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 these 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 important and widespread commercial enterprises, with operations spread across the globe whereas tasked with recovering an virtually inexhaustible record of valuable commodities.
In fact, according to the World Mining Congress’s World Mining Data 2020 report, 17.7 billion metric tons of mined merchandise were 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 fifty eight 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.three 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 whole fifty one.1 p.c of manufacturing greater than the relaxation of the world combined.
This means that the mining trade is a strong one, with strong development expected to continue in the coming years in many regions of the world. It also signifies that mining operations will continue to depend on pumping technologies that supply robust, reliable, and protected service in a variety of important liquid-handling operations. This white paper will illustrate why constructive displacement air-operated double-diaphragm (AODD) pumps could be the greatest choice for so much of of these purposes.
THE CHALLENGE
While mining might 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, actually, many complex and sometimes delicate operations that must be performed correctly if the mining operation is to carry out at its highest degree of effectivity.
From a macro standpoint, this requires a pumping know-how that may function reliably in harsh and remote areas, even when submerged, or when tasked with dealing with particulate-laden liquids or toxic/corrosive merchandise, and in addition one which is prepared to be maintained and repaired simply so downtime is lessened. The pumps must also be gentle sufficient to be manually moved from location to location throughout the mine itself.
For a few years, a well-liked choice to be used in these circumstances was centrifugal pumps. While centrifugal pumps are able to create the high move charges that are required, they’ve numerous operational “pain points” that hamper their use in mining purposes: an incapability to self-prime or run dry; special seals needed to prevent leaks; particular linings wanted to handle solids; excessive motor speeds of up to 1,800 rpm; and relatively excessive maintenance necessities and costs, especially when charged with transferring solid-heavy liquids.
Another well-liked alternative has been the progressive cavity pump, however, like centrifugal pumps, they’ve a quantity of operational shortcomings. These embrace an inability to constantly deal with liquids with excessive ranges of abrasives, which ends up in elevated maintenance costs, wear on expensive stators and rotors that may ultimately have to be changed, and overall higher buy, working, and repair/replacement costs.
Here are some of the specific liquid-transfer operations that happen in a mine and the ways that some pump technologies can fall short in satisfying them:
Mine dewatering: Removing extra produced water from the mine is a critical 24/7/365 operation and the water that’s recovered is often stuffed with particulates that could be as large as zero.12 to 0.sixteen inches in size. If used in this utility, centrifugal pumps require special materials of construction, which may be price prohibitive, to guard against impeller wear caused by the abrasive particles. Centrifugal pumps are additionally not dry-run succesful, which adversely impacts their stage of efficiency in this software.
General service: For frequent liquid-handling purposes, you need an easy-to-operate pump that reliably can run dry, strip strains, operate at low speeds whereas nonetheless delivering high flow rates, and be simple to maintain and restore. 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 typically demands a need to make use of particular mechanical seals, which might lead to exorbitant upkeep, repair, and substitute costs.
Press filter: Press filters are used to clean the liquids which are produced in the mines and, once more, centrifugal pumps can fall short in this software as a outcome of the solid-laden liquid can harm the pump’s internals except special, costlier materials of development 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 finest efficiency point (BEP), resulting in high vibration and radial masses that may lead to shortened service life. A solution to this is the incorporation of variable frequency drives (VFDs) and controllers, however these are expensive and can negatively affect the cost-effectiveness of the operation.
Product transfer: This comes in all varieties in a mining operation, from loading and unloading from transport vehicles with new and used oil for the heavy machinery, contemporary and fouled water, and any chemical substances which may be required. In every instance, there is the chance that the pump will be pressured to run dry as the truck or storage vessel is emptied, while discharge-pressure variation can even generate excessive vibration and radial loads. As previously illustrated, centrifugal pumps can’t run dry, so they want safety from this situation or the addition of particular seals. However, all of those upgrades still 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 resolution in many liquid-handling purposes 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 upkeep, and safety for mining personnel and the setting.
AODD pumps are in a place to perform effectively in mining purposes as a result of their method of operation allows them to simply deal with variable flow rates and pressures, while being dry-run and line-stripping succesful, and nimble enough to switch liquids which might be shear-sensitive or high-viscosity, as well as slurries laden with rocks, pebbles, and other particulates.
The easy design of the AODD pump options few transferring parts and comparably lower speeds than different pump applied sciences, which improves reliability and simplifies upkeep, while the pump’s seal-less development leads to fewer leaks, which is a important consideration when dealing with the numerous hard-to-seal, corrosive, or hazardous liquids which would possibly be prevalent in a mining operation. AODD pumps are available in both steel (most commonly aluminum, ductile iron and solid iron) and plastic (polypropylene and PVDF) housing constructions, whereas a broad selection of elastomers can be used in the diaphragms, which eliminates many chemical-compatibility considerations.
A wide variety of AODD pump configurations present operational flexibility that may also result in optimized efficiency at many ranges. The capacity to characteristic AODD pumps in a variety of functions, from basic common use to delicate chemical-handling processes, permits operators to extra cost-effectively outfit their mines. AODD pumps can be less costly to function, especially these fashions that are outfitted with a next-generation mechanically actuated air distribution system (ADS). At their most basic, AODD pumps excel within the typical rugged and harsh working circumstances discovered in the world’s mines, which reduces breakdown incidents together with corresponding downtime and repair costs.
Specifically, Wilden, whose founder, Jim Wilden, conceived the AODD pumping precept sixty-five years in the past, has been dedicated to growing applied sciences that meet the wants of mining operations. Today, Wilden presents three AODD pump fashions which may be constructed to excel in mining functions, out there in ductile iron, forged iron, aluminum, polypropylene and Kynar supplies of construction:
Brahma® Series: The Brahma pumps, which feature a bolted configuration, have been built for use in functions that require the dealing with of liquids featuring large solids. The Brahma pumps have a unique top-inlet/bottom-discharge move orientation and flap valves that permit the passage of enormous solids with no danger that injury will happen because of product entrapment or the settling of solids within the pump’s inner 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 minimize back air consumption by up to 60 percent. 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 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 options giant internal clearances and flow-through paths for straightforward passage of huge solids with no likelihood for clogging. An altered ball/seat check-valve assembly further permits solids passage, while a polyurethane display base on 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 sturdy ADS design for the toughest environments. Flow rates amongst the six fashions vary from fifty seven gallons per minute to 232 gallons per minute at working pressures up to 125 psi. Solids sizes that may 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 options different chamber supplies, together with steel and plastics, even Kynar, which is able to dealing with high ranges of abrasive materials. The Pro-Flo SHIFT can also be essentially the most efficient AODD pump available in the market, able to reducing up to 60 % air consumption. This makes it the best option for handling corrosive and abrasive merchandise 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 capable of be outfitted with a wide array of diaphragm styles—including the newer Chem-Fuse, EZ-Install, and Reduced-Stroke models—in a various array of materials, similar to Wil-Flex™ (Santoprene®), Geolast®, Polyurethane, Buna-N®, EPDM, Neoprene, FKM, and PTFE. This diaphragm range offers customers the widest number of diaphragms available on the market, all of that are able to providing prolonged mean time between failure (MTBF) for optimized uptime with lowered maintenance, restore, and alternative prices.
เกจวัดแก๊สหุงต้ม of those capabilities make AODD pumps the perfect alternative for the aforementioned common liquid-handling purposes in mining: dewatering, common service, corrosive-handling, filter press, and every day product transfer.
CONCLUSION
In abstract, Wilden AODD pumps are the finest option for mining applications because they provide considerable operational benefits, like comparable low-speed operation, dry-run, line-stripping, self-priming, and deadhead functionality, together with elevated operational safety and a discount in maintenance/repair costs that might be incurred by pumps that aren’t designed to deal with abrasive/corrosive or solid-laden liquids.
Wilden AODD pumps also outperform other AODD applied sciences in other vital ways: simple design with the bottom variety of components for quicker, simpler, and safer repairs and the lowest variety of spare parts to inventory; current improvements in materials of building that increase the pump’s MTBF; and improved efficiency through the utilization of the Pro-Flo SHIFT ADS, which finally leads to quicker product switch with lower air consumption. Wilden additionally continues to innovate via the development of the next-generation Chem-Fuse and EZ-Install diaphragms, both of which increase service life and security 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 may 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 firms, together with Abaque®, All-Flo™, Almatec®, Blackmer®, Ebsray, em-tec®, Griswold®, Hydro™, Mouvex®, Neptune®, Quantex™, Quattroflow®, RedScrew™, and Wilden®. For extra information, visit www.wildenpump.com or www.psgdover.com.
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