How AODD Pumps Can Satisfy All Demands in Mining Operations

Mining is amongst the world’s oldest industries, tracing its roots back to these prehistoric days when somebody 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 essential and widespread business enterprises, with operations unfold across the globe while tasked with recovering an almost inexhaustible record of useful commodities.
In truth, based on 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 almost double the 9.6 billion metric tons in 1985. Asian international locations accounted for 58 % of the 2018 production, with North America second at 15.1 percent, 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) have been essentially the most prolific producers, with their whole 51.1 percent of manufacturing greater than the relaxation of the world combined.
This means that the mining industry is a powerful one, with solid growth anticipated to proceed in the coming years in lots of regions of the world. It also implies that mining operations will proceed to depend on pumping applied sciences that provide robust, reliable, and secure service in a quantity of critical liquid-handling operations. This white paper will illustrate why optimistic displacement air-operated double-diaphragm (AODD) pumps may be your best option for a lot of of these functions.
THE CHALLENGE

While mining may appear to be nothing greater than a rough-and-tumble operation—holes are dug by heavy equipment or with explosives, opening the hidden ode to access from above—there are, in reality, many advanced and typically delicate operations that should be performed properly if the mining operation is to carry out at its highest degree of efficiency.
From a macro standpoint, this requires a pumping expertise that can operate reliably in harsh and distant areas, even when submerged, or when tasked with handling particulate-laden liquids or toxic/corrosive products, and in addition one that is prepared to be maintained and repaired in order that downtime is lessened. The pumps should even be light enough to be manually moved from location to location inside the mine itself.
For many years, a popular alternative to be used in these situations was centrifugal pumps. While centrifugal pumps are capable of create the high circulate charges that are required, they’ve numerous operational “pain points” that hamper their use in mining functions: an inability to self-prime or run dry; particular seals wanted to forestall leaks; special linings needed to handle solids; excessive motor speeds of up to 1,800 rpm; and comparatively high upkeep requirements and prices, particularly when charged with transferring solid-heavy liquids.
Another in style alternative has been the progressive cavity pump, however, like centrifugal pumps, they have a number of operational shortcomings. These embody an incapability to persistently deal with liquids with excessive levels of abrasives, which finally ends up in elevated upkeep costs, wear on expensive stators and rotors that will ultimately need to be changed, and total larger purchase, working, and repair/replacement costs.
Here are a number 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 crucial 24/7/365 operation and the water that’s recovered is usually full of particulates that can be as large as 0.12 to zero.16 inches in measurement. If used on this utility, centrifugal pumps require particular materials of building, which could be price prohibitive, to protect in opposition to impeller put on caused by the abrasive particles. Centrifugal pumps are also not dry-run succesful, which adversely affects their degree of performance in this software.
General service: For frequent liquid-handling applications, you need an easy-to-operate pump that reliably can run dry, strip strains, function at low speeds whereas nonetheless delivering high circulate rates, and be straightforward 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 demands a need to make use of special mechanical seals, which may lead to exorbitant maintenance, restore, and substitute prices.
Press filter: Press filters are used to wash the liquids that are produced in the mines and, once more, centrifugal pumps can fall quick in this software because the solid-laden liquid can harm the pump’s internals except particular, costlier materials of construction or linings are used. Also, the character of press-filter operation creates a powerful discharge-pressure variation that may pressure the centrifugal pump to function away from its greatest efficiency point (BEP), leading to excessive vibration and radial masses that may result in shortened service life. A answer to that is the incorporation of variable frequency drives (VFDs) and controllers, however these are costly and may negatively have an effect on the cost-effectiveness of the operation.
Product transfer: This comes in all varieties 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 substances which are required. In each occasion, there is the danger that the pump will be forced to run dry as the truck or storage vessel is emptied, while discharge-pressure variation also can generate high vibration and radial loads. As previously illustrated, centrifugal pumps can’t run dry, in order that they need safety from this condition or the addition of special seals. However, all of these upgrades nonetheless can not totally defend in opposition to a catastrophic failure.
THE SOLUTION

While centrifugal pumps—despite their popularity—have confirmed to not be the most effective solution in lots of liquid-handling purposes in mining, one pump expertise that has proven to be an optimum selection is AODD—in phrases of maximizing reliability, cost-effectiveness, ease of operation and upkeep, and safety for mining personnel and the environment.
AODD pumps are able to perform effectively in mining applications because their technique of operation allows them to simply handle variable circulate rates and pressures, while being dry-run and line-stripping succesful, and nimble enough to switch liquids which are 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 transferring elements and comparably lower speeds than different pump technologies, which improves reliability and simplifies upkeep, whereas the pump’s seal-less construction ends in fewer leaks, which is a crucial consideration when dealing with the numerous hard-to-seal, corrosive, or hazardous liquids which are prevalent in a mining operation. AODD pumps are available in each steel (most generally aluminum, ductile iron and solid iron) and plastic (polypropylene and PVDF) housing constructions, whereas a broad array of elastomers can be used within the diaphragms, which eliminates many chemical-compatibility concerns.
A extensive number of AODD pump configurations present operational flexibility that may also result in optimized performance at many levels. The capability to characteristic AODD pumps in a extensive range of applications, from basic general use to delicate chemical-handling processes, allows operators to extra cost-effectively outfit their mines. AODD pumps may also be less costly to function, especially those models that are outfitted with a next-generation mechanically actuated air distribution system (ADS). At their most basic, AODD pumps excel within the typical rugged and harsh working circumstances discovered within the world’s mines, which reduces breakdown incidents along 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 offers three AODD pump fashions that are built to excel in mining applications, available in ductile iron, cast iron, aluminum, polypropylene and Kynar materials of development:
Brahma® Series: The Brahma pumps, which characteristic a bolted configuration, have been built to be used in applications that require the dealing with of liquids that includes massive solids. The Brahma pumps have a unique top-inlet/bottom-discharge move orientation and flap valves that enable the passage of enormous solids with no risk that harm will happen as a end result of product entrapment or the settling of solids within the pump’s inside circulate paths. pressure gauge 10 bar 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 up to 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 as a lot as one hundred twenty five psi with solids-handling functionality starting from 2 to three inches.
Stallion® Series: The Stallion pumps feature a clamped design with carrying handles for lightweight portability. Their design features large inner clearances and flow-through paths for simple passage of enormous solids with no chance for clogging. An altered ball/seat check-valve meeting additional allows solids passage, whereas a polyurethane display screen base at the inlet increases the pump’s sturdiness. 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 range from fifty seven gallons per minute to 232 gallons per minute at working pressures as a lot as a 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 feature clamped or bolted configuration. Their design options totally different chamber materials, including metal and plastics, even Kynar, which is able to handling excessive levels of abrasive supplies. The Pro-Flo SHIFT is also essentially the most efficient AODD pump in the market, able to decreasing up to 60 % air consumption. This makes it the finest option for handling corrosive and abrasive merchandise in mining processes. The pumps have a product range 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 in a position to be outfitted with a wide selection of diaphragm styles—including the newer Chem-Fuse, EZ-Install, and Reduced-Stroke models—in a varying array of supplies, such as Wil-Flex™ (Santoprene®), Geolast®, Polyurethane, Buna-N®, EPDM, Neoprene, FKM, and PTFE. This diaphragm vary offers users the widest selection of diaphragms available on the market, all of that are capable of providing prolonged imply time between failure (MTBF) for optimized uptime with lowered upkeep, restore, and alternative prices.
All of these capabilities make AODD pumps the ideal alternative for the aforementioned common liquid-handling purposes in mining: dewatering, basic service, corrosive-handling, filter press, and daily product switch.
CONCLUSION

In abstract, Wilden AODD pumps are the greatest choice for mining purposes because they provide appreciable operational advantages, like comparable low-speed operation, dry-run, line-stripping, self-priming, and deadhead capability, together with increased operational security and a reduction in maintenance/repair costs that can be incurred by pumps that are not designed to deal with abrasive/corrosive or solid-laden liquids.
เพรสเชอร์เกจ outperform different AODD technologies in other important methods: simple design with the bottom variety of parts for faster, less complicated, and safer repairs and the bottom number of spare components to stock; current improvements in materials of building that increase the pump’s MTBF; and improved efficiency via the utilization of the Pro-Flo SHIFT ADS, which ultimately ends in quicker product transfer with decrease air consumption. Wilden additionally continues to innovate via the development of the next-generation Chem-Fuse and EZ-Install diaphragms, each of which improve service life and security whereas not compromising the dealing with of challenging liquids.
FOR MORE INFORMATION

Fernando Meneses is the regional supervisor North Latin America for Wilden, a quantity one producer of air-operated double-diaphragm (AODD) pumps. He can be reached at fernando.meneses@psgdover.com. Wilden is a product model of PSG®, a Dover company. PSG is comprised of a number of leading pump corporations, including Abaque®, All-Flo™, Almatec®, Blackmer®, Ebsray, em-tec®, Griswold®, Hydro™, Mouvex®, Neptune®, Quantex™, Quattroflow®, RedScrew™, and Wilden®. For more information, go to www.wildenpump.com or www.psgdover.com.
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