Mining is vital in powering modern industry, yet it has considerable environmental responsibilities. Mining companies must prioritise effective environmental management to safeguard ecosystems and ensure sustainable operations. This involves addressing key areas such as water and waste management and mitigating the risks of environmental spills and pollution risks.
At Chesterton, we offer advanced solutions to help mining companies tackle these challenges, promoting sustainability and operational efficiency.
Reducing Water Use with Flush-Free Mechanical Seals and Packing Solutions
Water is a critical resource in mining, and it is used extensively in mineral processing, dust suppression, and equipment cooling. However, the industry is under increased pressure to reduce water consumption to address supply shortages, escalating costs, environmental concerns and regulatory requirements.
One often overlooked area for water conservation is rotating equipment, such as pumps and mixers. The proper selection of sealing devices can significantly reduce water usage.
For example, slurry pumps are a significant source of water consumption in mining operations. Flushing systems in these pumps can use an average of 2 US gallons per minute. By selecting the appropriate sealing method, such as packing and flush-free mechanical seals, we can greatly reduce or even eliminate the need for flush water.
Some single mechanical seals have been specifically designed to operate without a flush. In this case, maximising clearances around the seal faces—combined with tighter face loading—prevents clogging and particulate build-up.
100mm Chesterton® 170L Mechanical Seal installed in a Warman® AH® pump in a mineral sand mine.
Some single slurry mechanical seals, such as the Chesterton 170/170L, can handle up to 40% solids by weight with no flush. In severe applications, where solids are greater than 40%,
mechanical seals need assistance from an environmental controller to remove larger solids from the stuffing box bore where the seal operates.
Using a split version of this type of environmental controller with split mechanical seals can offer additional benefits beyond flush-free operation. Split seals offer simple installation without the need for pump disassembly.
Whether using flush or not, reducing the solids that come into contact with the packing can increase packing life. SpiralTrac™ is one of the environmental control product technologies that can accomplish that goal. It also reduces the amount of flush water needed to flush the packing.
Chesterton 280™ Heavy Duty Cartridge Dual Seal.
Other benefits to the environmental controller include:
- Reduces product dilution
- Eliminates the need for a lantern ring
- Provides a clean flush to the sealing rings
Dual Mechanical Seals with Environmental Controls
Mechanical double seals like the Chesterton 280 are often recommended in more severe slurry services. Proper environmental control minimises product dilution to less than 50ml (2 fl. oz) daily.
Increased Reliability with Chesterton Dual Pac.
Using a barrier fluid tank in conjunction with a double mechanical seal offers the greatest water conservation available with dual seals. The barrier fluid tank is a closed-loop system with no need for continuous feed from an external water source, which can result in significant water cost savings. A double seal with an internal pumping ring can provide greater barrier fluid flow for more effective cooling, achieving higher reliability.
In cases where slight leakage is appropriate/acceptable, the best sealing practice is attained through packing. Because the flush water is reduced or virtually eliminated then the aspect of heat resistance in the packing is a crucial element. Chesterton’s DualPac® 2211 and 2212 is a graphite-filled ePTFE that resists consolidation without shaft wear that offers extended life in the most aggressive of slurry applications.
Waste Management in Mining: Hydraulic Seals for Bearing Isolation and Protection
Effective waste management is critical to minimising mining operations’ environmental footprint. This includes managing tailings, waste rock, and other by-products. At Chesterton Custom Seal, we provide solutions to enhance equipment reliability and reduce waste-related issues.
Proper hydraulic seal selection is essential to prevent leaks and premature wear in heavy-duty mining equipment. Chesterton Custom Seal offers high-performance seals, such as the Chesterton 33K Stacked Set and the Polymer Labyrinth Seal (PLS), which provide superior protection against environmental contaminants and ensure lubrication retention. These seals are particularly effective in the harsh conditions of the Australian mining industry, extending equipment life and reducing maintenance costs.
Chesterton 33K Lip Seal with Split Design.
Advanced Coatings for Abrasion and Chemical Resistance
Streamlining Slurry Pump Maintenance with Innovative Sealing Solutions.
Preventing spills and minimising environmental pollution are crucial aspects of sustainable mining. Chesterton’s ARC Coatings offer robust protection against chemical attack, corrosion, and abrasion. These ceramic-reinforced coatings are easy to apply and can extend the lifespan of equipment exposed to harsh mining conditions. Using ARC Coatings, mining companies can reduce the frequency of repairs and replacements, leading to lower operational costs and less environmental impact.
Seal Solutions for Leak Prevention
Chesterton’s range of seals, including the innovative Chesterton 442C Cartridge Split Seal, are designed to prevent leaks in large equipment. This seal features a unique interlocking face design that allows for easy installation and provides reliable sealing for shafts ranging from 25mm to 760mm. By using these advanced seals, mining companies can significantly reduce the risk of spills and environmental contamination.
Contact Us
At Chesterton, we are committed to helping mining companies achieve their environmental management goals. Contact us today for more information on how our products can benefit your mining operation.
