Modelación de un tambor aglomerador industrial mediante el método de elementos discretos.
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Date
2025
Journal Title
Journal ISSN
Volume Title
Publisher
Universidad de Concepción
Abstract
En la industria minera, existen múltiples equipos que permiten llevar a cabo el proceso de aglomeración. El tambor aglomerador se destaca como uno de los equipos más utilizados para el proceso de granulación, especialmente en la preparación del material para la lixiviación por pilas, donde se busca reducir los finos y mejorar la permeabilidad. A pesar de su amplia aplicación, existen limitados estudios que propongan modelos numéricos para profundizar en la optimización y mejora de estos equipos.
Este informe presenta un estudio detallado del comportamiento de un tambor aglomerador mediante simulación numérica por el método de elementos discretos (DEM) utilizando el software Ansys Rocky DEM. El objetivo principal es analizar el proceso de aglomeración de material en un tambor de 4.6 m de diámetro y 16.3 m de largo, ubicado en la minera BHP Spence. Se utilizó el módulo liquid bridge para simular la adherencia entre partículas durante el proceso.
Se realiza una revisión bibliográfica que permite calibrar los parámetros del material (mineral de cobre) y evaluación del modelo numérico con ensayos experimentales obtenidos de la literatura. Se establece una metodología para simplificar los tiempos de simulación DEM, debido al costo computacional y tiempo de resolución. El modelo numérico tiene por objetivo analizar el comportamiento del material de forma transversal y axial. Los resultados obtenidos son: Demanda de potencia y torque, distribución de humedad, análisis de fuerzas, distribución de humedad y tiempo de residencia del material.
Se realizan 9 simulaciones, donde se analiza la sección transversal del tambor, donde se varía la velocidad de rotación y grado de llenado. De los resultados obtenidos se puede destacar que la potencia RMS en régimen estacionario no es lineal, cuando se varían los parámetros antes mencionados. Las fuerzas en el eje y son un 135% mayores a las fuerzas en eje x. El aumento de la velocidad de rotación para un grado de llenado constante del tambor no implica una mejor distribución de humedad del material.
Por otra parte, se realiza una simulación en la cual se analiza el tiempo de residencia del material, en donde se obtiene un error del 3.97% con respecto al valor experimental, obtenido de la literatura e información recopilada.
Finalmente, se diseña, dimensiona y genera un presupuesto de un banco de ensayos de laboratorio con el propósito de estudiar en mayor profundidad la aglomeración en este tipo de equipos. Este banco de ensayos tiene por objetivo obtener datos experimentales (torque, potencia, granulometría, entre otros) para estudiar y analizar la aglomeración, validar un modelo numérico por el método de elementos discretos (reduciendo los costos computacionales) y poder tomar decisiones importantes en la industria.
In the mineral proccesing industry, there are multiple equipment types that allow the agglomeration process to be carried out. The agglomerator drum stands out as one of the most commonly used pieces of equipment for the granulation process, especially in preparing material for heap leaching, where the goal is to reduce fines and improve permeability. Despite its wide application, there are limited studies proposing numerical models to further optimize and improve these equipment. This report presents a detailed study of the behavior of an agglomerator drum through numerical simulation using the Discrete Element Method (DEM) with Ansys Rocky DEM software. The main objective is to analyze the agglomeration process of material in a drum 4.6m in diameter and 16.3m in length, located at the BHP Spence mine. The liquid bridge module was used to simulate the adhesion between particles during the process. A bibliographic review is carried out to calibrate the material parameters (copper ore) and evaluate the numerical model with experimental tests obtained from the literature. A methodology is established to simplify DEM simulation times due to computational costs and resolution time. The numerical model aims to analyze the material’s behavior both transversely and axially. The results obtained include: power and torque demand, moisture distribution, force analysis, moisture distribution, and material residence time. Nine simulations are conducted, analyzing the drum’s cross-sectional area where rotation speed and filling degree are varied. From the results obtained, it can be highlighted that the RMS power in steady-state is not linear when the previously mentioned parameters are varied. The forces in the y axis are 135% higher than the forces in the x-axis. Increasing the rotation speed for a constant drum filling degree does not result in better moisture distribution of the material. Additionally, a simulation is performed to analyze the material's residence time, where a 3.97% error compared to the experimental value is obtained, obtained from the bibliography and the information collected. Finally, a design, dimensioning, and budget for a laboratory test bench are generated with the purpose of studying agglomeration in these types of equipment in greater depth. This test bench aims to obtain experimental data (torque, power, particle size distribution, among others) to study and analyze agglomeration, validate a numerical model using the discrete element method (reducing computational costs), and support important decision-making in the industry.
In the mineral proccesing industry, there are multiple equipment types that allow the agglomeration process to be carried out. The agglomerator drum stands out as one of the most commonly used pieces of equipment for the granulation process, especially in preparing material for heap leaching, where the goal is to reduce fines and improve permeability. Despite its wide application, there are limited studies proposing numerical models to further optimize and improve these equipment. This report presents a detailed study of the behavior of an agglomerator drum through numerical simulation using the Discrete Element Method (DEM) with Ansys Rocky DEM software. The main objective is to analyze the agglomeration process of material in a drum 4.6m in diameter and 16.3m in length, located at the BHP Spence mine. The liquid bridge module was used to simulate the adhesion between particles during the process. A bibliographic review is carried out to calibrate the material parameters (copper ore) and evaluate the numerical model with experimental tests obtained from the literature. A methodology is established to simplify DEM simulation times due to computational costs and resolution time. The numerical model aims to analyze the material’s behavior both transversely and axially. The results obtained include: power and torque demand, moisture distribution, force analysis, moisture distribution, and material residence time. Nine simulations are conducted, analyzing the drum’s cross-sectional area where rotation speed and filling degree are varied. From the results obtained, it can be highlighted that the RMS power in steady-state is not linear when the previously mentioned parameters are varied. The forces in the y axis are 135% higher than the forces in the x-axis. Increasing the rotation speed for a constant drum filling degree does not result in better moisture distribution of the material. Additionally, a simulation is performed to analyze the material's residence time, where a 3.97% error compared to the experimental value is obtained, obtained from the bibliography and the information collected. Finally, a design, dimensioning, and budget for a laboratory test bench are generated with the purpose of studying agglomeration in these types of equipment in greater depth. This test bench aims to obtain experimental data (torque, power, particle size distribution, among others) to study and analyze agglomeration, validate a numerical model using the discrete element method (reducing computational costs), and support important decision-making in the industry.
Description
Tesis presentada para optar al título de Ingeniero Civil Mecánico
Keywords
Industria minera, Simulación por computadores, Maquinaria minera