear-sensitive or high-viscosity, in addition to slurries laden with rocks, pebbles, and different particulates.
The simple design of the AODD pump features few transferring components and comparably decrease speeds than other pump applied sciences, which improves reliability and simplifies upkeep, while the pump’s seal-less building results in fewer leaks, which is a crucial consideration when handling the various hard-to-seal, corrosive, or hazardous liquids which are prevalent in a mining operation. AODD pumps are available in both metallic (most commonly aluminum, ductile iron and forged iron) and plastic (polypropylene and PVDF) housing constructions, while a extensive array of elastomers can be utilized within the diaphragms, which eliminates many chemical-compatibility issues.
A wide number of AODD pump configurations provide operational flexibility that can additionally result in optimized performance at many levels. The capability to function AODD pumps in a broad range of applications, from basic general use to delicate chemical-handling processes, allows operators to more cost-effectively outfit their mines. AODD pumps can also be less costly to function, especially these models that are outfitted with a next-generation mechanically actuated air distribution system (ADS). At their most basic, AODD pumps excel in the typical rugged and harsh working circumstances discovered in the world’s mines, which reduces breakdown incidents along with corresponding downtime and restore prices.
Specifically, Wilden, whose founder, Jim Wilden, conceived the AODD pumping precept sixty-five years ago, has been dedicated to creating technologies that meet the wants of mining operations. Today, Wilden provides three AODD pump fashions which are constructed to excel in mining functions, obtainable in ductile iron, forged iron, aluminum, polypropylene and Kynar materials of building:
Brahma® Series: The Brahma pumps, which feature a bolted configuration, have been built for use in functions that require the handling of liquids featuring large solids. The Brahma pumps have a novel top-inlet/bottom-discharge move orientation and flap valves that permit the passage of enormous solids with no threat that harm will occur because of product entrapment or the settling of solids inside the pump’s internal 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 fashions 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 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 features large inner clearances and flow-through paths for simple passage of enormous solids with no chance for clogging. An altered ball/seat check-valve meeting additional enables solids passage, whereas a polyurethane 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 strong ADS design for the hardest environments. Flow charges amongst the six fashions range from 57 gallons per minute to 232 gallons per minute at working pressures up to one hundred twenty five psi. Solids sizes that may be handled range from half to 1 inch.
Pro-Flo SHIFT Series: Pro-Flo SHIFT pumps function clamped or bolted configuration. Their design options different chamber supplies, including metal and plastics, even Kynar, which is capable of dealing with excessive levels of abrasive supplies. The Pro-Flo SHIFT is also the most efficient AODD pump out there, able to lowering up to 60 p.c air consumption. This makes it the greatest option for handling corrosive and abrasive merchandise 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 in a place to 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 supplies, corresponding to Wil-Flex™ (Santoprene®), Geolast®, Polyurethane, Buna-N®, EPDM, Neoprene, FKM, and PTFE. This diaphragm vary provides customers the widest choice of diaphragms available on the market, all of which are able to offering extended mean time between failure (MTBF) for optimized uptime with lowered upkeep, restore, and alternative prices.
All of those capabilities make AODD pumps the best choice for the aforementioned common liquid-handling functions in mining: dewatering, basic service, corrosive-handling, filter press, and daily product switch.
CONCLUSION
In abstract, Wilden AODD pumps are the most fitted choice for mining applications because 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 prices that might be incurred by pumps that are not designed to handle abrasive/corrosive or solid-laden liquids.
Wilden AODD pumps also outperform different AODD technologies in other vital ways: simple design with the lowest variety of components for quicker, less complicated, and safer repairs and the lowest number of spare elements to stock; latest enhancements in materials of construction that improve the pump’s MTBF; and improved effectivity by way of using the Pro-Flo SHIFT ADS, which finally ends in sooner product switch with lower air consumption. Wilden also continues to innovate by way of the development of the next-generation Chem-Fuse and EZ-Install diaphragms, both of which increase service life and safety while not compromising the handling of challenging liquids.
FOR MORE INFORMATION
Fernando Meneses is the regional manager North Latin America for Wilden, a leading 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 firm. 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 more information, go to www.wildenpump.com or www.psgdover.com.
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