Published in the December 2007 American Longwall Magazine
Introduced to the US last December, the impetus for developing the new pump was the existence of "difficult" slurries at operations in Australia, according to company representative Lou Beatty. The competitor's units, he noted, were only lasting three or four weeks at that time.
To combat the issues others in its sector were having and to offer the industry the most efficiently designed and running pumps, the company developed and patented a system to eliminate the issues being reported.
The dual-diaphragm Pumps 2000 model is the first redesign of the AODD specifically for the mining market, Beatty said. Run by an air motor that is stall-free and runs smoothly without any lubrication, the currently available 1.5-inch and 2-inch versions of the pump are capable of passing sizable solids (1in and 4in models will be available soon).
A long life and efficiency edge are two benefits of Megator's product, according to the company. In tests the Pumps 2000, on average, lasted 10 to 12 times longer than its competitors' designs and allowed for the same work to be completed with fewer units.
The company highlights the pump's performance attributes, including low air consumption (about half that of the industry standard) and, at a lighter weight of 41 pounds in the 2in design, helps prevent neck and back injuries.
A fire retardant anti-static (FRAS) conductive plastic carrying an Atex M1 rating is also a proprietary feature of the unit, so its use in more explosive situations is not an issue. It is the only pump approved for use in UK coal mines as well, and the FRAS system can be used for dewatering and methane gas removal when needed and without interruption.
The high suction lift of Pumps 2000, which Megator refers to as its supersuction (27 feet wet or dry), allows for more efficient usage over time while designed to be maintenance-free. The supersuction ability, Beatty noted, is due to the unit's patented double-hinged diaphragms, long stroke and patented self-cleaning slurry valves.
The system's material design is not only a lighter alternative, but also resists deterioration even in low-pH locations. "It was the very first plastic pump ever made," Megator pointed out.
Historically, pumps have delivered a similar design and have been viewed as a commodity, both details the company sought to change in its design and research of Pumps 2000.
"Other AODD pumps on the market cannot be differentiated from one another," Beatty said. "Also, most do not completely dewater an area as they need to avoid the slurry.
"We believe that our design will reduce the amount of money spent on pumps yearly and will lower overall maintenance costs by keeping the mine dry."
He added that feedback from domestic operators had been good.
Beatty also noted the work done in Australia has had an impact on its interest in the US, and they'll work with operations to find its solution.
"We can offer each mine that uses the Pumps 2000 design significant cost savings as a result of the superior design features and benefits, as we have in Australia."
