How AODD Pumps Can Satisfy All Demands in Mining Operations

Mining is certainly one of the world’s oldest industries, tracing its roots again to those prehistoric days when somebody grabbed a digging instrument and started burrowing into the bottom. In the numerous millennia since, mining has grown into one of the world’s most important and widespread industrial enterprises, with operations unfold across the globe whereas tasked with recovering an almost inexhaustible record of priceless commodities.
In fact, in accordance with 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 international locations accounted for 58 percent of the 2018 manufacturing, with North America second at 15.1 percent, 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) had been essentially the most prolific producers, with their total fifty one.1 p.c of production more than the relaxation of the world mixed.
This means that the mining trade is a robust one, with solid development expected to continue in the coming years in plenty of areas of the world. It additionally implies that mining operations will proceed to rely on pumping technologies that provide strong, dependable, and safe service in numerous crucial liquid-handling operations. This white paper will illustrate why constructive displacement air-operated double-diaphragm (AODD) pumps can be the solely option for a lot of of those purposes.
THE CHALLENGE
While mining would possibly 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 access from above—there are, actually, many advanced and sometimes delicate operations that have to be carried out correctly if the mining operation is to perform at its highest stage of effectivity.
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 dealing with particulate-laden liquids or toxic/corrosive merchandise, and in addition one that is prepared to be maintained and repaired simply so downtime is lessened. The pumps must even be gentle enough to be manually moved from location to location throughout the mine itself.
For many years, a preferred alternative to be used in these circumstances was centrifugal pumps. While centrifugal pumps are able to create the excessive move rates that are required, they’ve a variety of operational “pain points” that hamper their use in mining purposes: an incapability to self-prime or run dry; particular seals needed to stop leaks; particular linings needed to deal with solids; excessive motor speeds of as a lot as 1,800 rpm; and relatively excessive upkeep necessities and prices, particularly when charged with transferring solid-heavy liquids.
Another popular choice has been the progressive cavity pump, but, like centrifugal pumps, they have numerous operational shortcomings. These embrace an lack of ability to consistently handle liquids with high ranges of abrasives, which outcomes in increased maintenance prices, wear on expensive stators and rotors that will ultimately must be changed, and general higher buy, operating, and repair/replacement costs.
Here are a variety 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 excess produced water from the mine is a critical 24/7/365 operation and the water that’s recovered is commonly full of particulates that might be as massive as zero.12 to zero.sixteen inches in dimension. If used in this software, centrifugal pumps require special materials of construction, which may be value prohibitive, to protect against impeller wear caused by the abrasive particles. Centrifugal pumps are also not dry-run succesful, which adversely impacts their stage of efficiency on this application.
General service: For frequent liquid-handling purposes, you want an easy-to-operate pump that reliably can run dry, strip lines, operate at low speeds while nonetheless delivering high circulate rates, and be simple 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 components of centrifugal and progressive cavity pumps. This usually calls for a need to use special mechanical seals, which might result in exorbitant upkeep, restore, and alternative costs.
Press filter: Press filters are used to clean the liquids which are produced in the mines and, again, centrifugal pumps can fall short in this software as a end result of the solid-laden liquid can injury the pump’s internals except special, dearer supplies of construction or linings are used. Also, the character of press-filter operation creates a robust discharge-pressure variation that can pressure the centrifugal pump to function away from its greatest efficiency level (BEP), resulting in excessive vibration and radial masses that can result in shortened service life. A resolution to this is the incorporation of variable frequency drives (VFDs) and controllers, however these are expensive and may negatively have an result on the cost-effectiveness of the operation.
Product switch: This comes in all forms in a mining operation, from loading and unloading from transport trucks with new and used oil for the heavy equipment, recent and fouled water, and any chemical substances which might be required. In every occasion, there could 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 even generate high vibration and radial masses. As previously illustrated, centrifugal pumps cannot run dry, so they need protection from this condition or the addition of special seals. However, all of those upgrades nonetheless can not totally shield towards a catastrophic failure.
THE SOLUTION
While centrifugal pumps—despite their popularity—have proven to not be the best resolution in plenty of liquid-handling functions in mining, one pump expertise 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 setting.
AODD pumps are able to carry out effectively in mining applications as a result of their methodology of operation permits them to simply deal with variable circulate charges and pressures, whereas being dry-run and line-stripping capable, and nimble sufficient to transfer liquids that are shear-sensitive or high-viscosity, in addition to slurries laden with rocks, pebbles, and other particulates.
The simple design of the AODD pump features few moving components and comparably decrease speeds than different pump technologies, which improves reliability and simplifies upkeep, whereas the pump’s seal-less building results in fewer leaks, which is a important consideration when dealing with the numerous hard-to-seal, corrosive, or hazardous liquids that are prevalent in a mining operation. AODD pumps are available in both steel (most commonly aluminum, ductile iron and forged iron) and plastic (polypropylene and PVDF) housing constructions, while a huge selection of elastomers can be utilized in the diaphragms, which eliminates many chemical-compatibility considerations.
A broad number of AODD pump configurations present operational flexibility that may also lead to optimized efficiency at many ranges. The ability to feature AODD pumps in a broad range of purposes, from primary basic use to delicate chemical-handling processes, permits operators to more cost-effectively outfit their mines. AODD pumps may also be less expensive to function, particularly these fashions that are outfitted with a next-generation mechanically actuated air distribution system (ADS). At their most elementary, AODD pumps excel in the typical rugged and harsh working circumstances found 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 ago, has been dedicated to growing technologies that meet the needs of mining operations. Today, Wilden provides three AODD pump fashions which are built to excel in mining applications, obtainable 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 for use in applications that require the handling of liquids featuring large solids. The Brahma pumps have a novel top-inlet/bottom-discharge circulate orientation and flap valves that permit the passage of large solids with no threat that damage will occur because of product entrapment or the settling of solids throughout the pump’s inside flow paths. Brahma pumps can be found 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 as a lot as 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 range for the four Brahma pumps is 166 to 258 gallons per minute at pressures up to a hundred twenty five psi with solids-handling capability starting 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 easy passage of large solids with no likelihood for clogging. An altered ball/seat check-valve meeting further allows solids passage, whereas a polyurethane screen base at 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 featuring the Turbo-Flo ADS, Wilden’s most strong ADS design for the hardest environments. Flow rates amongst the six fashions range from fifty seven gallons per minute to 232 gallons per minute at working pressures up to one hundred twenty five psi. Solids sizes that could be dealt with vary from half to 1 inch.
Pro-Flo SHIFT Series: Pro-Flo SHIFT pumps characteristic clamped or bolted configuration. Their design features totally different chamber materials, together with metal and plastics, even Kynar, which is capable of dealing with high levels of abrasive supplies. The Pro-Flo SHIFT can additionally be the most efficient AODD pump available within the market, able to decreasing as much as 60 p.c air consumption. This makes it the finest choice for handling corrosive and abrasive products in mining processes. The pumps have a product vary 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 able to be outfitted with a wide selection of diaphragm styles—including the newer Chem-Fuse, EZ-Install, and Reduced-Stroke models—in a varying array of materials, similar to Wil-Flex™ (Santoprene®), Geolast®, Polyurethane, Buna-N®, EPDM, Neoprene, FKM, and PTFE. This diaphragm vary provides customers the widest selection of diaphragms on the market, all of which are able to providing prolonged imply time between failure (MTBF) for optimized uptime with lowered maintenance, restore, and alternative costs.
All of these capabilities make AODD pumps the best choice for the aforementioned widespread liquid-handling functions in mining: dewatering, basic service, corrosive-handling, filter press, and day by day product switch.
CONCLUSION
In abstract, Wilden AODD pumps are the greatest choice for mining applications as a result of they provide appreciable operational benefits, 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 prices 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 other important ways: simple design with the bottom number of components for faster, easier, and safer repairs and the bottom variety of spare components to stock; recent enhancements in supplies of construction that increase the pump’s MTBF; and improved efficiency through the use of the Pro-Flo SHIFT ADS, which ultimately leads to quicker product transfer with lower air consumption. Wilden also continues to innovate through the event of the next-generation Chem-Fuse and EZ-Install diaphragms, each of which enhance service life and safety while not compromising the dealing with of difficult liquids.
FOR MORE INFORMATION
Fernando Meneses is the regional manager North Latin America for Wilden, a number one manufacturer of air-operated double-diaphragm (AODD) pumps. He may be reached at fernando.meneses@psgdover.com. เกจวัดแรงดันไฟฟ้า is a product brand of PSG®, a Dover company. PSG is comprised of a quantity of leading pump companies, together with 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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