How AODD Pumps Can Satisfy All Demands in Mining Operations

Mining is among the world’s oldest industries, tracing its roots again to these prehistoric days when someone grabbed a digging instrument and commenced burrowing into the bottom. In the many millennia since, mining has grown into one of the world’s most essential and widespread commercial enterprises, with operations spread across the globe while tasked with recovering an almost inexhaustible list of useful commodities.
In truth, in accordance with 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 eleven.three billion metric tons in 2000 and almost double the 9.6 billion metric tons in 1985. Asian nations accounted for fifty eight p.c of the 2018 manufacturing, with North America second at 15.1 p.c, followed by Europe (8 percent), Oceania (6.8 percent), Latin America (6.3 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 essentially the most prolific producers, with their total fifty one.1 % of manufacturing greater than the remainder of the world mixed.
This means that the mining industry is a strong one, with stable progress expected to continue in the coming years in many areas of the world. It also signifies that mining operations will proceed to rely on pumping applied sciences that supply strong, reliable, and secure service in a quantity of important liquid-handling operations. This white paper will illustrate why optimistic displacement air-operated double-diaphragm (AODD) pumps could be your finest option for many of these applications.
THE CHALLENGE

While mining would possibly 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 advanced and typically delicate operations that must be carried out properly if the mining operation is to perform at its highest level of effectivity.
From a macro standpoint, this requires a pumping know-how that can function reliably in harsh and remote locations, even when submerged, or when tasked with dealing with particulate-laden liquids or toxic/corrosive merchandise, and also one which is able 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 many years, a popular alternative to be used in these conditions was centrifugal pumps. While centrifugal pumps are able to create the excessive flow rates that are required, they’ve a selection of operational “pain points” that hamper their use in mining applications: an incapability to self-prime or run dry; particular seals wanted to forestall leaks; special linings wanted to handle solids; high motor speeds of up to 1,800 rpm; and comparatively excessive maintenance necessities 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’ve a number of operational shortcomings. These include an lack of ability to persistently deal with liquids with excessive levels of abrasives, which outcomes in elevated upkeep costs, wear on expensive stators and rotors that may ultimately need to be replaced, and general higher buy, operating, and repair/replacement costs.
Here are a number of the specific liquid-transfer operations that take place in a mine and the ways that some pump technologies can fall short in satisfying them:
Mine dewatering: Removing extra produced water from the mine is a important 24/7/365 operation and the water that is recovered is often stuffed with particulates that might be as large as 0.12 to 0.16 inches in measurement. If used in this utility, centrifugal pumps require special materials of building, which can be cost prohibitive, to guard in opposition to impeller wear caused by the abrasive particles. Centrifugal pumps are additionally not dry-run succesful, which adversely affects their stage of performance on this utility.
General service: For frequent liquid-handling purposes, you need an easy-to-operate pump that reliably can run dry, strip lines, operate at low speeds whereas still delivering excessive move charges, and be easy to maintain 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 elements of centrifugal and progressive cavity pumps. This sometimes demands a need to make use of special mechanical seals, which can result in exorbitant maintenance, restore, and substitute costs.
Press filter: Press filters are used to wash the liquids which might be produced within the mines and, again, centrifugal pumps can fall short in this software because the solid-laden liquid can damage the pump’s internals except special, costlier supplies of building or linings are used. Also, the character of press-filter operation creates a powerful discharge-pressure variation that may pressure the centrifugal pump to operate away from its best efficiency point (BEP), resulting in high vibration and radial masses that may result in shortened service life. A solution to this is the incorporation of variable frequency drives (VFDs) and controllers, however these are costly and can 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 trucks with new and used oil for the heavy machinery, recent and fouled water, and any chemical substances which are required. In each instance, there’s the danger that the pump shall be pressured to run dry as the truck or storage vessel is emptied, while discharge-pressure variation can also generate excessive vibration and radial loads. As previously illustrated, centrifugal pumps can not run dry, so that they need protection from this situation or the addition of special seals. However, all of these upgrades nonetheless cannot completely defend against a catastrophic failure.
THE SOLUTION

While centrifugal pumps—despite their popularity—have proven to not be the best resolution in plenty of liquid-handling purposes in mining, one pump know-how that has proven to be an optimum choice 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 capable of perform effectively in mining applications because their technique of operation permits them to simply deal with variable flow charges and pressures, while being dry-run and line-stripping succesful, and nimble sufficient to transfer liquids which 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 transferring parts and comparably lower speeds than other pump technologies, which improves reliability and simplifies maintenance, whereas the pump’s seal-less construction results in fewer leaks, which is a crucial 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 metallic (most generally aluminum, ductile iron and solid iron) and plastic (polypropylene and PVDF) housing constructions, whereas a big selection of elastomers can be utilized in the diaphragms, which eliminates many chemical-compatibility concerns.
A wide number of AODD pump configurations present operational flexibility that can additionally result in optimized efficiency at many ranges. The capacity to characteristic AODD pumps in a variety of purposes, from fundamental common use to delicate chemical-handling processes, permits operators to more cost-effectively outfit their mines. AODD pumps may additionally be less costly to operate, particularly those fashions which are outfitted with a next-generation mechanically actuated air distribution system (ADS). At their most simple, AODD pumps excel in the typical rugged and harsh operating conditions found in the world’s mines, which reduces breakdown incidents together with corresponding downtime and restore prices.
Specifically, Wilden, whose founder, Jim Wilden, conceived the AODD pumping principle sixty-five years ago, has been dedicated to growing technologies that meet the wants of mining operations. Today, Wilden provides three AODD pump fashions which are built to excel in mining functions, available in ductile iron, cast iron, aluminum, polypropylene and Kynar materials of building:
Brahma® Series: The Brahma pumps, which characteristic a bolted configuration, have been built for use in functions 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 allow the passage of huge solids with no threat 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 back 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 range for the 4 Brahma pumps is 166 to 258 gallons per minute at pressures up to a 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 options massive inside clearances and flow-through paths for straightforward passage of enormous solids with no probability for clogging. An altered ball/seat check-valve assembly further permits solids passage, while a polyurethane screen base at 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 that includes the Turbo-Flo ADS, Wilden’s most strong ADS design for the hardest environments. เกจวัดแรงดัน amongst the six fashions vary from 57 gallons per minute to 232 gallons per minute at working pressures up to one hundred twenty five psi. Solids sizes that might be handled range from half of to 1 inch.
Pro-Flo SHIFT Series: Pro-Flo SHIFT pumps function clamped or bolted configuration. Their design options different chamber supplies, including metal and plastics, even Kynar, which is able to handling high ranges of abrasive materials. The Pro-Flo SHIFT can additionally be essentially the most environment friendly AODD pump available within the market, able to lowering up to 60 percent air consumption. This makes it the finest option 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 in a place to be outfitted with a extensive array of diaphragm styles—including the newer Chem-Fuse, EZ-Install, and Reduced-Stroke models—in a various array of supplies, similar to Wil-Flex™ (Santoprene®), Geolast®, Polyurethane, Buna-N®, EPDM, Neoprene, FKM, and PTFE. This diaphragm vary provides customers the widest number of diaphragms on the market, all of that are capable of providing prolonged mean time between failure (MTBF) for optimized uptime with reduced upkeep, repair, and substitute costs.
All of those capabilities make AODD pumps the perfect choice for the aforementioned common liquid-handling applications in mining: dewatering, basic service, corrosive-handling, filter press, and every day product transfer.
CONCLUSION

In abstract, Wilden AODD pumps are the most suitable choice for mining purposes as a result of 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 reduction in maintenance/repair prices that may be incurred by pumps that aren’t designed to deal with abrasive/corrosive or solid-laden liquids.
Wilden AODD pumps additionally outperform other AODD applied sciences in different vital ways: easy design with the lowest number of components for faster, simpler, and safer repairs and the bottom number of spare parts to stock; latest improvements in materials of construction that improve the pump’s MTBF; and improved efficiency through using the Pro-Flo SHIFT ADS, which ultimately results in sooner product transfer with decrease air consumption. Wilden additionally continues to innovate through the development of the next-generation Chem-Fuse and EZ-Install diaphragms, each of which enhance service life and security whereas not compromising the dealing with of difficult liquids.
FOR MORE INFORMATION

Fernando Meneses is the regional manager North Latin America for Wilden, a leading 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 firms, together with Abaque®, All-Flo™, Almatec®, Blackmer®, Ebsray, em-tec®, Griswold®, Hydro™, Mouvex®, Neptune®, Quantex™, Quattroflow®, RedScrew™, and Wilden®. For extra data, go to www.wildenpump.com or www.psgdover.com.
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