The importance of mechanical seals when reducing water consumption in mining

In the industrial landscape, environmental sustainability has become a critical priority. Companies are increasingly assessing and refining their operations, processes, and systems to minimise their ecological footprint. One of the most significant areas of focus is the reduction of water consumption in mining activities, where effective pump and mixer management, along with high-quality sealing products, plays a pivotal role in conserving resources and lowering operational costs.

Water Management in Mining Operations

Water is essential in various industrial applications, especially for the hydraulic transport of solids in the mining sector. While alternative fluids like acids, kerosene, and caustics are occasionally used, water remains the primary medium due to its availability and effectiveness. However, many mines are located in regions where groundwater sources are limited, leading to increased costs for water removal and treatment. Moreover, extracting water for mining purposes can significantly impact local ecosystems and the surrounding environment.

Strategies for Reducing Water Consumption

Choosing the right selection of pumps, seals, and systems, in mining operations can significantly reduce water usage. By implementing optimal sealing solutions, companies can minimise or even eliminate the need for flushing water during the mining process.

When considering sealing solutions, it’s essential to evaluate several factors:

• Equipment Condition
• Downtime Costs
• Product Loss
• Installation Ease
• Techniques for Reducing Flush Water

Effective Sealing Options

1. Packing Solutions: Packing is cost-efficient for minor leaks or product dilution. Depending on the application, three packing types can facilitate a flush-free sealing approach:

Injectables: This thermoset, heat-resistant material is composed of lubricants and chopped reinforced fibers. It is injected into the stuffing box through the flush port and requires proper application to ensure strength.

Carbon/Graphite Packing: Known for its low heat generation and high thermal conductivity, this packing option can sometimes extrude under pressure. To mitigate this, specially designed braided corners are available.

Environmental Controllers: Technologies help minimise solid contact with the packing, thus extending packing life and reducing flush water requirements.

2. Mechanical Seals: For applications where product leakage and slurry dilution are unacceptable, mechanical seals are the best option. These seals typically require no flush water, reducing treatment costs and minimising product dilution.

Single Mechanical Seals: Ideal for flush-free operations, these seals feature optimised face loading and clearances to prevent clogging.

Split Mechanical Seals: Offering water conservation and ease of assembly, split seals allow for quick installation without disassembling pumps.

Dual Mechanical Seals: In harsher slurry conditions, these seals, combined with appropriate environmental controls, can greatly minimise product dilution. Utilising a closed-loop barrier fluid system also conserves water by eliminating reliance on an external source.

Explore Our High-Quality Sealing Solutions

For dependable sealing products, FPE Seals offers a comprehensive range designed to meet your specific needs. To discuss your requirements or to learn more about our products, contact our expert team at +44 (0) 1325 282732

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