How AODD Pumps Can Satisfy All Demands in Mining Operations

Mining is doubtless certainly one of the world’s oldest industries, tracing its roots back to these prehistoric days when somebody grabbed a digging instrument and commenced burrowing into the ground. In the numerous millennia since, mining has grown into one of many world’s most important and widespread commercial enterprises, with operations spread throughout the globe while tasked with recovering an nearly inexhaustible record of priceless commodities.
In reality, based on the World Mining Congress’s World Mining Data 2020 report, 17.7 billion metric tons of mined products had been recovered in 2018, up from 11.3 billion metric tons in 2000 and nearly double the 9.6 billion metric tons in 1985. Asian international locations accounted for fifty eight % of the 2018 production, with North America second at 15.1 p.c, 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) had been essentially the most prolific producers, with their whole 51.1 % of manufacturing more than the relaxation of the world mixed.
This signifies that the mining business is a powerful one, with strong growth expected to proceed within the coming years in lots of regions of the world. It also signifies that mining operations will continue to rely on pumping applied sciences that supply strong, dependable, and protected service in numerous critical liquid-handling operations. This white paper will illustrate why constructive displacement air-operated double-diaphragm (AODD) pumps can be your greatest option for many of these functions.
THE CHALLENGE
While mining may seem like nothing greater than a rough-and-tumble operation—holes are dug by heavy equipment or with explosives, opening the hidden ode to entry from above—there are, in fact, many complicated and typically delicate operations that must be carried out properly if the mining operation is to perform at its highest level of efficiency.
From a macro standpoint, this requires a pumping technology that may function reliably in harsh and remote places, even when submerged, or when tasked with handling particulate-laden liquids or toxic/corrosive products, and also one which is ready to be maintained and repaired in order that downtime is lessened. The pumps should even be gentle enough to be manually moved from location to location throughout the mine itself.
For a few years, a preferred alternative to be used in these circumstances was centrifugal pumps. While centrifugal pumps are capable of create the excessive flow charges that are required, they’ve a variety of operational “pain points” that hamper their use in mining applications: an inability to self-prime or run dry; special seals needed to stop leaks; particular linings needed to handle solids; high motor speeds of up to 1,800 rpm; and relatively high upkeep requirements and costs, particularly when charged with transferring solid-heavy liquids.
Another popular alternative has been the progressive cavity pump, but, like centrifugal pumps, they have a selection of operational shortcomings. These embody an incapability to constantly deal with liquids with excessive ranges of abrasives, which outcomes in elevated upkeep prices, wear on expensive stators and rotors that can eventually need to be replaced, and overall larger purchase, operating, and repair/replacement costs.
Here are a number of the specific liquid-transfer operations that take place in a mine and the ways that some pump technologies can fall short in satisfying them:
Mine dewatering: Removing excess produced water from the mine is a crucial 24/7/365 operation and the water that is recovered is usually stuffed with particulates that can be as large as zero.12 to 0.sixteen inches in measurement. If used on this application, centrifugal pumps require special supplies of construction, which may be cost prohibitive, to guard towards impeller put on brought on by the abrasive particles. Centrifugal pumps are additionally not dry-run succesful, which adversely affects their degree of efficiency in this application.
General service: For common liquid-handling applications, you want an easy-to-operate pump that reliably can run dry, strip strains, function at low speeds while still delivering excessive circulate charges, and be easy to maintain and repair. Centrifugal pumps simply 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 sometimes demands a need to make use of particular mechanical seals, which can lead to exorbitant maintenance, repair, and alternative costs.
Press filter: Press filters are used to wash the liquids which may be produced in the mines and, once more, centrifugal pumps can fall short in this application as a result of the solid-laden liquid can injury the pump’s internals except particular, more expensive materials of building or linings are used. Also, the character of press-filter operation creates a robust discharge-pressure variation that may pressure the centrifugal pump to operate away from its finest efficiency point (BEP), resulting in excessive vibration and radial masses that may result in shortened service life. A solution 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 is available in all varieties in a mining operation, from loading and unloading from transport vehicles with new and used oil for the heavy equipment, fresh and fouled water, and any chemical compounds which might be required. In each occasion, there is the danger that the pump might be compelled to run dry because the truck or storage vessel is emptied, whereas discharge-pressure variation also can generate excessive vibration and radial masses. As previously illustrated, centrifugal pumps can not run dry, so they need safety from this situation or the addition of particular seals. However, all of those upgrades nonetheless can’t totally shield in opposition to a catastrophic failure.
THE SOLUTION
While pressure gauge nuova fima ราคา despite their popularity—have proven to not be the most effective solution in lots of liquid-handling purposes in mining, one pump technology that has confirmed to be an optimum choice is AODD—in phrases of maximizing reliability, cost-effectiveness, ease of operation and maintenance, and safety for mining personnel and the surroundings.
AODD pumps are capable of carry out successfully in mining functions because their technique of operation permits 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 are shear-sensitive or high-viscosity, as nicely as slurries laden with rocks, pebbles, and other particulates.
The easy design of the AODD pump options few shifting components and comparably lower speeds than different pump applied sciences, which improves reliability and simplifies maintenance, whereas the pump’s seal-less building ends in fewer leaks, which is a important consideration when handling the numerous hard-to-seal, corrosive, or hazardous liquids which are prevalent in a mining operation. AODD pumps are available in each metallic (most generally aluminum, ductile iron and solid iron) and plastic (polypropylene and PVDF) housing constructions, while a big selection of elastomers can be used within the diaphragms, which eliminates many chemical-compatibility issues.
A wide variety of AODD pump configurations present operational flexibility that can additionally result in optimized performance at many ranges. The capacity to characteristic AODD pumps in a variety of purposes, from basic common use to delicate chemical-handling processes, allows operators to more cost-effectively outfit their mines. AODD pumps can be less costly to operate, especially these models which 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 situations found in 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 principle sixty-five years ago, has been devoted to creating technologies that meet the wants of mining operations. Today, Wilden provides three AODD pump models that are constructed to excel in mining purposes, obtainable in ductile iron, forged iron, aluminum, polypropylene and Kynar supplies of construction:
Brahma® Series: The Brahma pumps, which feature a bolted configuration, have been constructed for use in purposes that require the handling of liquids featuring large solids. The Brahma pumps have a singular top-inlet/bottom-discharge circulate orientation and flap valves that permit the passage of large solids with no threat that harm will happen as a outcome of product entrapment or the settling of solids throughout the pump’s inside move 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 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 range 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 3 inches.
Stallion® Series: The Stallion pumps feature a clamped design with carrying handles for light-weight portability. Their design features large inner clearances and flow-through paths for easy passage of enormous solids with no probability for clogging. An altered ball/seat check-valve assembly further enables solids passage, while a polyurethane screen base at the inlet will increase 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 rates amongst the six fashions vary from 57 gallons per minute to 232 gallons per minute at working pressures as much as one hundred twenty five psi. Solids sizes that can be handled range from 1/2 to 1 inch.
Pro-Flo SHIFT Series: Pro-Flo SHIFT pumps function clamped or bolted configuration. Their design features totally different chamber materials, including metallic and plastics, even Kynar, which is capable of dealing with excessive levels of abrasive supplies. The Pro-Flo SHIFT can additionally be probably the most efficient AODD pump in the market, capable of decreasing up to 60 p.c air consumption. This makes it the greatest option for dealing with corrosive and abrasive merchandise 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 able to be outfitted with a massive selection of diaphragm styles—including the newer Chem-Fuse, EZ-Install, and Reduced-Stroke models—in a varying array of supplies, similar to Wil-Flex™ (Santoprene®), Geolast®, Polyurethane, Buna-N®, EPDM, Neoprene, FKM, and PTFE. This diaphragm range provides users the widest number of diaphragms in the marketplace, all of that are capable of providing extended mean time between failure (MTBF) for optimized uptime with decreased upkeep, restore, and substitute prices.
All of those capabilities make AODD pumps the perfect choice for the aforementioned common liquid-handling purposes in mining: dewatering, common service, corrosive-handling, filter press, and daily product transfer.
CONCLUSION
In summary, Wilden AODD pumps are the finest option for mining functions as a outcome of they offer appreciable operational advantages, like comparable low-speed operation, dry-run, line-stripping, self-priming, and deadhead functionality, along with increased operational safety and a discount in maintenance/repair costs that can be incurred by pumps that aren’t designed to deal with abrasive/corrosive or solid-laden liquids.
Wilden AODD pumps additionally outperform different AODD technologies in different significant ways: easy design with the lowest variety of parts for sooner, easier, and safer repairs and the bottom number of spare components to stock; current improvements in materials of construction that increase the pump’s MTBF; and improved effectivity via the utilization of the Pro-Flo SHIFT ADS, which in the end leads to quicker product switch with decrease air consumption. Wilden also continues to innovate by way of the development of the next-generation Chem-Fuse and EZ-Install diaphragms, each of which enhance service life and security whereas not compromising the dealing with 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 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 companies, 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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