Paint Manufacturing Abrasive Slurry Diaphragm Failure

Paint Manufacturing Abrasive Slurry Diaphragm Failure

Problem: A major U.S. paint manufacturer uses 3” air operated double diaphragm pumps (AODD) in their tank farm to transfer ingredients to their paint blending process area. One of the main ingredients is titanium dioxide (TiO2) which is both high in specific gravity and very abrasive. The 3” AODD pumps sit at the bottom of holding tanks that are 25 feet tall. Pump inlet pressure is high and this combined with the characteristics of the TiO2 acts to shorten normal pump diaphragm life. When an unexpected diaphragm failure occurs, several thousand gallons of TiO2 can be lost because when a pump diaphragm fails, the TiO2 is pulled through the diaphragm on the pump’s suction stroke and then expelled out the air exhaust.

Achieving Even Application of Screen Coating

Achieving Even Application of Screen Coating

Problem: A manufacturer producing coated screens for residential and industrial windows relied on air operated double diaphragm (AODD) pumps to deliver coating material to their screen coating machines. However, pulsations generated by the pumps caused the spray nozzles to apply an uneven coating across the screens.

This inconsistency led to quality issues and required re coating, increasing both material waste and production time. Compounding the challenge, the existing equipment layout provided no vertical installation space for a traditional pulsation dampener.

Decontamination Facility Spray Pulsation

Decontamination Facility Spray Pulsation

Problem: A decontamination facility pumped acids and water through a series of 15" spray nozzles to rinse radiation from contaminated metals. However, the pulsating action of their reciprocating pumps caused uneven spray into the rinse tanks, and the metals were not rinsed completely.

Reliable Tailings and Concentrate Sampling

Reliable Tailings and Concentrate Sampling

Problem: A mining operation required a reliable tailings and concentrate sampling solution that could be installed directly in the flotation cell area and easily relocated as sampling points or process requirements changed.

Although the application itself was not large in scale, it needed to be:
- Simple to transport and handle
- Quick to connect and disconnect
- Robust enough for repeated use in different locations
- Stable in operation to ensure representative sampling


The challenge was delivering a compact, repeatable system without sacrificing flow stability or reliability.

Transport of Copper Bearing Solution in Remote Mining

Transport of Copper Bearing Solution in Remote Mining

Problem: A mining facility in Chile required a reliable and flexible solution to recover and transport copper-bearing solution just over 2 miles (3.5 km), from the leach pad to the process ponds. The operation had to be performed in a harsh, remote environment with no fixed infrastructure, while minimizing pressure losses and allowing the system to be easily relocated based on operational needs.

Pump Inlet Cavitation in Power Gen Facility

Pump Inlet Cavitation in Power Gen Facility

Problem: A power generation facility operating an industrial water system experienced recurring cavitation and dry running events on a reciprocating metering pump supplying deionized water.

The pump was fed from a large, elevated vertical supply tank with approximately 200 feet of suction piping, and from a static design perspective, the system appeared more than adequate. There was ample static head, no obvious restrictions, and a properly sized tank.

Despite this, the pump exhibited noise, instability, and signs of incomplete liquid end filling creating concern about accelerated wear and potential equipment damage. The operating team struggled to reconcile these issues with what seemed like “plenty of inlet pressure.”

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