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How AODD Pumps Can Satisfy All Demands in Mining Operations

Mining is among the world’s oldest industries, tracing its roots back to those prehistoric days when somebody grabbed a digging instrument and started burrowing into the bottom. In the various millennia since, mining has grown into one of many world’s most important and widespread commercial enterprises, with operations spread throughout the globe whereas tasked with recovering an almost inexhaustible list of priceless commodities.
In fact, in accordance with the World Mining Congress’s World Mining Data 2020 report, 17.7 billion metric tons of mined products 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 58 p.c of the 2018 production, with North America second at 15.1 percent, followed 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) have been probably the most prolific producers, with their whole fifty one.1 p.c of production more than the rest of the world combined.
This signifies that the mining business is a robust one, with strong growth expected to proceed in the coming years in lots of areas of the world. It additionally implies that mining operations will continue to rely on pumping applied sciences that supply strong, dependable, and protected service in numerous critical liquid-handling operations. This white paper will illustrate why positive displacement air-operated double-diaphragm (AODD) pumps may be the only option for many of these purposes.
THE CHALLENGE
While mining may appear to be 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 typically delicate operations that have to be performed correctly if the mining operation is to carry out at its highest level of efficiency.
From a macro standpoint, this requires a pumping know-how that may operate reliably in harsh and distant places, even when submerged, or when tasked with dealing with particulate-laden liquids or toxic/corrosive products, and likewise one that is able to be maintained and repaired in order that downtime is lessened. The pumps must even be light enough to be manually moved from location to location within the mine itself.
For a few years, a popular selection for use in these conditions was centrifugal pumps. While centrifugal pumps are able to create the excessive flow rates which would possibly be required, they have a quantity of operational “pain points” that hamper their use in mining functions: an lack of ability to self-prime or run dry; special seals needed to stop leaks; particular linings needed to handle solids; excessive motor speeds of up to 1,800 rpm; and comparatively excessive upkeep necessities and costs, particularly when charged with transferring solid-heavy liquids.
Another in style choice has been the progressive cavity pump, but, like centrifugal pumps, they have a quantity of operational shortcomings. These embody an lack of ability to consistently deal with liquids with high levels of abrasives, which results in elevated upkeep costs, put on on expensive stators and rotors that will ultimately must be replaced, and general larger buy, working, and repair/replacement prices.
Here are a few of the specific liquid-transfer operations that take place in a mine and the ways in which some pump applied sciences 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 is recovered is often full of particulates that can be as giant as 0.12 to 0.sixteen inches in dimension. If used on this utility, centrifugal pumps require special supplies of construction, which can be cost prohibitive, to protect in opposition to impeller put on caused by the abrasive particles. Centrifugal pumps are also not dry-run capable, which adversely impacts their degree of performance on this utility.
pressure gauge nuova fima ราคา : For common liquid-handling purposes, you need an easy-to-operate pump that reliably can run dry, strip lines, function at low speeds while nonetheless delivering excessive move charges, and be simple to take care of and repair. Centrifugal pumps simply 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 typically demands a need to make use of special mechanical seals, which might lead to exorbitant maintenance, repair, and replacement costs.
Press filter: Press filters are used to scrub the liquids which are produced in the mines and, again, centrifugal pumps can fall quick on this application because the solid-laden liquid can injury the pump’s internals unless particular, costlier materials of construction or linings are used. Also, the nature of press-filter operation creates a robust discharge-pressure variation that may pressure the centrifugal pump to operate away from its greatest effectivity point (BEP), leading to high vibration and radial hundreds that can result in shortened service life. A resolution to that is the incorporation of variable frequency drives (VFDs) and controllers, but these are costly and might negatively have an effect on 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 equipment, recent and fouled water, and any chemical compounds that are required. In every instance, there’s the risk that the pump will be compelled to run dry as the truck or storage vessel is emptied, whereas discharge-pressure variation also can generate excessive vibration and radial hundreds. As previously illustrated, centrifugal pumps can’t run dry, in order that they need protection from this situation or the addition of special seals. However, all of these upgrades nonetheless cannot completely defend in opposition to a catastrophic failure.
THE SOLUTION
While centrifugal pumps—despite their popularity—have confirmed to not be the best answer in lots of 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 safety for mining personnel and the environment.
pressure gauge น้ำ are capable of perform successfully in mining functions as a result of their methodology of operation permits them to easily handle variable move charges and pressures, whereas being dry-run and line-stripping capable, and nimble enough to transfer liquids which may be shear-sensitive or high-viscosity, as nicely as slurries laden with rocks, pebbles, and other particulates.
The simple design of the AODD pump options few moving parts and comparably lower speeds than other pump applied sciences, which improves reliability and simplifies upkeep, while the pump’s seal-less building ends in fewer leaks, which is a important consideration when dealing with the numerous hard-to-seal, corrosive, or hazardous liquids that are prevalent in a mining operation. AODD pumps can be found in both metal (most generally aluminum, ductile iron and cast iron) and plastic (polypropylene and PVDF) housing constructions, whereas a broad selection of elastomers can be utilized within the diaphragms, which eliminates many chemical-compatibility considerations.
A extensive number of AODD pump configurations provide operational flexibility that can also end in optimized performance at many ranges. The capacity to feature AODD pumps in a variety of functions, from basic basic use to delicate chemical-handling processes, allows operators to extra cost-effectively outfit their mines. AODD pumps may additionally be less costly to function, especially these fashions which are outfitted with a next-generation mechanically actuated air distribution system (ADS). At their most elementary, AODD pumps excel within the typical rugged and harsh working conditions found within the world’s mines, which reduces breakdown incidents together with corresponding downtime and repair prices.
Specifically, Wilden, whose founder, Jim Wilden, conceived the AODD pumping principle sixty-five years in the past, has been dedicated to developing technologies that meet the needs of mining operations. Today, Wilden presents three AODD pump models which are constructed to excel in mining purposes, out there in ductile iron, forged iron, aluminum, polypropylene and Kynar materials of building:
Brahma® Series: The Brahma pumps, which feature a bolted configuration, have been constructed to be used in purposes that require the handling of liquids featuring massive solids. The Brahma pumps have a novel top-inlet/bottom-discharge move orientation and flap valves that permit the passage of large solids with no danger that damage will occur on account of product entrapment or the settling of solids inside the pump’s inner circulate 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 %. 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 up to one 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 large inside clearances and flow-through paths for simple passage of huge solids with no chance for clogging. An altered ball/seat check-valve assembly further allows solids passage, whereas a polyurethane display screen base on 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 that includes the Turbo-Flo ADS, Wilden’s most sturdy ADS design for the hardest environments. Flow rates amongst the six fashions range from fifty seven gallons per minute to 232 gallons per minute at working pressures up to one hundred twenty five psi. Solids sizes that may be dealt with range from half to 1 inch.
Pro-Flo SHIFT Series: Pro-Flo SHIFT pumps characteristic clamped or bolted configuration. Their design features different chamber supplies, together with metallic and plastics, even Kynar, which is capable of dealing with high ranges of abrasive materials. The Pro-Flo SHIFT is also the most environment friendly AODD pump in the market, capable of decreasing up to 60 p.c air consumption. This makes it the best suited choice for handling corrosive and abrasive products in mining processes. The pumps have a product range 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 able to be outfitted with a wide array of diaphragm styles—including the newer Chem-Fuse, EZ-Install, and Reduced-Stroke models—in a varying array of supplies, corresponding 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 capable of offering prolonged mean time between failure (MTBF) for optimized uptime with reduced maintenance, restore, and replacement costs.
All of these capabilities make AODD pumps the perfect choice for the aforementioned frequent liquid-handling purposes in mining: dewatering, common service, corrosive-handling, filter press, and every day product transfer.
CONCLUSION
In summary, Wilden AODD pumps are the best suited choice for mining applications because they offer considerable operational advantages, like comparable low-speed operation, dry-run, line-stripping, self-priming, and deadhead capability, along with increased operational security and a discount in maintenance/repair costs that can be incurred by pumps that are not designed to handle abrasive/corrosive or solid-laden liquids.
Wilden AODD pumps additionally outperform other AODD technologies in other significant methods: simple design with the bottom variety of parts for faster, simpler, and safer repairs and the lowest number of spare parts to inventory; recent improvements in supplies of development that enhance the pump’s MTBF; and improved effectivity by way of the use of the Pro-Flo SHIFT ADS, which ultimately leads to sooner product switch 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 increase service life and safety while not compromising the dealing with of challenging 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 could be reached at fernando.meneses@psgdover.com. Wilden is a product brand of PSG®, a Dover company. PSG is comprised of a number of main pump corporations, together with Abaque®, All-Flo™, Almatec®, Blackmer®, Ebsray, em-tec®, Griswold®, Hydro™, Mouvex®, Neptune®, Quantex™, Quattroflow®, RedScrew™, and Wilden®. For more info, visit www.wildenpump.com or www.psgdover.com.
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