How AODD Pumps Can Satisfy All Demands in Mining Operations

Mining is certainly one of the world’s oldest industries, tracing its roots back to these prehistoric days when somebody grabbed a digging instrument and began burrowing into the bottom. In the various millennia since, mining has grown into one of many world’s most important and widespread industrial enterprises, with operations unfold throughout the globe while tasked with recovering an virtually inexhaustible list of useful commodities.
In reality, 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 eleven.3 billion metric tons in 2000 and almost double the 9.6 billion metric tons in 1985. Asian nations accounted for fifty eight % of the 2018 production, with North America second at 15.1 %, followed by Europe (8 percent), Oceania (6.8 percent), Latin America (6.3 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) were probably the most prolific producers, with their total fifty one.1 p.c of production greater than the remainder of the world combined.
This implies that the mining trade is a powerful one, with solid development expected to proceed in the coming years in many regions of the world. It additionally signifies that mining operations will proceed to rely on pumping applied sciences that supply strong, dependable, and protected service in a number of important liquid-handling operations. This white paper will illustrate why constructive displacement air-operated double-diaphragm (AODD) pumps can be your finest option for so much of of these purposes.
THE CHALLENGE
While mining might seem like nothing more than a rough-and-tumble operation—holes are dug by heavy equipment or with explosives, opening the hidden ode to entry 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 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 products, and likewise one which is prepared to be maintained and repaired in order that downtime is lessened. The pumps should also be gentle sufficient to be manually moved from location to location within the mine itself.
For a few years, a well-liked alternative to be used in these conditions was centrifugal pumps. While centrifugal pumps are capable of create the high circulate charges which would possibly be required, they have a selection of operational “pain points” that hamper their use in mining applications: an incapability to self-prime or run dry; particular seals needed to forestall leaks; special linings wanted to handle solids; high motor speeds of up to 1,800 rpm; and relatively high maintenance requirements and costs, especially 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 embody an incapability to consistently deal with liquids with high levels of abrasives, which outcomes in elevated maintenance prices, put on on expensive stators and rotors that can ultimately need to be replaced, and general higher buy, operating, and repair/replacement costs.
Here are a few 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 excess produced water from the mine is a important 24/7/365 operation and the water that’s recovered is commonly full of particulates that might be as massive as zero.12 to 0.16 inches in size. If used on this application, centrifugal pumps require particular supplies of construction, which can be cost prohibitive, to guard towards impeller wear caused by the abrasive particles. Centrifugal pumps are also not dry-run succesful, which adversely affects their degree of efficiency in this utility.
General service: For widespread liquid-handling purposes, you need an easy-to-operate pump that reliably can run dry, strip strains, function at low speeds whereas nonetheless delivering excessive flow charges, and be easy to keep up and repair. Centrifugal pumps merely don’t possess these capabilities.
Corrosive liquids: Much like solid-laden liquids, corrosive ones can wreak havoc on the wetted parts of centrifugal and progressive cavity pumps. This typically demands a necessity to use particular mechanical seals, which can lead to exorbitant upkeep, repair, and replacement costs.
Press filter: Press filters are used to scrub the liquids which may be produced in the mines and, once more, centrifugal pumps can fall quick in this utility as a outcome of the solid-laden liquid can injury the pump’s internals unless particular, more expensive materials of development or linings are used. Also, the character of press-filter operation creates a powerful discharge-pressure variation that can pressure the centrifugal pump to function away from its best effectivity point (BEP), resulting in excessive vibration and radial hundreds that may result in shortened service life. A solution to that is the incorporation of variable frequency drives (VFDs) and controllers, however these are costly and may negatively affect the cost-effectiveness of the operation.
Product transfer: This comes in all forms in a mining operation, from loading and unloading from transport vans with new and used oil for the heavy machinery, fresh and fouled water, and any chemicals which are required. In every occasion, there is the danger that the pump shall be pressured to run dry because the truck or storage vessel is emptied, whereas discharge-pressure variation also can generate high vibration and radial hundreds. As beforehand illustrated, centrifugal pumps can’t run dry, in order that they need safety from this condition or the addition of particular seals. However, all of those upgrades nonetheless can’t completely defend in opposition to a catastrophic failure.
THE SOLUTION
While centrifugal pumps—despite their popularity—have proven to not be the best resolution in many liquid-handling applications in mining, one pump technology that has proven 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 setting.
AODD pumps are capable of carry out effectively in mining purposes as a outcome of their technique of operation allows them to simply deal with variable move charges and pressures, whereas being dry-run and line-stripping capable, and nimble enough to transfer liquids that are shear-sensitive or high-viscosity, in addition to slurries laden with rocks, pebbles, and different particulates.
The simple design of the AODD pump features few transferring parts and comparably decrease speeds than different pump applied sciences, which improves reliability and simplifies maintenance, while the pump’s seal-less development ends in fewer leaks, which is a critical consideration when handling the various hard-to-seal, corrosive, or hazardous liquids which would possibly be prevalent in a mining operation. AODD pumps are available in both metal (most generally aluminum, ductile iron and solid 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 considerations.
A extensive number of AODD pump configurations provide operational flexibility that may additionally lead to optimized performance at many levels. The ability to characteristic AODD pumps in a variety of purposes, from primary common use to delicate chemical-handling processes, permits operators to extra cost-effectively outfit their mines. AODD pumps can be less expensive to function, particularly 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 discovered within 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 principle sixty-five years ago, has been devoted to developing applied sciences that meet the wants of mining operations. Today, Wilden offers three AODD pump models which would possibly be built to excel in mining functions, 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 built for use in functions that require the handling of liquids featuring massive solids. The Brahma pumps have a unique top-inlet/bottom-discharge circulate orientation and flap valves that allow the passage of enormous solids with no threat that injury will happen on account of product entrapment or the settling of solids within the pump’s inner move 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 much as 60 %. 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 4 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 characteristic 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 meeting additional allows solids passage, whereas a polyurethane display screen base on the inlet increases the pump’s sturdiness. 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 featuring the Turbo-Flo ADS, Wilden’s most robust ADS design for the hardest environments. Flow charges amongst the six fashions vary from 57 gallons per minute to 232 gallons per minute at working pressures as much as 125 psi. Solids sizes that may be handled range from 1/2 to 1 inch.
Pro-Flo SHIFT Series: Pro-Flo SHIFT pumps characteristic clamped or bolted configuration. Their design features completely different chamber materials, including steel and plastics, even Kynar, which is capable of handling high levels of abrasive supplies. The Pro-Flo SHIFT can additionally be the most efficient AODD pump in the market, capable of decreasing as much as 60 percent air consumption. This makes it the most fitted choice for handling corrosive and abrasive merchandise in mining processes. The pumps have a product range 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 position to be outfitted with a huge selection of diaphragm styles—including the newer Chem-Fuse, EZ-Install, and Reduced-Stroke models—in a various array of supplies, such as Wil-Flex™ (Santoprene®), Geolast®, Polyurethane, Buna-N®, EPDM, Neoprene, FKM, and PTFE. This diaphragm vary offers users the widest selection of diaphragms available on the market, all of which are capable of providing prolonged mean time between failure (MTBF) for optimized uptime with lowered upkeep, restore, and alternative prices.
ราคาเกจวัดแรงดันน้ำ of these capabilities make AODD pumps the ideal alternative for the aforementioned frequent liquid-handling functions in mining: dewatering, common service, corrosive-handling, filter press, and daily product switch.
CONCLUSION
In summary, Wilden AODD pumps are the finest choice for mining purposes as a end result of they offer considerable operational benefits, like comparable low-speed operation, dry-run, line-stripping, self-priming, and deadhead capability, together with elevated operational security and a reduction 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 other AODD applied sciences in different important methods: easy design with the lowest variety of elements for quicker, simpler, and safer repairs and the lowest variety of spare parts to stock; recent enhancements in materials of development that enhance the pump’s MTBF; and improved efficiency by way of using the Pro-Flo SHIFT ADS, which ultimately results in faster product switch with decrease air consumption. Wilden also continues to innovate by way of the event of the next-generation Chem-Fuse and EZ-Install diaphragms, each of which enhance service life and security while not compromising the handling of challenging liquids.
FOR MORE INFORMATION
Fernando Meneses is the regional manager North Latin America for Wilden, a quantity one producer of air-operated double-diaphragm (AODD) pumps. He may be reached at fernando.meneses@psgdover.com. Wilden is a product model of PSG®, a Dover company. PSG is comprised of several leading pump firms, including Abaque®, All-Flo™, Almatec®, Blackmer®, Ebsray, em-tec®, Griswold®, Hydro™, Mouvex®, Neptune®, Quantex™, Quattroflow®, RedScrew™, and Wilden®. For extra info, visit www.wildenpump.com or www.psgdover.com.
Share

Leave a Comment