Descripción técnica y operativa del sistema de tratamiento de lodos planta desaladora MLP.
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Date
2025
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Publisher
Universidad de Concepción
Abstract
La presente memoria de título aborda el análisis técnico y operativo del sistema de tratamiento de lodos de la planta desaladora de Minera Los Pelambres. El diagnóstico inicial reveló una cascada de deficiencias interconectadas: la unidad de Frotación por Aire Disuelto (FAD) operaba con una presión en los saturadores un 22% por debajo de su valor de diseño, mientras que los equipos de la línea de deshidratación se encontraban fuera de servicio, impidiendo la purga efectiva de sólidos del sistema. Para cuantificar el impacto de la principal desviación detectada, se evalúo el rendimiento del sistema FAD en dos escenarios: pre y post-ajuste de la presión de los saturadores. El análisis demostró que la corrección de este parámetro al valor de diseño de 4.5 bar generó una mejora radical en el proceso. La eficiencia de captura de sólidos aumentó de manera estadísticamente significativa de un 27.1% a un 52.5% y, de forma crucial, el sistema pasó de un estado de alta volatilidad a una operación estable y predecible. Paralelamente, y para resolver la falta de purga, se desarrollaron planes estructurados de Puesta en Marcha (PEM) para los equipos de deshidratación de lodos. Se concluye, por tanto, que la presión de saturación era un parámetro limitante y una de las causas principales de la ineficiencia e inestabilidad de la unidad FAD. Su corrección es una acción fundamental que habilita el correcto funcionamiento de la etapa de separación. En consecuencia, la estrategia de optimización propuesta es doble: en primer lugar, mantener la operación a la presión de diseño de forma permanente y, en segundo lugar, iniciar la puesta en marcha del sistema de deshidratación de lodos utilizando los protocolos PEM desarrollados, como acción clave para asegurar la gestión global de sólidos de la planta.
This thesis addresses the technical and operational analysis of the sludge treatment system at the Minera Los Pelambres desalination plant. The initial diagnosis revealed a cascade of interconnected deficiencies: the Dissolved Air Flotation (DAF) unit operated with a saturator pressure 22% below its design value, while the dewatering equipment was out of service, preventing an effective solids purge from the system. To quantify the impact of the main deviation detected, the DAF system’s performance was evaluated in two scenarios: pre- and post-adjustment of the saturator pressure. The analysis showed that correcting this parameter to the design value of 4.5 bar led to a radical improvement in the process. The solids capture efficiency showed a statistically significant increase from 27.1% to 52.5%, and crucially, the system transitioned from a state of high volatility to a stable and predictable operation. Concurrently, to address the lack of a purge system, structured Commissioning Plans (PEM) were developed for the sludge dewatering equipment. It is concluded, therefore, that the saturator pressure was a limiting parameter and one of the main causes of the DAF unit’s inefficiency and instability. Its correction is a fundamental action that enables the proper functioning of the separation stage. Consequently, the proposed optimization strategy is twofold: first, to permanently maintain operation at the design pressure, and second, to initiate the commissioning of the dewatering system using the developed protocols, as a key action to ensure the overall management of solids in the plant.
This thesis addresses the technical and operational analysis of the sludge treatment system at the Minera Los Pelambres desalination plant. The initial diagnosis revealed a cascade of interconnected deficiencies: the Dissolved Air Flotation (DAF) unit operated with a saturator pressure 22% below its design value, while the dewatering equipment was out of service, preventing an effective solids purge from the system. To quantify the impact of the main deviation detected, the DAF system’s performance was evaluated in two scenarios: pre- and post-adjustment of the saturator pressure. The analysis showed that correcting this parameter to the design value of 4.5 bar led to a radical improvement in the process. The solids capture efficiency showed a statistically significant increase from 27.1% to 52.5%, and crucially, the system transitioned from a state of high volatility to a stable and predictable operation. Concurrently, to address the lack of a purge system, structured Commissioning Plans (PEM) were developed for the sludge dewatering equipment. It is concluded, therefore, that the saturator pressure was a limiting parameter and one of the main causes of the DAF unit’s inefficiency and instability. Its correction is a fundamental action that enables the proper functioning of the separation stage. Consequently, the proposed optimization strategy is twofold: first, to permanently maintain operation at the design pressure, and second, to initiate the commissioning of the dewatering system using the developed protocols, as a key action to ensure the overall management of solids in the plant.
Description
Tesis presentada para optar al título de Ingeniero/a en Civil Metalúrgico/a.
Keywords
Minería, Sequías