How AODD Pumps Can Satisfy All Demands in Mining Operations

Mining is considered one of the world’s oldest industries, tracing its roots again to those 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 necessary and widespread business enterprises, with operations spread across the globe while tasked with recovering an virtually inexhaustible listing of useful commodities.
In fact, based on the World Mining Congress’s World Mining Data 2020 report, 17.7 billion metric tons of mined products were recovered in 2018, up from eleven.3 billion metric tons in 2000 and practically double the 9.6 billion metric tons in 1985. Asian countries accounted for 58 p.c of the 2018 manufacturing, with North America second at 15.1 %, adopted 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) had been probably the most prolific producers, with their complete fifty one.1 percent of production greater than the rest of the world mixed.
This signifies that the mining trade is a robust one, with stable progress expected to proceed within the coming years in lots of regions of the world. It additionally signifies that mining operations will continue to depend on pumping technologies that offer robust, dependable, and protected service in a quantity of critical liquid-handling operations. This white paper will illustrate why positive displacement air-operated double-diaphragm (AODD) pumps may be your best option for many of these applications.
THE CHALLENGE
While mining might appear to be nothing more 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 reality, many advanced and typically delicate operations that must be carried out correctly if the mining operation is to perform at its highest degree of efficiency.
From a macro standpoint, this requires a pumping expertise that can function reliably in harsh and distant places, even when submerged, or when tasked with handling particulate-laden liquids or toxic/corrosive products, and likewise one that is ready to be maintained and repaired in order that downtime is lessened. The pumps must also be gentle enough to be manually moved from location to location within the mine itself.
For a few years, a well-liked selection for use in these situations was centrifugal pumps. While centrifugal pumps are capable of create the excessive flow rates which would possibly be required, they’ve a variety of operational “pain points” that hamper their use in mining purposes: an lack of ability to self-prime or run dry; special seals needed to prevent leaks; special linings wanted to deal with solids; excessive motor speeds of up to 1,800 rpm; and relatively excessive upkeep requirements and prices, especially when charged with transferring solid-heavy liquids.
Another in style selection has been the progressive cavity pump, but, like centrifugal pumps, they’ve a selection of operational shortcomings. These embody an lack of ability to constantly deal with liquids with high ranges of abrasives, which ends up in increased maintenance costs, wear on expensive stators and rotors that may eventually need to be replaced, and total greater buy, working, and repair/replacement costs.
Here are some of the specific liquid-transfer operations that take place in a mine and the ways that some pump technologies can fall quick in satisfying them:
Mine dewatering: Removing excess produced water from the mine is a important 24/7/365 operation and the water that is recovered is often full of particulates that might be as massive as zero.12 to 0.16 inches in dimension. If used on this software, centrifugal pumps require particular supplies of building, which can be price prohibitive, to protect against impeller wear brought on by the abrasive particles. Centrifugal pumps are additionally not dry-run capable, which adversely affects their degree of efficiency in this software.
General service: For frequent liquid-handling applications, you need an easy-to-operate pump that reliably can run dry, strip lines, function at low speeds whereas still delivering excessive move charges, and be straightforward to maintain and restore. Centrifugal pumps simply do not 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 necessity to use particular mechanical seals, which can lead to exorbitant maintenance, repair, and replacement costs.
Press filter: Press filters are used to wash the liquids that are produced in the mines and, once more, centrifugal pumps can fall quick on this utility as a end result of the solid-laden liquid can damage the pump’s internals except particular, costlier supplies of construction or linings are used. Also, the nature of press-filter operation creates a robust discharge-pressure variation that may pressure the centrifugal pump to function away from its best efficiency level (BEP), resulting in excessive vibration and radial masses that may lead to shortened service life. A resolution 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 switch: This comes in all forms 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 chemicals which are required. In every occasion, there is the risk that the pump might be compelled to run dry as the truck or storage vessel is emptied, while discharge-pressure variation also can generate high vibration and radial loads. As beforehand illustrated, centrifugal pumps can not run dry, so that they need protection from this situation or the addition of particular seals. However, all of these upgrades still can not completely defend towards a catastrophic failure.
THE SOLUTION
While centrifugal pumps—despite their popularity—have confirmed to not be the most effective resolution in many liquid-handling applications in mining, one pump know-how that has proven to be an optimum selection is AODD—in phrases of maximizing reliability, cost-effectiveness, ease of operation and upkeep, and safety for mining personnel and the environment.
AODD pumps are capable of carry out successfully in mining purposes as a end result of their method of operation permits them to simply handle variable flow charges and pressures, whereas being dry-run and line-stripping succesful, and nimble enough to switch liquids which are shear-sensitive or high-viscosity, as nicely as slurries laden with rocks, pebbles, and different particulates.
The simple design of the AODD pump options few moving elements and comparably decrease speeds than different pump technologies, which improves reliability and simplifies upkeep, while the pump’s seal-less building ends in fewer leaks, which is a crucial consideration when handling the various hard-to-seal, corrosive, or hazardous liquids that are prevalent in a mining operation. AODD pumps can be found in each steel (most commonly aluminum, ductile iron and forged iron) and plastic (polypropylene and PVDF) housing constructions, whereas a broad selection of elastomers can be utilized within the diaphragms, which eliminates many chemical-compatibility concerns.
เกจวัดแรงดันอาร์กอน of AODD pump configurations present operational flexibility that may also result in optimized efficiency at many ranges. The capability to function AODD pumps in a extensive range of functions, from fundamental common use to delicate chemical-handling processes, permits operators to more cost-effectively outfit their mines. AODD pumps can be less expensive to function, especially those models that are outfitted with a next-generation mechanically actuated air distribution system (ADS). At their most elementary, AODD pumps excel within the typical rugged and harsh working conditions discovered within 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 precept sixty-five years in the past, has been devoted to developing technologies that meet the needs of mining operations. Today, Wilden provides three AODD pump models that are constructed to excel in mining applications, out there in ductile iron, forged iron, aluminum, polypropylene and Kynar supplies of building:
Brahma® Series: The Brahma pumps, which function a bolted configuration, have been built to be used in functions that require the dealing with of liquids that includes giant solids. The Brahma pumps have a singular top-inlet/bottom-discharge flow orientation and flap valves that enable the passage of enormous solids with no danger that damage 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 back air consumption by as much as 60 p.c. 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 much as one hundred twenty five psi with solids-handling capability ranging from 2 to 3 inches.
Stallion® Series: The Stallion pumps characteristic a clamped design with carrying handles for lightweight portability. Their design features giant internal clearances and flow-through paths for simple passage of huge solids with no chance for clogging. An altered ball/seat check-valve meeting additional allows solids passage, while a polyurethane display screen base at the inlet increases the pump’s durability. 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 featuring the Turbo-Flo ADS, Wilden’s most sturdy ADS design for the toughest environments. Flow rates amongst the six models vary from fifty seven gallons per minute to 232 gallons per minute at working pressures as a lot as 125 psi. Solids sizes that might be dealt with vary 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 steel and plastics, even Kynar, which is capable of handling high levels of abrasive supplies. The Pro-Flo SHIFT can also be probably the most environment friendly AODD pump in the market, capable of reducing as a lot as 60 p.c air consumption. This makes it the finest option for handling corrosive and abrasive products in mining processes. The pumps have a product range 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 extensive 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 provides users the widest selection of diaphragms in the marketplace, all of that are able to offering extended imply time between failure (MTBF) for optimized uptime with decreased upkeep, restore, and substitute costs.
All of these capabilities make AODD pumps the ideal choice for the aforementioned frequent liquid-handling applications in mining: dewatering, basic service, corrosive-handling, filter press, and every day product transfer.
CONCLUSION
In summary, Wilden AODD pumps are the most fitted choice for mining purposes as a result of they provide considerable operational advantages, like comparable low-speed operation, dry-run, line-stripping, self-priming, and deadhead capability, along with increased operational safety and a discount in maintenance/repair costs that can be incurred by pumps that are not designed to deal with abrasive/corrosive or solid-laden liquids.
Wilden AODD pumps also outperform different AODD technologies in different important ways: simple design with the lowest number of components for sooner, simpler, and safer repairs and the lowest variety of spare elements to inventory; latest improvements in supplies of building that enhance the pump’s MTBF; and improved efficiency by way of the usage of the Pro-Flo SHIFT ADS, which ultimately results in faster product switch with lower air consumption. Wilden also continues to innovate through the event of the next-generation Chem-Fuse and EZ-Install diaphragms, both of which improve service life and security whereas not compromising the dealing with of challenging 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 [email protected]. Wilden is a product brand of PSG®, a Dover firm. 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 more data, visit www.wildenpump.com or www.psgdover.com.
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