OVERVIEW

A mining customer had trouble with the old hose pump they used for handling slurry. As experts in providing effective slurry handling solutions, All-Pumps recommended an Abaque hose pump for mining to reduce maintenance costs and time and improve their system’s performance.

THE PROBLEM

A customer was chasing a new hose pump for mining to replace their old Bredel pump, which was not very durable. With the low-quality construction of the said pump, the customer would go on hours of breakdown, greatly affecting their timeline and bottom line.

THE SOLUTION

We supplied an Abaque hose pump (also peristaltic or peristaltic hose pump) made in France that is suitable for slurries on mine sites. Abaque hose pumps use durable materials like Buna-N (NBR) and natural rubber (NR), known for high wear and abrasion resistance. Also, Abaque hose pumps are easy to maintain as the hose is the only wearing component.

Project Highlights & Results

Abaque hose pumps are designed to give continuous, reliable performance in some of the most demanding applications in the mining industry. They have a capacity of up to 54,000 litres per hour for intermittent operation and 36,000 litres per hour for continuous pumping.

Abaque hose pumps can also handle viscosities up to 70,000 cst and temperatures up to 80 degrees Celsius – perfect for slurry handling and mining environments. The company manufactures hose using different materials to ensure chemical compatibility – a key to prolonging hose life and minimising leaks and breakdown.

We coupled the hose pump to a WEG W22 mining motor designed to operate in hazardous mining conditions where temperatures are extreme and risk of explosion is always present.

Together, the Abaque hose pump and WEG mining motor ensure low maintenance, significantly reducing undesirable downtime and providing greater plant availability.

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OVERVIEW

All-Pumps designed a pump set consisting of a Wangen twin screw pump and gear motor for a bakery manufacturing process customer. The assembly replaced the customer's old, inefficient pump they used to transfer pancake batter.

THE PROBLEM

Initially, a bakery customer utilized a European OEM lobe pump. Unfortunately, it would not transfer their pancake batter to the oven due to an incorrect pump selection during the design phase. Subsequently, the actual process changed because the pancake batter was colder and thicker than initially anticipated. The existing pump could not meet the new transfer conditions, which slowed the whole operation and caused the bakery to miss their production quotas.

THE SOLUTION

All-Pumps visited the site and identified the existing pump's constraints. The unit had limited ability to pump within the range of flows needed for the given range of viscosities. Our application engineers reviewed the system with the customer’s production and engineering managers and analysed pipework losses, pressures, flows, and the suction/feed set-up.

Given the data collected, our team recommended a custom, German-built "Wangen Twin Screw Pump" to increase the transfer time from the mixer to the storage tank. We chose the NG 70 model with vertical orientation to overcome cavitation, along with a special gear motor and pitched screw to maximise torque and minimise slip during extreme flow parameters of the flows. The pump set was commissioned into the customer’s VSD control automation software.

Project Highlights & Results

Compatibility + Conformance

Our thorough pump selection process and large inventory significantly contributed to this project's success. We chose a Wangen twin screw pump with the proper specifications for pumping the customer's viscous and cold pancake batter. The Wangen pump was also compatible with their existing equipment, which made installation easy. As a result, the new pump set overcame the customer’s tricky situation.

All-Pumps has access to over 18.5 million pump configurations and renowned brands like Wangen. This allows us to develop tailored solutions for our customer's unique application requirements.

Better Pump Performance

The Wangen Twin NG screw pump provides a reliable solution for gently feeding high-viscosity media like the customer's pancake batter. We used the NG 70 food-grade model for this application to transfer thick pancake batter at low temperatures efficiently and quickly.

After running the new pump, the customer reported a very satisfactory outcome, as they can now exceed their production expectations. With the same settings as their old pump, the Wangen twin screw pump reportedly transfers their pancake batter twice faster as the previous. The customer will also benefit from lower maintenance costs in the long run, thanks to the new generation Wangen twin screw pump's fast-X-change® technology.

Speedy Customisation and Installation

With the bare Wangen twin screw pump in stock and ready for modification at our warehouse, we assembled and delivered the custom pump set – complete with a gear motor – ready for installation and start-up within four weeks. This meant a speedy recovery for the customer.

With 50 years of experience in pump supply and service, we honed our expertise in selecting the best pumps for different applications. All-Pumps has a local stock of various pump brands and models at our warehouses. This enables us to deliver timely orders to help our customers return to production quickly.

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Overview

A repeat and loyal customer contacted us to order helical rotor pumps for use in their water treatment process. Several centrifugal pumps were also needed in their newly set up refinery application. After our thorough selection process, all pumps were delivered to their mining site in the North Territory.

The customer is in the process of building a tricanter centrifuge system to treat HFO wash waters. The application requires various pumps for the water treatment phase, where the system will extract oil and particles and clean the water for reuse.

Their engineering team pre-selected pumps that could satisfy the transfer duty conditions and sent us the piping and instrumentation diagram (P&ID). Our task was to check the P&ID and to size and supply the pumps suitable for the application. Value-added services included the fabrication of the pumps’ baseplates and the supply of variable speed drives and control panels to optimise efficiency and safety.

A progressive cavity pump is being installed and fitted in a water treatment facility of a mining company in the Northern Territory of Australia

The Problem

Our team had to size and select the correct water treatment pumps for transferring various fluids with different viscosities and pressure ranges, including acids, sludges, slurries and oils.

The Solution

All-Pumps chose Nexus helical rotor pumps (AKA progressive cavity pumps) for the water treatment phase. The project also included other pumps, such as vertical multistage pumps functioning as the application’s decontamination pump that feed cleaning heads to the system. Horizontal centrifugal pumps were also used for pumping oil and chemicals in Zone 2-certified areas of the mines.

Project Highlights and Results

A Helical rotor pump used in a water treatment facility of a mining company in the Northern Territory of Australia

Nexus Helical Rotor Pumps for Water Treatment Process

Helical rotor pumps are widely used in water treatment processes. Self-priming and valveless, they can move sludge and other difficult fluids like solids, abrasives, and chemicals at high pressures and viscosities – making them the most suitable water treatment pumps for this refinery project.

Helical rotor pumps do not disappoint when it comes to performance. They can withstand temperatures up to 150 °C, have high discharge pressures up to 48 bar and capacities up to 345 m3/hr, and are designed for solid handling up to 7% without clogging and viscosities up to 30,000 cst.

Pumps Fitted and Mounted on Galvanised Baseplates

Pumps for this project were assembled on galvanised baseplates for uninterrupted and reliable service even when exposed to the harsh mining environment. Galvanised steel baseplates are used for corrosion protection that can last for decades. This technique is known as the toughest coating that provides outstanding resistance to mechanical damage. Galvanising of steel baseplates is done according to the Australian/New Zealand Standard 4680 (AS/NZS 4680-2006) to ensure reliable coating life and performance.

Variable Speed Drives and Pump Control Panels

In this application where variable flow and pressure are required, a variable speed drive (VSD) is needed to reduce power during periods of reduced demand. A VSD is one of the most efficient flow control methods for pumps and does not waste shaft input energy.

Variable speed drives adjust flow or pressure to the actual demand by controlling the frequency of the electrical power supplied to pumps. As a result, significant power savings can be achieved, and in most cases, improved performance, increased reliability, and reduced life cycle costs are also expected.

We also supplied control panels alongside pumps and VSD. The explosion-proof panels were customised to provide a centralised location from which operators can monitor and adjust the full range of pump process variables. This not only simplifies the control process of the pumps but also enhances safety for both the operators and the pumps.

Our longstanding relationships with world-famous pump manufacturers allow us to ship all pumps and accessories that our customers need.

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Overview

An urban mining company needed several chemical pumps to build a new wet crush processing plant in Sydney. Being a major recycler in the city, the client deals with large volumes of waste to reclaim elements and compounds that can be reused for different purposes, such as construction materials and electronics. Sample wastes include concrete, bricks, steel reinforcements, roofing materials, copper pipes or aluminum, electronics, and other scrap metals. These recovered materials undergo complex processing, which includes crushing.

The Problem

The customer needed pumps to handle highly corrosive and abrasive chemicals daily. The chemical pumps should also handle high-flow, high-pressure chemical transfer conditions. Apart from these system requirements, the customer wanted to minimise capital outlay while ensuring reliable results. They also needed local support and knowledgeable backup for operational success in the future.

The Solution

We went through our selection process with several engineers from both sides to pinpoint the best pumps for the project that wouldn’t cost the earth. Our wide range of products and our partnership with Graco, Blacoh, Finish Thompson, and Grundfos enabled us to deliver a complete solution without complicating it for the client. Each pump was tested and supplied to the customer’s exact duty requirements. Overall, the success of this project depended on our our pump selection process expertise, access to pumps for every application, and knowledgeable and trained technicians to provide assistance in the whole process—from setting up the new crusher plant’s pump system to maintaining it.

Graco air diaphragm pumps and Blacoh pulsation dampeners and FTi magnetic Drive pumps installed in a bio mining facility

Project Highlights and Results

FTI Mag Drive Pumps to Handle Different Chemicals

Not all pumps are built to handle harsh substances like the chemicals used to process wastes in urban mining. Magnetic-driven pumps (or mag drive pumps) have no mechanical seal that could be affected by strong chemicals, making them ideal for handling demanding chemical applications.

The sealless technology of mag drive pumps also means no leaks. Mag drive pumps have two separate contained areas for the motor and the impeller. The pumped fluid remains in a hermetically sealed housing. Even the most corrosive chemicals can be pumped without concern of leakage.

The mag drive pump design also decreases maintenance costs and dramatically improves system uptime. Mechanical seals are among the frequently worn-out parts in a sealed pump. They need regular maintenance to prevent damage. Thus, without them, mag drive pumps can greatly minimise system downtime.

With all these benefits, it was obvious that an FTI mag drive pump would be fit for the job.

FTi magnetic Drive pumps Graco air diaphragm pumps and Blacoh pulsation dampeners installed in a bio mining facility
FTi magnetic Drive pumps Graco air diaphragm pumps and Blacoh pulsation dampeners installed in a bio mining facility

Ability to Couple the Graco Husky Air-Operated Pumps with Blacoh Pulsation Dampeners for Reliable and Pulseless Operation

Several air-operated double diaphragm pumps were used in the plant. Given the application requirements, we concluded that a Graco Husky plastic AODD would be the best type to use in the system.

Blacoh Pulsation dampeners were used along with the AODD pumps to maintain regularity to the outgoing flow. These instruments minimise pulsations, vibrations, and water hammers to safeguard the entire pump system. Blacoh dampeners come in a wide choice of construction materials, which helped us determine the best chemical compatibility with the duty fluid in our customer’s applications.

Air-operated double-diaphragm (AODD) pumps provide a reliable transfer solution in chemical applications. The lack of electrical components means diaphragm pumps can be operated in challenging, damp, flammable environments and can be installed easily and quickly. Plastic AODD pumps also offer superior chemical resistance and rugged, leak-free construction.

Additionally, they tend to resist corrosion, are capable of running dry and self-priming, produce a shear-sensitive flow, have no mechanical seals, can deadhead, and can be easily maintained.

The Polypropylene Husky 3300 with the new centre discharge also features an improved diaphragm design for longer life, satisfying the customer’s wish to cut costs. Among other benefits, these chemical pumps are also designed to increase efficiency by up to 30% and flow by up to 10%.

Graco air diaphragm pumps and Blacoh pulsation dampeners installed in a bio mining facility
Graco air diaphragm pumps and Blacoh pulsation dampeners and FTi magnetic Drive pumps installed in a bio mining facility

Overall, our engineering team worked on all small details of the project, from design to pump selection, and ironed out any potential issues before the pumps were ordered — all based on the experience we have accumulated over the last 50 years that is built into our selection process, ability to service and provide commissioning support with real solutions, and skills and experience in dealing with dangerous chemicals.

The project will have a significant positive environmental impact over the coming years, and we are proud to partner on this journey.

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