Mining: An Oversimplification
During the mining process, ore is broken down into the desired minerals. This process also yields what are known as “tails” or “tailings”—the leftovers. These leftovers are comprised of water and particles of varying sizes, with the fine particles creating a slurry texture that is difficult for most pumps to move through a piping system. Regardless, this slurry still has to be moved from the processing plant to the tailings pond.
Enter peristaltic pumps.
The Mightiest of Pumps
Peristaltic pumps (aka hose pumps, tube pumps, or roller pumps) are beastly, and therefore the preferred method for transferring slurry to tailings ponds. While peristaltic pumps have several advantages such as self-priming and the ability to handle almost any fluid, by their nature they also generate pulsations in the system. These pulsations can cause operational issues and reduce equipment lifespan.
Peristaltic pumps discharge discrete quantities of fluid, resulting in cyclic variations in instantaneous flow rate. These variations cause pressure spikes or pulsations in the system. (Imagine rock-laden fluid slamming against pipe walls and ripping supports from their anchors—not fun). Pulsation dampeners help absorb these pressure spikes and smooth the fluid flow.
Though the abrasiveness of the slurry will ultimately cause excessive wear of the hose and premature failure, a pulsation dampener will help extend the life as it reduces the turbulence in the harsh slurry to a laminar flow. Proper hose material and a correctly sized pulsation dampener will extend pump, valves, and hose life.
What is a Pulsation Dampener?
Pulsation dampeners are pressure vessels containing compressed air or nitrogen and a bladder that separates the process fluid from the gas charge. As pulsating fluid travels through the discharge line, the trapped air in the dampener absorbs up to 90% of the pulsations, creating a smoother flow.
Properly sizing the dampener is crucial. An undersized dampener won't adequately compensate for pressure fluctuations, while an oversized one will act as an accumulator, storing too much fluid and causing slow stabilization. Personnel must quantitatively define acceptable performance and calculate pressure fluctuations to determine proper dampener size.
In a Nutshell
To recap, tailings are an inevitable result of the mining process, and while the slurry that gets relocated into tailings ponds is abrasive and difficult to pump, peristaltic pumps can handle the application. Blacoh pulsation dampeners help mitigate the pressure pulsations that occur in peristaltic pump systems, enhancing overall performance and reliability. So, when dealing with peristaltic pumps in mining applications, consider adding a properly sized dampener to maintain stable flow and protect system components.