How AODD Pumps Can Satisfy All Demands in Mining Operations

Mining is among the world’s oldest industries, tracing its roots back to these prehistoric days when somebody grabbed a digging instrument and started burrowing into the bottom. In the various millennia since, mining has grown into one of the world’s most necessary and widespread commercial enterprises, with operations unfold across the globe while tasked with recovering an almost inexhaustible list of priceless commodities.
In truth, according to the World Mining Congress’s World Mining Data 2020 report, 17.7 billion metric tons of mined merchandise 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 58 p.c of the 2018 production, with North America second at 15.1 p.c, 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) have been probably the most prolific producers, with their total 51.1 percent of manufacturing more than the relaxation of the world mixed.
This signifies that the mining trade is a powerful one, with stable growth anticipated to continue within the coming years in plenty of regions of the world. It additionally implies that mining operations will proceed to depend on pumping technologies that supply strong, dependable, and secure service in numerous critical liquid-handling operations. This white paper will illustrate why optimistic displacement air-operated double-diaphragm (AODD) pumps may be your finest option for so much of of these purposes.
THE CHALLENGE
While mining might appear to be 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 complex and sometimes delicate operations that have to be performed properly if the mining operation is to perform at its highest stage of efficiency.
From a macro standpoint, this requires a pumping technology 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 ready to be maintained and repaired simply so downtime is lessened. The pumps must also be light enough to be manually moved from location to location inside the mine itself.
For many years, a popular alternative to be used in these circumstances was centrifugal pumps. While centrifugal pumps are capable of create the excessive flow rates which are required, they’ve a quantity of operational “pain points” that hamper their use in mining purposes: an inability to self-prime or run dry; particular seals needed to forestall leaks; particular linings needed to deal with solids; excessive motor speeds of up to 1,800 rpm; and comparatively high upkeep requirements and prices, particularly when charged with transferring solid-heavy liquids.
Another well-liked selection has been the progressive cavity pump, but, like centrifugal pumps, they have numerous operational shortcomings. These include an inability to constantly handle liquids with excessive levels of abrasives, which leads to elevated upkeep prices, wear on expensive stators and rotors that will finally need to be changed, and total higher purchase, operating, and repair/replacement costs.
Here are some of the specific liquid-transfer operations that take place 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 important 24/7/365 operation and the water that is recovered is commonly stuffed with particulates that can be as massive as 0.12 to 0.sixteen inches in measurement. If used on this application, centrifugal pumps require special supplies of building, which may be value prohibitive, to guard towards impeller wear brought on by the abrasive particles. Centrifugal pumps are also not dry-run capable, which adversely impacts their level of performance in this application.
General service: For widespread liquid-handling purposes, you need an easy-to-operate pump that reliably can run dry, strip traces, function at low speeds whereas nonetheless delivering excessive move charges, and be straightforward to take care of 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 sometimes demands a need to make use of particular mechanical seals, which may result in exorbitant upkeep, restore, and replacement prices.
Press filter: Press filters are used to wash the liquids which may be produced in the mines and, once more, centrifugal pumps can fall quick on this application as a outcome of the solid-laden liquid can injury the pump’s internals unless special, more expensive materials of development or linings are used. Also, the nature of press-filter operation creates a powerful discharge-pressure variation that can pressure the centrifugal pump to operate away from its best efficiency level (BEP), leading to excessive vibration and radial loads that can lead to shortened service life. A resolution 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.
pressure gauge ลม : This comes in all forms in a mining operation, from loading and unloading from transport vehicles with new and used oil for the heavy machinery, fresh and fouled water, and any chemicals which would possibly be required. In every occasion, there may be the danger that the pump will be pressured to run dry as the truck or storage vessel is emptied, while discharge-pressure variation also can generate high vibration and radial masses. As previously illustrated, centrifugal pumps can’t run dry, so that they need protection from this condition or the addition of special seals. However, all of these upgrades nonetheless can’t completely protect in opposition to a catastrophic failure.
THE SOLUTION
While centrifugal pumps—despite their popularity—have confirmed to not be the most effective answer in many liquid-handling applications in mining, one pump technology that has proven to be an optimum selection is AODD—in phrases of maximizing reliability, cost-effectiveness, ease of operation and maintenance, and security for mining personnel and the setting.
AODD pumps are able to perform effectively in mining applications as a end result of their technique of operation allows them to simply deal with variable flow rates and pressures, whereas being dry-run and line-stripping succesful, and nimble enough to transfer liquids which might be shear-sensitive or high-viscosity, in addition to slurries laden with rocks, pebbles, and other particulates.
The easy design of the AODD pump features few shifting components and comparably lower speeds than other pump technologies, which improves reliability and simplifies maintenance, while the pump’s seal-less building ends 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 can be found in both steel (most commonly aluminum, ductile iron and solid iron) and plastic (polypropylene and PVDF) housing constructions, while a extensive array of elastomers can be used in the diaphragms, which eliminates many chemical-compatibility issues.
A extensive variety of AODD pump configurations present operational flexibility that can also lead to optimized performance at many levels. The capacity to function AODD pumps in a variety of purposes, from primary common use to delicate chemical-handling processes, allows operators to extra cost-effectively outfit their mines. AODD pumps may additionally be more value effective to operate, particularly those fashions which 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 operating 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 principle sixty-five years ago, has been dedicated to growing technologies that meet the wants of mining operations. เกจ์ลมsumo , Wilden provides three AODD pump models which are built to excel in mining functions, out there in ductile iron, cast iron, aluminum, polypropylene and Kynar materials of construction:
Brahma® Series: The Brahma pumps, which characteristic a bolted configuration, have been constructed for use in applications that require the dealing with 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 risk that injury will occur on account of product entrapment or the settling of solids inside 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 scale back air consumption by up to 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 vary for the four Brahma pumps is 166 to 258 gallons per minute at pressures up to a hundred twenty five psi with solids-handling functionality starting from 2 to three inches.
Stallion® Series: The Stallion pumps feature a clamped design with carrying handles for lightweight portability. Their design options 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 further permits solids passage, while a polyurethane display screen base at the inlet will increase the pump’s durability. 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 robust 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 one hundred twenty five psi. Solids sizes that can be dealt with range from half of to 1 inch.
Pro-Flo SHIFT Series: Pro-Flo SHIFT pumps characteristic clamped or bolted configuration. Their design features totally different chamber supplies, together with metal and plastics, even Kynar, which is capable of dealing with excessive levels of abrasive materials. The Pro-Flo SHIFT can also be the most environment friendly AODD pump out there, capable of reducing as a lot as 60 p.c air consumption. This makes it the greatest choice for handling corrosive and abrasive products 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 big 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 gives customers the widest selection of diaphragms available on the market, all of which are capable of providing prolonged imply time between failure (MTBF) for optimized uptime with reduced maintenance, repair, and replacement costs.
All of these capabilities make AODD pumps the best alternative for the aforementioned frequent liquid-handling functions in mining: dewatering, common service, corrosive-handling, filter press, and daily product transfer.
CONCLUSION
In abstract, Wilden AODD pumps are the best suited choice for mining purposes because they provide considerable operational advantages, like comparable low-speed operation, dry-run, line-stripping, self-priming, and deadhead functionality, together with increased operational security and a reduction in maintenance/repair prices that can be incurred by pumps that aren’t designed to handle abrasive/corrosive or solid-laden liquids.
Wilden AODD pumps additionally outperform other AODD applied sciences in other vital methods: simple design with the bottom number of components for faster, less complicated, and safer repairs and the bottom number of spare parts to inventory; latest improvements in supplies of development that improve the pump’s MTBF; and improved effectivity via the use of the Pro-Flo SHIFT ADS, which finally ends in quicker product transfer with decrease air consumption. Wilden additionally continues to innovate through the development of the next-generation Chem-Fuse and EZ-Install diaphragms, both of which increase service life and safety while not compromising the dealing with of difficult liquids.
FOR MORE INFORMATION
Fernando Meneses is the regional supervisor 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 a quantity of main pump corporations, 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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