Since its invention in 1955 as
a mining pump, Wilden's air-operated double diaphragm pneumatic pump (AODD) and
distributed by Fluid Technique, has earned a huge reputation as the ideal
technology for utilitarian, auxiliary or basic handling applications and
transfer of liquids.
AODD pump stand out in this type of
applications because they have design features that allow them to offer a
simple operation, without mechanical seals, the possibility of self-priming, dry
function, achieve a suction lift of up to 9 meters, resist head pumping
conditions dead, operate while submerged and pass solids up to 76 mm in
diameter.
Companies did not take long to
realize the advantages of these operational features in many processes
applications and why AODD pumps are true “process” pumps capable of operating
efficiently, reliably and safely in a wide range of applications critics. AODD
pumps also reach the optimum point of operation in many of the fluid handling
tasks that prevail in the chemical processing industry.
There are four key areas where
AODD pumps often outperform other technologies in terms of efficient, reliable
and cost-effective operation. Chemical plants that seek to optimize their
operations should consider the benefits that AODD pumps can provide in several
areas.
The Importance of Air
As the name implies, the
operation of AODD pumps is based on compressed air, which can be found in most
chemical processing plants around the world. Taking advantage of this air can
make the AODD pump a plug-and-play device that does not require infrastructure
updates. In addition, the use of air to drive the pump is the key source of one
of its most coveted capabilities: the ability to stop the feed without damaging
the pump, system or fluid. This makes AODD pumps easy and flexible to operate.
Keeping air use low is critical
to a healthy plant environment, and recent technological advances have taken
significant steps toward achieving these goals. Advances have focused on a
deficiency in the operation of the AODD pump. At the end of each pump stroke, a
small amount of air is consumed that does not contribute to fluid movement.
Imagine stepping on the accelerator in a vehicle that is on the ice; The wheels
turn, but the car does not move.
Our redesigned air distribution the system solves this problem with an air control reel that reduces the amount of
air allowed in the pump at the end of the run, reducing the amount of waste the energy that would have been traditionally lost in the atmosphere.
This allows the AODD pump to
obtain savings of up to 60% in air consumption, improves the suction-lift the capacity of the pump and allows the pump to handle high inlet pressures better,
while providing more performance per cubic meters per hour (m3 / h) of air
consumed than AODDs that have traditional air distribution technology.
Low Maintenance Costs Thanks to Proper Diaphragm Selection
Diaphragm pumps have a unique
benefit when compared to many rotary pump technologies, they do not require any
seals. Eliminating the need for gaskets or mechanical seals means that
maintenance costs tend to be cheap and infrequent. Combined with simple
operation, AODDs are a kind of “set-and-forget” pump, as long because the
appropriate diaphragms are selected for the appliance. The choice of diaphragm
material, the shape, and the design of the pump play an important role.
Along with the advances in the
design and operation of air distribution, the improvements made in the
construction and function of the diaphragm over the years have been
significant. The main one is that long-lasting diaphragms (designed for use in
chemical processing activities) require less maintenance, which reduces repair
costs.
A piston diaphragm pump has an
outer piston that is fully encapsulated within the thermoplastic elastomer
(TPE) the material of the diaphragm, which provides several advantages. First, the
design eliminates the phenomenon known as external abrasion of the piston,
which is when the external piston rubs against the diaphragm as it circulates
and over time, such as sandpaper, wears out the material. Removal of the outer
piston eliminates this failure mode, dramatically increasing the life of the
diaphragm. Second, it also eliminates a known leakage point in traditional
diaphragm designs around the outer piston, improving overall safety when handling
hazardous chemicals. Finally, the design eliminates an area along with the outer
piston where the pumped fluid can get trapped.
In the end, the downtime and
maintenance that unplanned failures may incur are typically costlier for the
power operator than the spare parts necessary to stay the AODD pump running.
The use of these new designs allows the pump to run longer before requiring
diaphragm maintenance and translates directly into a healthier result.
Versatility and Compatibility
By definition, chemical
processing requires the performance of some of the most complex industrial
operations in the world. One of the most important operations is the transfer
of liquids along the production chain.
Because of the importance of
numerous fluid transfer operations throughout the chemical manufacturing chain,
facility operators need to identify the best pumping technology for the job.
Technology must possess the versatility necessary to function reliably and
efficiently at any number of points in the production hierarchy.
AODD pumps can offer a Number of Operational Advantages
They are suitable for use with
high viscosity fluids and can handle fluids ranging from liquids like water to
liquids of medium and very high viscosity.
They can run dry and strip the
discharge lines without being damaged. If the pressures become too high, the
pump will simply stop working, but will not break.
They are simple devices and
their control is based solely on solenoid operators, pump cycle counters and
surge absorber sets.
Their operating costs can be
lower when all maintenance, accessories, and controllers are included, and in
many cases their total cost of ownership is lower throughout their useful life
compared to competing for pump styles.
In addition, some of the Air Operated
Double Diaphram pump styles have been designed to be direct
bolt-to-bolt and pipe-to-pipe replacements in existing pumping systems. This
makes AODD pump styles a price effective thanks to improving fluid transfer
performance while realizing the advantages inherent within the operation of an
AODD pump that has an advanced air distribution system. These benefits include
reduction of air consumption and expenses, optimization of handling and
containment of products, and reduction of maintenance and replacement costs.
Finally, the design and
operation of AODD pumps allow them to transfer a wide range of liquids with
different handling characteristics. One of the most prominent is the viscosity or the thickness of the liquid being transferred. The operation of AODD pumps
virtually eliminates product slippage, regardless of the viscosity of the
fluid, since the pump's ball check valves, control fluid transfer. In contrast,
gear pump, screw and lobe technologies use fixed tolerances to control
slippage, which means they are less likely to adjust properly to viscosity
changes.
Pump Construction
The quality of the construction
of the pump is key when handling dangerous chemicals, and the use of a pump
designed with the right materials is important for the safety of a plant. To
meet these demands, AODD pumps are available in a wide range of building
materials to meet a variety of chemical handling needs. Common materials for
chemical pumps include polypropylene, Kynar, stainless steel, ductile iron and
Hastelloy and some companies have the ability to offer special materials such
as super duplex when really unique materials are required to ensure
uninterrupted production processes and safety. of the plant staff.
If metal pumps are required, a
material that is overlooked in the world of chemical processes is ductile iron,
which works well in application ranges from 4 to 10 both acidic and basic ph.
Provided that the chemical compatibility is correct, operators who use ductile
iron pumps can obtain all the benefits of stainless steel but at a lower
purchase cost.
A screwed design does not
depend, as mentioned above, on gaskets or expensive mechanical seals to prevent
leaks. In this case, the most important benefit of screwed pumps is their
ability to offer one of the highest levels of product containment. This is
critical for two main reasons: many raw or finished chemicals are high-value
products and any loss through leaks can be detrimental to the result of the
operation and, secondly, most of the chemicals can be harmful to humans and the
environment.
Go-To Technology
Thanks to its simple but
innovative design, the AODD pump has proven to be ready to consistently meet
the stress of chemical processors while building a reputation as a “go-to”
pumping technology where basic transfer capabilities are required of fluids The
AODD pump, which has a stability of remarkable operating characteristics, has
become a technology of the first choice for chemical manufacturers seeking a pump
that mimics cost-conscious air consumption with reliable production rates.
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