Vale uses DEM and FEA simulations to improve equipment and reduce costs

Rocky DEM and ANSYS software help the Carajás mine analyze equipment, test modifications, and ensure proper operation with speed and reliably.

Vale had the challenge of improving two of their beneficiation plants at their Carajás mine. For that, it was necessary separate out the larger pieces of ore at the first plant before the ore transferred to the second plant. With this separation accomplished, Vale could reduce the maintenance stop time of the latter plant and increase the productivity.

Rocky DEM’s non-sphere, full-polygon particle function was for our company the deciding factor for DEM software selection. Additionally, we appreciate that we can use GPUs to process DEM simulations with accurate and highspeed results. And by inputting several simulation files into the Rocky DEM Scheduler tool, we can easily calculate many simulations as a series process, saving us even more time and effort.”

Yoichi Narita

Researcher at NSSMC

During the transfer of iron ore from the first plant to the second, reduce the maintenance stop time of the second plant by first filtering the particles with a roller screen so that only the smaller-sized ore reaches it.

Use Rocky DEM simulations to test the efficiency of the roller screen equipment at optimal calibrations, and use ANSYS FEA simulations to verify that the structure design can support the added weight.

Rocky DEM and ANSYS simulations helped ensure a reliable design that met the goal of reducing the maintenance costs of the second plant. Design development was reduced from 12 to 3 months with a predicted return on investment of almost R$ 7 million in just the first year of operation.


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