Cálculo de esfuerzos mediante modelación con elementos finitos en suportación axial del horno de cal, celulosa Arauco planta Horcones.
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Date
2025
Journal Title
Journal ISSN
Volume Title
Publisher
Universidad de Concepción
Abstract
En la planta Horcones L2 de la empresa “Celulosa Arauco” se encuentra instalado un horno de cal, equipo crítico para la producción de óxido de calcio y la recuperación de licor blanco. Este horno cuenta con elementos de soporte, entre ellos se encuentran los rodillos axiales, cuya función es retener su desplazamiento axial, sin embargo, dada la longevidad del horno y sus componentes adyacentes, se requiere evaluar los esfuerzos a los que esta sometidos estos rodillos. Para ello se construye un modelo computacional 3D y se aplica el método de elementos finitos para la estimación de esfuerzos. En cuanto a las cargas que soporta el rodillo, se considera el peso de las componentes auxiliares del horno, siendo estas las llantas, los ladrillos refractarios, los enfriadores satélites, la corona del accionamiento y los lodos de cal retenidos en su interior. Para esto último se opta por utilizar el modelo de Saeman para determinar la distribución de lodos dentro del horno, teniendo en cuenta la presencia de anillos internos. Como resultado, se determina que el peso total del horno equivale a 1664.70 toneladas.
Al evaluar el caso en que los rodillos de soporte funcionan únicamente como soportes móviles, se estima que los rodillos axiales soportan una fuerza de 410.39 kN. Una vez resuelto el modelo de elementos finitos, se obtiene que los máximos esfuerzos se presentan en la zona de contacto entre el rodillo axial y la llanta adyacente a este. Los resultados indican un esfuerzo de Von Mises igual a 420.58 MPa, un esfuerzo máximo de compresión equivalente a 658.81 MPa y un esfuerzo cortante máximo de 231.04 MPa. En cuanto a la presión de contacto, se alcanza una presión altamente concentrada igual a 656.08 MPa.
Analizando la falla a la fluencia, se obtiene un factor de seguridad de 1.0937. En relación con el análisis de fatiga, se estima que, bajo las condiciones extremas consideradas, el rodillo axial tendría una vida útil estimada de 27,805 ciclos.
El análisis realizado subraya la importancia de monitorear adecuadamente las condiciones de operación del horno. Es crucial evaluar el estado y la alineación de los demás soportes del horno con el propósito de aliviar las cargas a las que se somete el rodillo axial, lo que permitiría prolongar considerablemente su vida útil. Además, se discute la viabilidad de reemplazar la unidad instalada en terreno, dado que el rodillo axial corresponde a un modelo anticuado.
In the pulp plant “Horcones L2” from the company "Celulosa Arauco," a rotary lime kiln is installed, which is a critical machine in charge of producing calcium oxide, required for the recovery of white liquor. This kiln includes various support elements, among which are the thrust rollers, whose function is to prevent the kiln’s axial displacement. However, due to the longevity of the kiln and its adjacent components, it is necessary to evaluate the stresses to which these rollers are subjected. To do this, a 3D computational model is created, and the finite element method is applied to estimate the stresses. Regarding the loads on the thrust roller, the weight of the auxiliary components of the kiln is considered, including the tires, refractory bricks, satellite coolers, the girth gear and the lime sludge retained inside. For the latter, the Saeman model is used to determine the distribution of sludge within the kiln, considering the presence of internal rings. As a result, the total weight of the kiln was found to be 1664.70 tons. When evaluating the case in which the support rollers function only as movable supports, it is estimated that the axial rollers bear a force of 410.39 kN. Once the finite element model is solved, the maximum stresses are found to be localized at the contact area between the axial roller and the adjacent tire. The results indicate a Von Mises stress of 420.58 MPa, a maximum equivalent compressive stress of 658.81 MPa, and a maximum shear stress of 231.04 MPa. Regarding the contact pressure, a highly concentrated pressure of 656.08 MPa is reached. When analyzing the yield failure, a safety factor of 1.0937 is obtained. In relation to the fatigue analysis, it is estimated that, under the extreme conditions considered, the axial roller would have an estimated lifetime of 27,805 cycles. The analysis underscores the importance of properly monitoring the kiln's operating conditions. It is crucial to evaluate the state and alignment of the other supports of the kiln to relieve the loads placed on the axial roller, which would significantly extend its service life. Furthermore, the feasibility of replacing the installed unit is discussed, as the current axial roller corresponds to be an outdated model.
In the pulp plant “Horcones L2” from the company "Celulosa Arauco," a rotary lime kiln is installed, which is a critical machine in charge of producing calcium oxide, required for the recovery of white liquor. This kiln includes various support elements, among which are the thrust rollers, whose function is to prevent the kiln’s axial displacement. However, due to the longevity of the kiln and its adjacent components, it is necessary to evaluate the stresses to which these rollers are subjected. To do this, a 3D computational model is created, and the finite element method is applied to estimate the stresses. Regarding the loads on the thrust roller, the weight of the auxiliary components of the kiln is considered, including the tires, refractory bricks, satellite coolers, the girth gear and the lime sludge retained inside. For the latter, the Saeman model is used to determine the distribution of sludge within the kiln, considering the presence of internal rings. As a result, the total weight of the kiln was found to be 1664.70 tons. When evaluating the case in which the support rollers function only as movable supports, it is estimated that the axial rollers bear a force of 410.39 kN. Once the finite element model is solved, the maximum stresses are found to be localized at the contact area between the axial roller and the adjacent tire. The results indicate a Von Mises stress of 420.58 MPa, a maximum equivalent compressive stress of 658.81 MPa, and a maximum shear stress of 231.04 MPa. Regarding the contact pressure, a highly concentrated pressure of 656.08 MPa is reached. When analyzing the yield failure, a safety factor of 1.0937 is obtained. In relation to the fatigue analysis, it is estimated that, under the extreme conditions considered, the axial roller would have an estimated lifetime of 27,805 cycles. The analysis underscores the importance of properly monitoring the kiln's operating conditions. It is crucial to evaluate the state and alignment of the other supports of the kiln to relieve the loads placed on the axial roller, which would significantly extend its service life. Furthermore, the feasibility of replacing the installed unit is discussed, as the current axial roller corresponds to be an outdated model.
Description
Tesis presentada para optar al título de Ingeniero Civil Mecánico
Keywords
Resistencia de materiales, Análisis estructural (Ingeniería), Optimización estructural