How AODD Pumps Can Satisfy All Demands in Mining Operations

Mining is one of the world’s oldest industries, tracing its roots back to those prehistoric days when someone grabbed a digging instrument and started 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 unfold throughout the globe while tasked with recovering an nearly inexhaustible record of priceless commodities.
In truth, in accordance with 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 practically double the 9.6 billion metric tons in 1985. Asian nations accounted for 58 percent of the 2018 production, with North America second at 15.1 percent, 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) have been probably the most prolific producers, with their total fifty one.1 percent of production more than the relaxation of the world combined.
This means that the mining business is a strong one, with strong development expected to continue within the coming years in lots of regions of the world. It additionally signifies that mining operations will continue to depend on pumping technologies that provide strong, reliable, and safe service in numerous important liquid-handling operations. This white paper will illustrate why positive displacement air-operated double-diaphragm (AODD) pumps could be your finest option for many of these functions.
THE CHALLENGE
While mining may 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 access from above—there are, in reality, many advanced and generally delicate operations that have to be carried out correctly if the mining operation is to carry out at its highest level of effectivity.
From a macro standpoint, this requires a pumping know-how that can operate reliably in harsh and distant places, 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 just so downtime is lessened. The pumps should even be light enough 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 circumstances was centrifugal pumps. While centrifugal pumps are capable of create the excessive flow charges which are required, they’ve numerous operational “pain points” that hamper their use in mining purposes: an inability to self-prime or run dry; special seals wanted to stop leaks; particular linings needed to deal with solids; excessive motor speeds of as a lot as 1,800 rpm; and comparatively high upkeep necessities and costs, especially when charged with transferring solid-heavy liquids.
Another popular alternative has been the progressive cavity pump, however, like centrifugal pumps, they have a number of operational shortcomings. These embody an inability to consistently deal with liquids with high ranges of abrasives, which outcomes in increased maintenance prices, wear on costly stators and rotors that may finally have to be replaced, and total larger buy, working, and repair/replacement costs.
Here are a few of the specific liquid-transfer operations that happen in a mine and the ways in which some pump technologies 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 often filled with particulates that can be as massive as 0.12 to 0.16 inches in size. If used on this utility, centrifugal pumps require particular supplies of development, which can be value prohibitive, to guard in opposition to impeller put on attributable to the abrasive particles. Centrifugal pumps are additionally not dry-run capable, which adversely impacts their stage of efficiency on this application.
General service: For frequent liquid-handling purposes, you need an easy-to-operate pump that reliably can run dry, strip traces, operate at low speeds while nonetheless delivering high move charges, and be straightforward to keep up 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 demands a need to make use of particular mechanical seals, which may lead to exorbitant upkeep, repair, and replacement costs.
Press filter: Press filters are used to clean the liquids which are produced within the mines and, again, centrifugal pumps can fall short in this software as a result of the solid-laden liquid can damage the pump’s internals until particular, costlier materials of building or linings are used. Also, the character of press-filter operation creates a powerful discharge-pressure variation that may force the centrifugal pump to function away from its finest effectivity level (BEP), resulting in excessive vibration and radial masses that may lead to shortened service life. A resolution to that is the incorporation of variable frequency drives (VFDs) and controllers, however these are expensive and may negatively affect the cost-effectiveness of the operation.
Product switch: 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 chemical substances which are required. In every occasion, there might be the danger that the pump will be forced to run dry as 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 not run dry, so they want safety from this situation 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 simplest resolution in many liquid-handling applications in mining, one pump technology that has confirmed 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 environment.
AODD pumps are in a place to perform effectively in mining applications because their method of operation allows them to easily handle variable move charges and pressures, while being dry-run and line-stripping capable, and nimble enough to transfer liquids that are shear-sensitive or high-viscosity, as well as 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, whereas the pump’s seal-less construction leads to fewer leaks, which is a important consideration when handling the various hard-to-seal, corrosive, or hazardous liquids which are prevalent in a mining operation. AODD pumps are available in both metal (most generally aluminum, ductile iron and cast iron) and plastic (polypropylene and PVDF) housing constructions, while a huge selection of elastomers can be utilized in the diaphragms, which eliminates many chemical-compatibility issues.
A wide variety of AODD pump configurations present operational flexibility that may additionally end in optimized performance at many ranges. The capacity to characteristic AODD pumps in a broad range of purposes, from fundamental common use to delicate chemical-handling processes, allows operators to extra cost-effectively outfit their mines. AODD pumps can additionally be less costly to operate, particularly those 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 working circumstances discovered 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 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 models which would possibly be built to excel in mining purposes, out there in ductile iron, cast iron, aluminum, polypropylene and Kynar materials of construction:
Brahma® Series: The Brahma pumps, which function a bolted configuration, have been constructed to be used in applications that require the dealing with of liquids that includes giant solids. The Brahma pumps have a unique top-inlet/bottom-discharge flow orientation and flap valves that allow the passage of enormous solids with no danger that injury will happen as a outcome of product entrapment or the settling of solids within the pump’s inner move 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 reduce air consumption by as a lot 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 vary for the 4 Brahma pumps is 166 to 258 gallons per minute at pressures as much as one hundred twenty five psi with solids-handling capability starting from 2 to 3 inches.
Stallion® Series: The Stallion pumps characteristic a clamped design with carrying handles for light-weight portability. Their design features giant internal clearances and flow-through paths for straightforward passage of large solids with no probability for clogging. An altered ball/seat check-valve assembly further allows solids passage, while a polyurethane display base on the inlet will increase 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 featuring the Turbo-Flo ADS, Wilden’s most robust ADS design for the toughest environments. Flow rates amongst the six fashions range 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 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 able to dealing with excessive levels of abrasive materials. The Pro-Flo SHIFT can additionally be the most efficient AODD pump out there, able to lowering as much as 60 percent air consumption. This makes it the greatest choice for dealing with corrosive and abrasive products in mining processes. เกจวัดแรงดันลมดิจิตอล 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 huge selection of diaphragm styles—including the newer Chem-Fuse, EZ-Install, and Reduced-Stroke models—in a various array of supplies, corresponding to Wil-Flex™ (Santoprene®), Geolast®, Polyurethane, Buna-N®, EPDM, Neoprene, FKM, and PTFE. This diaphragm vary provides customers the widest choice of diaphragms available on the market, all of that are capable of offering extended imply time between failure (MTBF) for optimized uptime with lowered maintenance, restore, and alternative costs.
All of these capabilities make AODD pumps the best selection for the aforementioned widespread liquid-handling purposes in mining: dewatering, general service, corrosive-handling, filter press, and daily product switch.
CONCLUSION
In summary, Wilden AODD pumps are the greatest option for mining purposes as a result of they provide considerable operational advantages, like comparable low-speed operation, dry-run, line-stripping, self-priming, and deadhead capability, together with increased operational safety and a discount in maintenance/repair prices that could be incurred by pumps that are not designed to handle abrasive/corrosive or solid-laden liquids.
Wilden AODD pumps also outperform other AODD applied sciences in other vital methods: simple design with the bottom number of parts for sooner, easier, and safer repairs and the lowest variety of spare elements to stock; current improvements in materials of development that increase the pump’s MTBF; and improved effectivity by way of the utilization of the Pro-Flo SHIFT ADS, which finally leads to faster product switch with lower 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 increase service life and security whereas not compromising the handling of difficult liquids.
FOR MORE INFORMATION
Fernando Meneses is the regional manager North Latin America for Wilden, a leading manufacturer of air-operated double-diaphragm (AODD) pumps. เกจวัดแรงดันสูญญากาศ can be reached at fernando.meneses@psgdover.com. Wilden is a product model of PSG®, a Dover company. PSG is comprised of several leading pump companies, 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