Mejora de confiabilidad en sistema de harneros lineales del área de transporte de relaves en Minera Los Pelambres.
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Date
2024
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Universidad de Concepción
Abstract
En el proceso de obtención de cobre, el relave constituye el 98% del material extraído. En Minera Los Pelambres, estos relaves se depositan en el Tranque de Relaves Mauro, ubicado a 50 km de la planta. Para su transporte, se utiliza un Sistema de Transporte de Relaves (STR), que envía los relaves hidráulicamente bajo presión a través de dos líneas de tuberías (relaveductos) de 28” y 36”.
Para garantizar el óptimo funcionamiento de los relaveductos, es esencial acondicionar el relave, minimizando la presencia de sólidos de gran tamaño en la pulpa. Esto previene desgastes excesivos, caídas de presión o embancamientos, situaciones que podrían comprometer la producción. Por esta razón, el STR cuenta con una Estación de Harneado, compuesta por 10 Harneros Lineales, que acondicionan el relave rechazando los sólidos de gran tamaño para su reprocesamiento. La efectividad de esta clasificación depende en gran medida del correcto funcionamiento del harnero.
Este estudio realiza un análisis de fallas de la Estación de Harneado del Sistema de Transporte de Relaves de Minera Los Pelambres. Actualmente, los activos de la estación son mantenidos bajo un enfoque de mantenimiento por condición, lo que ha permitido mantener una disponibilidad suficiente para el proceso. Sin embargo, se busca alcanzar el máximo potencial de estos equipos.
Para abordar la falla más recurrente en estos activos, se realizó una sesión de Resolución de Problemas RdP) en colaboración con ingenieros expertos de la gerencia de mantenimiento. Como resultado, se implementaron dos estrategias de mantenimiento y se propuso una mejora al sistema de lubricación de los activos, que buscan lograr un aumento en la disponibilidad y generar una reducción en costos de mantenimiento.
In the copper extraction process, tailings make up 98% of the material extracted. At Minera Los Pelambres, these tailings are deposited in the Mauro Tailings Dam, located 50 km from the plant. For their transportation, a Tailings Transport System is used, which hydraulically sends the tailings under pressure through two pipeline of 28” and 36”. To ensure the optimal functioning of the tailings pipelines, it is essential to condition the tailings by minimizing the presence of large solids in the slurry. This prevents excessive wear, pressure drops, or blockages, situations that could compromise production. For this reason, the STR is equipped with a Screening Station, consisting of 10 Linear Screens, which condition the tailings by rejecting large solids for reprocessing. The effectiveness of this classification depends largely on the proper functioning of the screens. This study conducts a failure analysis of the Screening Station of the Tailings Transport System at Minera Los Pelambres. Currently, the station's assets are maintained under a condition-based maintenance approach, which has allowed for sufficient availability for the process. However, there is a desire to reach the full potential of these assets. To address the most recurrent failure in these assets, a Problem Solving session was conducted in collaboration with expert engineers from the maintenance management team. As a result, two maintenance strategies were implemented, and an improvement to the lubrication system of the assets was proposed, aiming to increase availability and reduce maintenance costs.
In the copper extraction process, tailings make up 98% of the material extracted. At Minera Los Pelambres, these tailings are deposited in the Mauro Tailings Dam, located 50 km from the plant. For their transportation, a Tailings Transport System is used, which hydraulically sends the tailings under pressure through two pipeline of 28” and 36”. To ensure the optimal functioning of the tailings pipelines, it is essential to condition the tailings by minimizing the presence of large solids in the slurry. This prevents excessive wear, pressure drops, or blockages, situations that could compromise production. For this reason, the STR is equipped with a Screening Station, consisting of 10 Linear Screens, which condition the tailings by rejecting large solids for reprocessing. The effectiveness of this classification depends largely on the proper functioning of the screens. This study conducts a failure analysis of the Screening Station of the Tailings Transport System at Minera Los Pelambres. Currently, the station's assets are maintained under a condition-based maintenance approach, which has allowed for sufficient availability for the process. However, there is a desire to reach the full potential of these assets. To address the most recurrent failure in these assets, a Problem Solving session was conducted in collaboration with expert engineers from the maintenance management team. As a result, two maintenance strategies were implemented, and an improvement to the lubrication system of the assets was proposed, aiming to increase availability and reduce maintenance costs.
Description
Tesis presentada para optar al título de Ingeniero Civil Mecánica
Keywords
Mantenimiento, Minería, Relaves (cobre)