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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 began burrowing into the bottom. In the numerous millennia since, mining has grown into one of the world’s most important and widespread commercial enterprises, with operations unfold across the globe while tasked with recovering an virtually inexhaustible record of valuable commodities.
In fact, based on the World Mining Congress’s World Mining Data 2020 report, 17.7 billion metric tons of mined merchandise had been 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 fifty eight percent of the 2018 production, with North America second at 15.1 %, followed by Europe (8 percent), Oceania (6.eight 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) had been probably the most prolific producers, with their total fifty one.1 percent of manufacturing greater than the relaxation of the world mixed.
This implies that the mining business is a strong one, with strong growth anticipated to continue within the coming years in many regions of the world. It also signifies that mining operations will proceed to rely on pumping technologies that provide sturdy, dependable, and secure service in a variety of critical liquid-handling operations. This white paper will illustrate why optimistic displacement air-operated double-diaphragm (AODD) pumps may be the solely option for many of those functions.
THE CHALLENGE
While mining would possibly appear to be 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, in reality, many advanced and sometimes delicate operations that must be performed correctly if the mining operation is to perform at its highest stage of effectivity.
From a macro standpoint, this requires a pumping technology that can operate reliably in harsh and distant areas, even when submerged, or when tasked with dealing with particulate-laden liquids or toxic/corrosive merchandise, and in addition one that is prepared to be maintained and repaired in order that downtime is lessened. The pumps must also be gentle sufficient to be manually moved from location to location within the mine itself.
For many years, a popular alternative for use in these circumstances was centrifugal pumps. While centrifugal pumps are able to create the excessive move charges which are required, they’ve a variety of operational “pain points” that hamper their use in mining functions: an lack of ability to self-prime or run dry; special seals wanted to prevent leaks; special linings wanted to handle solids; excessive motor speeds of up to 1,800 rpm; and relatively excessive upkeep requirements and prices, especially when charged with transferring solid-heavy liquids.
Another in style alternative has been the progressive cavity pump, however, like centrifugal pumps, they’ve a variety of operational shortcomings. These include an lack of ability to constantly handle liquids with excessive levels of abrasives, which results in elevated maintenance prices, wear on expensive stators and rotors that may eventually have to be replaced, and general greater purchase, operating, 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 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 stuffed with particulates that might be as large as zero.12 to 0.sixteen inches in size. If used on this utility, centrifugal pumps require special supplies of construction, which can be price prohibitive, to protect against impeller wear caused by the abrasive particles. Centrifugal pumps are additionally not dry-run capable, which adversely affects their level of performance in this application.
General service: For widespread liquid-handling applications, you need an easy-to-operate pump that reliably can run dry, strip lines, operate at low speeds while nonetheless delivering excessive flow rates, and be easy to take care of and restore. Centrifugal pumps merely do not 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 sometimes demands a need to make use of particular mechanical seals, which may result in exorbitant maintenance, restore, and substitute prices.
Press filter: Press filters are used to clean the liquids which are produced within the mines and, again, centrifugal pumps can fall short on this software as a end result of the solid-laden liquid can injury the pump’s internals unless special, costlier materials of building or linings are used. Also, the character of press-filter operation creates a robust discharge-pressure variation that may pressure the centrifugal pump to function away from its greatest efficiency point (BEP), resulting in excessive vibration and radial hundreds that may result in shortened service life. A answer to this is the incorporation of variable frequency drives (VFDs) and controllers, but these are costly and may negatively have an effect on the cost-effectiveness of the operation.
Product switch: This is available in all forms in a mining operation, from loading and unloading from transport vans with new and used oil for the heavy equipment, fresh and fouled water, and any chemicals which would possibly be required. In each instance, there may be the chance that the pump will be compelled to run dry as the truck or storage vessel is emptied, whereas discharge-pressure variation can even generate high vibration and radial loads. As beforehand illustrated, centrifugal pumps can not run dry, in order that they want safety from this situation or the addition of special seals. However, all of those upgrades nonetheless can not totally protect towards a catastrophic failure.
THE SOLUTION
While เพรสเชอร์เกจ despite their popularity—have confirmed to not be the best answer in lots of liquid-handling purposes in mining, one pump technology that has confirmed to be an optimum choice is AODD—in terms of maximizing reliability, cost-effectiveness, ease of operation and maintenance, and safety for mining personnel and the environment.
AODD pumps are able to carry out effectively in mining applications because their technique of operation allows them to easily handle variable flow rates and pressures, whereas being dry-run and line-stripping succesful, and nimble sufficient to switch liquids that are shear-sensitive or high-viscosity, in addition to slurries laden with rocks, pebbles, and other particulates.
The easy design of the AODD pump features few moving components and comparably lower speeds than other pump applied sciences, which improves reliability and simplifies upkeep, while the pump’s seal-less development results in fewer leaks, which is a important consideration when dealing with the various hard-to-seal, corrosive, or hazardous liquids that are prevalent in a mining operation. AODD pumps can be found in each metal (most commonly aluminum, ductile iron and cast iron) and plastic (polypropylene and PVDF) housing constructions, while a extensive selection of elastomers can be used in the diaphragms, which eliminates many chemical-compatibility issues.
A broad variety of AODD pump configurations present operational flexibility that can additionally lead to optimized efficiency at many levels. The ability to function AODD pumps in a variety of purposes, from basic common use to delicate chemical-handling processes, allows operators to extra cost-effectively outfit their mines. AODD pumps may additionally be less costly to operate, particularly those models which may be outfitted with a next-generation mechanically actuated air distribution system (ADS). At their most simple, AODD pumps excel in the typical rugged and harsh working situations found within the world’s mines, which reduces breakdown incidents together with corresponding downtime and restore 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 purposes, obtainable in ductile iron, forged 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 handling of liquids that includes massive solids. The Brahma pumps have a singular top-inlet/bottom-discharge move orientation and flap valves that permit the passage of huge solids with no danger that injury will happen on account of product entrapment or the settling of solids within the pump’s internal 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 much as 60 p.c. 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 ranging from 2 to 3 inches.
Stallion® Series: The Stallion pumps feature a clamped design with carrying handles for lightweight portability. Their design options massive inside clearances and flow-through paths for straightforward passage of large solids with no chance for clogging. An altered ball/seat check-valve assembly further allows solids passage, whereas a polyurethane display base at the inlet will increase the pump’s durability. The PS4, PS8, and PS15 (1.5-, 2-, and 3-inch) models 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 strong ADS design for the hardest environments. Flow charges amongst the six models vary from 57 gallons per minute to 232 gallons per minute at working pressures as much as a hundred twenty five psi. Solids sizes that can be dealt with range from half of to 1 inch.
Pro-Flo SHIFT Series: Pro-Flo SHIFT pumps feature clamped or bolted configuration. Their design options totally different chamber materials, including metallic and plastics, even Kynar, which is able to dealing with excessive levels of abrasive supplies. The Pro-Flo SHIFT is also probably the most environment friendly AODD pump available within the market, able to reducing as much as 60 p.c air consumption. This makes it the most fitted choice 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 wide selection of diaphragm styles—including the newer Chem-Fuse, EZ-Install, and Reduced-Stroke models—in a various array of materials, corresponding to Wil-Flex™ (Santoprene®), Geolast®, Polyurethane, Buna-N®, EPDM, Neoprene, FKM, and PTFE. This diaphragm vary provides users the widest choice of diaphragms in the marketplace, all of which are capable of offering extended mean time between failure (MTBF) for optimized uptime with decreased maintenance, restore, and replacement prices.
All of those capabilities make AODD pumps the best selection for the aforementioned frequent liquid-handling applications in mining: dewatering, general service, corrosive-handling, filter press, and every day product switch.
CONCLUSION
In summary, Wilden AODD pumps are the greatest option for mining purposes as a result of they provide appreciable operational benefits, like comparable low-speed operation, dry-run, line-stripping, self-priming, and deadhead capability, along with elevated operational safety and a discount in maintenance/repair prices that may be incurred by pumps that are not designed to deal with abrasive/corrosive or solid-laden liquids.
Wilden AODD pumps also outperform different AODD applied sciences in other important methods: easy design with the bottom number of parts for sooner, less complicated, and safer repairs and the bottom variety of spare components to inventory; latest improvements in materials of building that improve the pump’s MTBF; and improved effectivity through the usage of the Pro-Flo SHIFT ADS, which finally ends in quicker product transfer with lower air consumption. Wilden also continues to innovate by way of the development of the next-generation Chem-Fuse and EZ-Install diaphragms, each of which improve 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 number one producer of air-operated double-diaphragm (AODD) pumps. He can be reached at fernando.meneses@psgdover.com. Wilden is a product brand of PSG®, a Dover company. PSG is comprised of a quantity of main pump companies, together with Abaque®, All-Flo™, Almatec®, Blackmer®, Ebsray, em-tec®, Griswold®, Hydro™, Mouvex®, Neptune®, Quantex™, Quattroflow®, RedScrew™, and Wilden®. For more data, visit www.wildenpump.com or www.psgdover.com.
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