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 commenced burrowing into the bottom. In เกจวัดแรงดัน10bar since, mining has grown into one of the world’s most necessary and widespread business enterprises, with operations unfold throughout the globe while tasked with recovering an virtually inexhaustible record of useful 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.three billion metric tons in 2000 and almost double the 9.6 billion metric tons in 1985. Asian international locations accounted for 58 p.c of the 2018 manufacturing, with North America second at 15.1 %, followed by Europe (8 percent), Oceania (6.8 percent), Latin America (6.three 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) have been essentially the most prolific producers, with their total 51.1 percent of production greater than the relaxation of the world mixed.
This signifies that the mining business is a strong one, with solid progress expected to proceed within the coming years in lots of areas of the world. It also implies that mining operations will continue to depend on pumping technologies that offer sturdy, dependable, and safe service in a selection of important liquid-handling operations. This white paper will illustrate why optimistic displacement air-operated double-diaphragm (AODD) pumps could be the only 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 access from above—there are, in reality, many complicated and typically delicate operations that should be performed properly if the mining operation is to carry out at its highest level of efficiency.
From a macro standpoint, this requires a pumping expertise that may operate reliably in harsh and distant locations, even when submerged, or when tasked with handling particulate-laden liquids or toxic/corrosive merchandise, and likewise one that is prepared to be maintained and repaired simply so downtime is lessened. The pumps should even be gentle sufficient to be manually moved from location to location throughout the mine itself.
For many years, a well-liked selection to be used in these conditions was centrifugal pumps. While centrifugal pumps are able to create the high flow charges which may be required, they have a quantity of operational “pain points” that hamper their use in mining applications: an lack of ability to self-prime or run dry; special seals wanted to prevent leaks; special linings wanted to deal with solids; excessive motor speeds of as much as 1,800 rpm; and relatively high upkeep necessities and costs, especially when charged with transferring solid-heavy liquids.
Another in style choice has been the progressive cavity pump, however, like centrifugal pumps, they’ve a quantity of operational shortcomings. These include an incapability to constantly handle liquids with excessive levels of abrasives, which leads to elevated maintenance prices, wear on costly stators and rotors that can eventually need to be changed, and total greater buy, operating, and repair/replacement prices.
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 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 could be as massive as 0.12 to zero.sixteen inches in dimension. If used in this application, centrifugal pumps require particular materials of development, which can be cost prohibitive, to protect in opposition to impeller wear caused by the abrasive particles. Centrifugal pumps are additionally not dry-run capable, which adversely affects their level of efficiency in this application.
General service: For common liquid-handling functions, you want an easy-to-operate pump that reliably can run dry, strip traces, function at low speeds whereas still delivering high circulate charges, and be straightforward to hold up 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 components of centrifugal and progressive cavity pumps. This usually demands a need to use particular mechanical seals, which might result in exorbitant maintenance, restore, and alternative prices.
Press filter: Press filters are used to clean the liquids which would possibly be produced within the mines and, once more, centrifugal pumps can fall brief on this application because the solid-laden liquid can injury the pump’s internals until special, dearer materials of development or linings are used. Also, the character of press-filter operation creates a powerful discharge-pressure variation that can force the centrifugal pump to operate away from its greatest efficiency level (BEP), resulting in excessive vibration and radial hundreds that can lead to shortened service life. A solution to that is the incorporation of variable frequency drives (VFDs) and controllers, however these are expensive and might negatively have an result on the cost-effectiveness of the operation.
Product transfer: 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, recent and fouled water, and any chemicals that are required. In every instance, there is the chance that the pump will be forced to run dry as the truck or storage vessel is emptied, whereas discharge-pressure variation also can generate excessive vibration and radial hundreds. As previously illustrated, centrifugal pumps can’t run dry, so that they need safety from this situation or the addition of special seals. However, all of these upgrades still can not totally protect against a catastrophic failure.
THE SOLUTION
While centrifugal pumps—despite their popularity—have proven to not be the best solution in many liquid-handling functions in mining, one pump expertise that has confirmed to be an optimum selection is AODD—in terms of maximizing reliability, cost-effectiveness, ease of operation and upkeep, and security for mining personnel and the environment.
AODD pumps are able to perform successfully in mining purposes as a result of their method of operation permits them to easily deal with variable flow charges and pressures, whereas being dry-run and line-stripping capable, and nimble sufficient to switch liquids which might be shear-sensitive or high-viscosity, as properly as slurries laden with rocks, pebbles, and different particulates.
The simple design of the AODD pump features few moving components and comparably lower speeds than different pump technologies, which improves reliability and simplifies maintenance, while the pump’s seal-less building leads to fewer leaks, which is a important 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 steel (most commonly aluminum, ductile iron and cast iron) and plastic (polypropylene and PVDF) housing constructions, whereas a broad array of elastomers can be utilized in the diaphragms, which eliminates many chemical-compatibility concerns.
A broad number of AODD pump configurations present operational flexibility that can additionally lead to optimized performance at many ranges. The capability to characteristic AODD pumps in a variety of applications, from basic general use to delicate chemical-handling processes, permits operators to extra cost-effectively outfit their mines. AODD pumps can also be less expensive to function, especially these models that 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 conditions found in the world’s mines, which reduces breakdown incidents along with corresponding downtime and restore prices.
Specifically, Wilden, whose founder, Jim Wilden, conceived the AODD pumping principle sixty-five years in the past, has been devoted to developing technologies that meet the wants of mining operations. Today, Wilden presents three AODD pump models that are built to excel in mining purposes, available in ductile iron, cast iron, aluminum, polypropylene and Kynar materials of construction:
Brahma® Series: The Brahma pumps, which feature a bolted configuration, have been constructed for use in applications that require the handling of liquids featuring giant solids. The Brahma pumps have a unique top-inlet/bottom-discharge move orientation and flap valves that allow the passage of huge solids with no risk that harm will happen as a outcome of product entrapment or the settling of solids throughout the pump’s inside 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 minimize back air consumption by up to 60 p.c. 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 starting from 2 to three inches.
Stallion® Series: The Stallion pumps feature a clamped design with carrying handles for light-weight portability. Their design options massive inside clearances and flow-through paths for simple passage of large solids with no likelihood for clogging. An altered ball/seat check-valve assembly further permits solids passage, whereas a polyurethane display 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 that includes the Turbo-Flo ADS, Wilden’s most robust ADS design for the hardest environments. Flow rates amongst the six models 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 might be handled range from 1/2 to 1 inch.
Pro-Flo SHIFT Series: Pro-Flo SHIFT pumps function clamped or bolted configuration. Their design options different chamber supplies, together with metal and plastics, even Kynar, which is able to handling high levels of abrasive supplies. The Pro-Flo SHIFT can be probably the most efficient AODD pump available within the market, capable of lowering up to 60 % air consumption. This makes it the finest choice for handling corrosive and abrasive products in mining processes. The pumps have a product range 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 capable of 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 offers customers the widest choice of diaphragms in the marketplace, all of that are able to offering prolonged imply time between failure (MTBF) for optimized uptime with decreased upkeep, restore, and replacement prices.
All of these capabilities make AODD pumps the best selection for the aforementioned frequent liquid-handling purposes in mining: dewatering, general service, corrosive-handling, filter press, and daily product transfer.
CONCLUSION
In summary, Wilden AODD pumps are the most fitted choice for mining purposes as a end result of they offer considerable operational advantages, like comparable low-speed operation, dry-run, line-stripping, self-priming, and deadhead functionality, together with elevated operational safety and a reduction in maintenance/repair costs that could be incurred by pumps that are not designed to handle abrasive/corrosive or solid-laden liquids.
Wilden AODD pumps additionally outperform different AODD technologies in different vital ways: simple design with the bottom variety of parts for quicker, easier, and safer repairs and the lowest variety of spare parts to stock; current enhancements in materials of building that enhance the pump’s MTBF; and improved efficiency by way of using the Pro-Flo SHIFT ADS, which in the end results in quicker product switch with decrease air consumption. Wilden also continues to innovate via the event of the next-generation Chem-Fuse and EZ-Install diaphragms, both of which increase service life and security while not compromising the handling of challenging 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 several main pump corporations, including Abaque®, All-Flo™, Almatec®, Blackmer®, Ebsray, em-tec®, Griswold®, Hydro™, Mouvex®, Neptune®, Quantex™, Quattroflow®, RedScrew™, and Wilden®. For more information, visit www.wildenpump.com or www.psgdover.com.
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