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 someone 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 spread throughout the globe while tasked with recovering an nearly 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 products were recovered in 2018, up from 11.3 billion metric tons in 2000 and nearly double the 9.6 billion metric tons in 1985. Asian international locations accounted for 58 % of the 2018 manufacturing, 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) were probably the most prolific producers, with their complete 51.1 p.c of production greater than the relaxation of the world combined.
This means that the mining industry is a strong one, with solid development anticipated to continue in the coming years in many areas of the world. It also means that mining operations will continue to depend on pumping applied sciences that offer strong, dependable, and safe service in numerous critical liquid-handling operations. This white paper will illustrate why positive displacement air-operated double-diaphragm (AODD) pumps may be the greatest choice for many 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 entry from above—there are, actually, many advanced and generally delicate operations that have to 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 expertise that may function reliably in harsh and distant areas, even when submerged, or when tasked with dealing with particulate-laden liquids or toxic/corrosive products, and likewise one which is ready to be maintained and repaired just so downtime is lessened. The pumps should even be mild enough to be manually moved from location to location inside the mine itself.
For a few years, a well-liked selection to be used in these circumstances was centrifugal pumps. While centrifugal pumps are in a place to create the high circulate charges that are required, they have a variety of operational “pain points” that hamper their use in mining applications: an lack of ability to self-prime or run dry; particular seals wanted to prevent leaks; special linings wanted to deal with solids; high motor speeds of up to 1,800 rpm; and comparatively high maintenance necessities 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 a number of operational shortcomings. These include an inability to persistently deal with liquids with excessive ranges of abrasives, which outcomes in increased upkeep prices, wear on expensive stators and rotors that may eventually must be replaced, and total larger purchase, operating, and repair/replacement costs.
Here are a number of the particular liquid-transfer operations that take place in a mine and the ways in which some pump technologies can fall brief in satisfying them:
Mine dewatering: Removing extra produced water from the mine is a crucial 24/7/365 operation and the water that’s recovered is commonly full of particulates that could be as massive as 0.12 to zero.16 inches in dimension. If used in this software, centrifugal pumps require particular materials of construction, which can be value prohibitive, to protect towards impeller wear brought on by the abrasive particles. Centrifugal pumps are additionally not dry-run capable, which adversely affects their degree of efficiency in this application.
General service: For widespread liquid-handling applications, you need an easy-to-operate pump that reliably can run dry, strip traces, operate at low speeds while nonetheless delivering high move rates, and be simple to maintain and restore. Centrifugal pumps simply do not 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 calls for a necessity to make use of special mechanical seals, which might result in exorbitant maintenance, restore, and substitute costs.
Press filter: Press filters are used to clean the liquids which are produced in the mines and, again, centrifugal pumps can fall quick in this utility as a end result of the solid-laden liquid can injury the pump’s internals unless particular, dearer supplies of building 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 hundreds that may result in shortened service life. A resolution to that is the incorporation of variable frequency drives (VFDs) and controllers, but these are costly and can negatively have an effect on the cost-effectiveness of the operation.
Product switch: This is available in all types in a mining operation, from loading and unloading from transport trucks with new and used oil for the heavy machinery, contemporary and fouled water, and any chemical substances that are required. In each occasion, there could be the risk that the pump will be forced to run dry as the truck or storage vessel is emptied, while discharge-pressure variation can also generate excessive vibration and radial loads. As beforehand illustrated, centrifugal pumps can’t run dry, in order that they want protection from this condition or the addition of special seals. However, all of those upgrades still can not completely defend in opposition to a catastrophic failure.
THE SOLUTION
While centrifugal pumps—despite their popularity—have confirmed to not be the simplest resolution in lots of liquid-handling functions in mining, one pump expertise that has proven to be an optimum alternative is AODD—in terms of maximizing reliability, cost-effectiveness, ease of operation and upkeep, and safety for mining personnel and the setting.
AODD pumps are able to carry out effectively in mining applications as a end result of their methodology of operation permits them to easily deal with variable move charges and pressures, whereas being dry-run and line-stripping capable, and nimble enough to switch liquids which may be shear-sensitive or high-viscosity, in addition to slurries laden with rocks, pebbles, and different particulates.
The easy design of the AODD pump features few shifting elements and comparably decrease speeds than different pump applied sciences, which improves reliability and simplifies upkeep, while the pump’s seal-less development results in fewer leaks, which is a crucial consideration when dealing with the various hard-to-seal, corrosive, or hazardous liquids which are prevalent in a mining operation. AODD pumps are available in both metallic (most generally aluminum, ductile iron and forged 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 concerns.
A extensive variety of AODD pump configurations provide operational flexibility that can also lead to optimized performance at many levels. The capability to function AODD pumps in a broad range of functions, from fundamental general use to delicate chemical-handling processes, allows operators to extra cost-effectively outfit their mines. AODD pumps can additionally be more cost effective to operate, particularly these models which are outfitted with a next-generation mechanically actuated air distribution system (ADS). At their most elementary, AODD pumps excel in the typical rugged and harsh operating circumstances discovered in the world’s mines, which reduces breakdown incidents along with corresponding downtime and restore costs.
Specifically, Wilden, whose founder, Jim Wilden, conceived the AODD pumping principle sixty-five years in the past, has been devoted to growing technologies that meet the wants of mining operations. Today, Wilden provides three AODD pump models that are built to excel in mining functions, out there in ductile iron, forged iron, aluminum, polypropylene and Kynar supplies of building:
Brahma® Series: The Brahma pumps, which function a bolted configuration, have been constructed for use in applications that require the dealing with of liquids featuring giant solids. The Brahma pumps have a unique top-inlet/bottom-discharge move orientation and flap valves that enable the passage of huge solids with no threat that injury will happen on account of product entrapment or the settling of solids throughout the pump’s internal 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 reduce air consumption by as much as 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 range for the 4 Brahma pumps is 166 to 258 gallons per minute at pressures up to one hundred twenty five psi with solids-handling functionality ranging from 2 to 3 inches.
Stallion® Series: The Stallion pumps function a clamped design with carrying handles for lightweight portability. Their design options giant inside clearances and flow-through paths for easy passage of huge solids with no chance for clogging. An altered ball/seat check-valve meeting further allows solids passage, whereas a polyurethane display screen 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 hardest environments. Flow rates amongst the six models vary from fifty seven gallons per minute to 232 gallons per minute at working pressures up to one hundred twenty five psi. Solids sizes that can 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 materials, including metal and plastics, even Kynar, which is able to dealing with high levels of abrasive supplies. The Pro-Flo SHIFT can also be the most environment friendly AODD pump in the market, able to reducing as much as 60 % air consumption. This makes it the greatest option for dealing with 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 capable of 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 materials, similar to Wil-Flex™ (Santoprene®), Geolast®, Polyurethane, Buna-N®, EPDM, Neoprene, FKM, and PTFE. This diaphragm range provides customers the widest selection of diaphragms on the market, all of that are capable of providing extended mean time between failure (MTBF) for optimized uptime with reduced upkeep, restore, and alternative costs.
All of those capabilities make AODD pumps the best alternative for the aforementioned frequent liquid-handling functions in mining: dewatering, general service, corrosive-handling, filter press, and day by day product switch.
CONCLUSION
In abstract, Wilden AODD pumps are the best suited choice for mining functions because they offer appreciable operational advantages, like comparable low-speed operation, dry-run, line-stripping, self-priming, and deadhead capability, along with increased operational safety and a reduction in maintenance/repair costs that may 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 different vital ways: easy design with the bottom number of elements for quicker, simpler, and safer repairs and the bottom number of spare parts to inventory; latest enhancements in supplies of building that enhance the pump’s MTBF; and improved effectivity through using the Pro-Flo SHIFT ADS, which in the end leads to sooner product switch with decrease air consumption. Wilden additionally continues to innovate through the event of the next-generation Chem-Fuse and EZ-Install diaphragms, both of which improve service life and safety while not compromising the handling of challenging liquids.
เกจวัดแรงดันpressuregauge is the regional manager North Latin America for Wilden, a quantity one 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 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 information, go to www.wildenpump.com or www.psgdover.com.
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