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 somebody grabbed a digging instrument and began burrowing into the ground. In the numerous millennia since, mining has grown into one of the world’s most important and widespread business enterprises, with operations spread throughout the globe whereas tasked with recovering an almost 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 have been recovered in 2018, up from eleven.3 billion metric tons in 2000 and nearly double the 9.6 billion metric tons in 1985. Asian international locations accounted for fifty eight percent of the 2018 manufacturing, with North America second at 15.1 percent, adopted by Europe (8 percent), Oceania (6.eight percent), Latin America (6.3 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) were probably the most prolific producers, with their complete 51.1 % of manufacturing greater than the the rest of the world combined.
This signifies that the mining trade is a powerful one, with solid progress anticipated to proceed within the coming years in many regions of the world. It additionally means that mining operations will proceed to rely on pumping technologies that offer sturdy, dependable, and protected 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 lots of of those purposes.
THE CHALLENGE
While mining would possibly seem like nothing greater than a rough-and-tumble operation—holes are dug by heavy machinery or with explosives, opening the hidden ode to access from above—there are, in fact, many complicated and generally delicate operations that have to be performed properly if the mining operation is to carry out at its highest stage of effectivity.
From a macro standpoint, this requires a pumping expertise that can operate reliably in harsh and remote areas, even when submerged, or when tasked with handling particulate-laden liquids or toxic/corrosive products, and likewise one that is prepared to be maintained and repaired simply so downtime is lessened. The pumps should also be gentle enough to be manually moved from location to location inside the mine itself.
For a few years, a well-liked choice for use in these conditions was centrifugal pumps. While centrifugal pumps are capable of create the high flow charges which would possibly be required, they have 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 prevent leaks; particular linings wanted to handle solids; excessive motor speeds of up to 1,800 rpm; and comparatively excessive upkeep requirements and costs, particularly when charged with transferring solid-heavy liquids.
Another in style selection has been the progressive cavity pump, however, like centrifugal pumps, they have numerous operational shortcomings. These include an lack of ability to consistently deal with liquids with excessive levels of abrasives, which outcomes in increased upkeep costs, put on on costly stators and rotors that can finally need to be changed, and total larger purchase, operating, and repair/replacement prices.
Here are a variety of the particular liquid-transfer operations that happen in a mine and the ways that some pump technologies can fall brief in satisfying them:
Mine dewatering: Removing extra produced water from the mine is a important 24/7/365 operation and the water that is recovered is often full of particulates that may be as large as 0.12 to zero.16 inches in size. If used on this utility, centrifugal pumps require special materials of development, which could be cost prohibitive, to protect towards impeller wear brought on by the abrasive particles. Centrifugal pumps are also not dry-run capable, which adversely affects their degree of performance on this utility.
General service: For frequent liquid-handling purposes, you want an easy-to-operate pump that reliably can run dry, strip strains, operate at low speeds while still delivering excessive circulate charges, and be simple to maintain and repair. Centrifugal pumps simply 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 calls for a need to make use of special mechanical seals, which can lead to exorbitant upkeep, restore, and alternative prices.
Press filter: Press filters are used to wash the liquids that are produced within the mines and, once more, centrifugal pumps can fall brief on this software as a result of the solid-laden liquid can damage the pump’s internals unless particular, more expensive materials of construction 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 best efficiency point (BEP), resulting in high vibration and radial masses that can result in shortened service life. A answer to this is the incorporation of variable frequency drives (VFDs) and controllers, however these are expensive and may negatively have an effect on the cost-effectiveness of the operation.
Product transfer: This is available in all forms in a mining operation, from loading and unloading from transport trucks with new and used oil for the heavy equipment, contemporary and fouled water, and any chemical compounds which might be required. In each occasion, there might be the risk that the pump will be forced to run dry because the truck or storage vessel is emptied, whereas discharge-pressure variation can also generate excessive vibration and radial masses. As beforehand illustrated, centrifugal pumps cannot run dry, so that they want safety from this condition or the addition of particular seals. However, all of those upgrades nonetheless cannot totally protect towards a catastrophic failure.
THE SOLUTION
While centrifugal pumps—despite their popularity—have proven to not be the best solution in lots of liquid-handling functions in mining, one pump know-how that has confirmed 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 environment.
AODD pumps are capable of carry out effectively in mining applications as a end result of their technique of operation permits them to easily handle variable flow charges and pressures, while being dry-run and line-stripping capable, and nimble enough to transfer 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 options few transferring elements and comparably lower speeds than other pump applied sciences, which improves reliability and simplifies upkeep, whereas the pump’s seal-less building results in fewer leaks, which is a crucial consideration when handling the many hard-to-seal, corrosive, or hazardous liquids that are prevalent in a mining operation. AODD pumps are available in both metallic (most commonly aluminum, ductile iron and solid iron) and plastic (polypropylene and PVDF) housing constructions, while a wide array of elastomers can be utilized within the diaphragms, which eliminates many chemical-compatibility issues.
A wide number of AODD pump configurations present operational flexibility that may additionally result in optimized performance at many ranges. The capability to characteristic AODD pumps in a variety of purposes, from basic common use to delicate chemical-handling processes, allows operators to extra cost-effectively outfit their mines. AODD pumps can be less expensive to operate, especially these fashions which might be outfitted with a next-generation mechanically actuated air distribution system (ADS). At their most simple, AODD pumps excel within the typical rugged and harsh working circumstances found within the world’s mines, which reduces breakdown incidents together with corresponding downtime and restore costs.
Specifically, Wilden, whose founder, Jim Wilden, conceived the AODD pumping precept sixty-five years in the past, has been devoted to creating applied sciences that meet the wants of mining operations. Today, Wilden provides three AODD pump models which might be 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 characteristic a bolted configuration, have been built to be used in applications that require the dealing with of liquids featuring giant solids. The Brahma pumps have a singular top-inlet/bottom-discharge circulate orientation and flap valves that allow the passage of enormous solids with no risk that harm will happen because of product entrapment or the settling of solids throughout the pump’s inside circulate 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 reduce air consumption by as a lot 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 range for the 4 Brahma pumps is 166 to 258 gallons per minute at pressures up to 125 psi with solids-handling functionality starting from 2 to 3 inches.
Stallion® Series: The Stallion pumps function a clamped design with carrying handles for lightweight portability. Their design features massive internal clearances and flow-through paths for simple passage of large solids with no chance for clogging. An altered ball/seat check-valve assembly additional enables solids passage, whereas a polyurethane display base on 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 featuring the Turbo-Flo ADS, Wilden’s most sturdy ADS design for the toughest environments. Flow charges 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. Solids sizes that may be dealt with vary from 1/2 to 1 inch.
pressure gauge น้ำมัน -Flo SHIFT Series: Pro-Flo SHIFT pumps function clamped or bolted configuration. Their design features totally different chamber materials, including metal and plastics, even Kynar, which is able to dealing with excessive levels of abrasive supplies. The Pro-Flo SHIFT is also essentially the most environment friendly AODD pump in the market, capable of lowering as much as 60 p.c air consumption. This makes it the best suited choice for handling 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 in a place to be outfitted with a extensive array 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 capable of offering prolonged imply time between failure (MTBF) for optimized uptime with lowered maintenance, restore, and substitute costs.
All of those capabilities make AODD pumps the ideal alternative for the aforementioned widespread liquid-handling purposes in mining: dewatering, basic service, corrosive-handling, filter press, and every day product transfer.
CONCLUSION
In summary, Wilden AODD pumps are the finest option for mining applications because they provide appreciable operational benefits, like comparable low-speed operation, dry-run, line-stripping, self-priming, and deadhead functionality, together with increased operational safety and a discount in maintenance/repair costs that can be incurred by pumps that aren’t designed to handle abrasive/corrosive or solid-laden liquids.
Wilden AODD pumps additionally outperform different AODD applied sciences in other important methods: simple design with the lowest number of elements for quicker, less complicated, and safer repairs and the lowest variety of spare elements to inventory; recent enhancements in materials of construction that enhance the pump’s MTBF; and improved effectivity by way of the use of the Pro-Flo SHIFT ADS, which finally leads to sooner product transfer with decrease air consumption. Wilden additionally 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 security whereas not compromising the dealing with of difficult liquids.
FOR MORE INFORMATION
Fernando Meneses is the regional manager North Latin America for Wilden, a leading manufacturer of air-operated double-diaphragm (AODD) pumps. He could be reached at fernando.meneses@psgdover.com. Wilden is a product brand of PSG®, a Dover firm. PSG is comprised of several leading pump corporations, including Abaque®, All-Flo™, Almatec®, Blackmer®, Ebsray, em-tec®, Griswold®, Hydro™, Mouvex®, Neptune®, Quantex™, Quattroflow®, RedScrew™, and Wilden®. For extra info, go to www.wildenpump.com or www.psgdover.com.
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