Diseño de una metodología para la maniobra cambio de trunnion de descarga de un molino SAG en Minera Los Pelambres.
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Date
2026
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Publisher
Universidad de Concepción
Abstract
En el contexto de la minería nacional, el proceso de conminución mediante molinos SAG forma parte de una de las etapas más críticas debido a su alta incidencia en la producción, costos operacionales y mantenciones mecánicas planificadas. Este último aspecto pasa a ser totalmente necesario cuando los componentes mecánicos del molino sufren algún tipo de desgaste o deterioro, incluso cuando estos no corresponden a elementos de desgaste directo como en el caso del trunnion, donde una pequeña falla en estos elementos puede comprometer la continuidad operacional del equipo, especialmente por efectos que se asocian al ingreso de pulpa, holguras, fricción y golpes de carga. Por lo tanto, dada la necesidad de planificar mantenciones de manera constante en este tipo de componentes, en el presente proyecto se elaboró una metodología para la maniobra de recambio del trunnion de descarga del molino SAG 02, abordando de manera sistemática las etapas de desmontaje, izaje y montaje del nuevo componente. En el desarrollo de estas etapas, se diseñaron dispositivos específicos de retiro e izaje del muñón, estableciendo criterios que se orientan a reducir las cargas presentes en el accionamiento, criterios de resistencia estructural definidos por el cliente y evaluación de cargas mediante análisis estructural de Ansys Mechanical. Además, para el montaje del nuevo componente, se seleccionaron herramientas certificadas y componentes definidos por catálogo según vendor, abarcando aspectos de seguridad operacional en terreno y control de calidad necesarios para ejecutar la intervención de manera confiable. Los resultados de simulación permitieron respaldar la factibilidad estructural de la metodología propuesta, lo cual se validó en terreno durante la ejecución global del proyecto.
In the context of the national mining industry, the comminution process carried out through SAG mills constitutes one of the most critical stages due to its high impact on production, operating costs, and planned mechanical maintenance. This latter aspect becomes entirely necessary when the mill’s mechanical components undergo some type of wear or deterioration, even when they are not direct wear elements, as in the case of the trunnion, where a minor failure in these components may compromise the operational continuity of the equipment, especially due to effects associated with pulp ingress, clearances, friction, and load impacts. Therefore, given the need to continuously plan maintenance for this type of component, the present project developed a methodology for the replacement maneuver of the discharge trunnion of SAG Mill 02, systematically addressing the stages of disassembly, lifting, and installation of the new component. During the development of these stages, specific devices for trunnion removal and lifting were designed, establishing criteria aimed at reducing the loads involved during actuation, structural resistance criteria defined by the client, and load evaluation through structural analysis in Ansys Mechanical. In addition, for the installation of the new component, certified tools and vendor catalog-defined components were selected, encompassing on-site operational safety aspects and quality control measures required to carry out the intervention reliably. The simulation results supported the structural feasibility of the proposed methodology, which was validated in the field during the overall execution of the project.
In the context of the national mining industry, the comminution process carried out through SAG mills constitutes one of the most critical stages due to its high impact on production, operating costs, and planned mechanical maintenance. This latter aspect becomes entirely necessary when the mill’s mechanical components undergo some type of wear or deterioration, even when they are not direct wear elements, as in the case of the trunnion, where a minor failure in these components may compromise the operational continuity of the equipment, especially due to effects associated with pulp ingress, clearances, friction, and load impacts. Therefore, given the need to continuously plan maintenance for this type of component, the present project developed a methodology for the replacement maneuver of the discharge trunnion of SAG Mill 02, systematically addressing the stages of disassembly, lifting, and installation of the new component. During the development of these stages, specific devices for trunnion removal and lifting were designed, establishing criteria aimed at reducing the loads involved during actuation, structural resistance criteria defined by the client, and load evaluation through structural analysis in Ansys Mechanical. In addition, for the installation of the new component, certified tools and vendor catalog-defined components were selected, encompassing on-site operational safety aspects and quality control measures required to carry out the intervention reliably. The simulation results supported the structural feasibility of the proposed methodology, which was validated in the field during the overall execution of the project.
Description
Tesis presentada para optar al título de Ingeniero/a Civil Mecánico/a.
Keywords
Molinos, Desgaste mecánico, Minería, Mantenibilidad (Ingeniería)