Advanced engineering simulation for the global mining and extractive industries

The mining and extractive industries face increasingly complex challenges – from equipment reliability under extreme conditions, to optimising resource extraction and energy efficiency. The advent of high-fidelity engineering simulation tools, however, has revolutionised these sectors, enabling detailed virtual assessments that reduce risks, optimise design, and enhance operational reliability. Engineering simulation, including digital twin technology, computational fluid dynamics (CFD), finite element analysis (FEA), and multiphysics modeling, has become essential for addressing these challenges.

 

Vale simulates for equipment reliability

 

In the mining industry, equipment reliability is paramount due to the high cost of downtime and the potential risks associated with failure. Vale, one of the world’s largest mining companies, leveraged digital twin technology to enhance the reliability of its mining equipment. By integrating sensor data with simulation models, Vale was able to perform predictive maintenance and adjust operational parameters in real time.

Key challenges and solutions using simulation included:

• Ensuring reliable performance of mining equipment operating in harsh conditions and using simulation to predict lifetime performance metrics. Vale did this by creating a digital twin of a large complex magnetic separator unit with moving parts.
• Safety loading calculations on the magnetic separator conveyor belt using FEA.
• Reduced physical prototype and manufacturing costs.
• Successfully predicted failure point of the iron ore conveyor belt.

 

Zenito’s simulation-driven design

 

Zenito’s design of a mineral processing plant exemplifies the use of simulation in process optimisation. By developing a detailed CFD model, Zenito was able to predict fluid dynamics, mixing efficiencies, and separation performance within the plant, specifically the screen feed boxes of the SAG mills it uses on-site. A SAG mill is used to grind and crush large pieces of rock into smaller pieces of rock, gravel, or dust; this is commonly used in the mining industry. An efficient way to transport this crushed material for further processing is as slurries in an open channel, called launders. Launders are subject to intense wear and tear from the slurries and are sensitive to the design as they utilise gravity for flow. The design of a launder is paramount to its flow efficiency, maintenance costs, and hence lifetime operation. The operation of the screen feed box, which is used to pre-mix the solid feed (crushed material) with water before it is presented as slurry to the classification screen.

Key simulation contributions included:

• Flow optimisation: Modelling turbulent flows to optimise pipe and channel geometries, ensuring uniform distribution of slurry and minimising dead zones.
• Phase interaction: Incorporating multiphase flow models to simulate the interaction between solid particles and the carrying fluid, which is critical for the efficiency of separation processes.
• Process scale-up: Using simulation results to guide the scale-up from pilot plant data to full-scale industrial operation, ensuring that design parameters remain robust under varied operational conditions.

 

Conclusion

 

Engineering simulation has become an indispensable tool in the global mining and extractive industries, driving advancements in equipment reliability, process design, and energy extraction. The digital twin implementation at Vale, the CFD-driven design approach at Zenito, and the simulation of geothermal systems by Hephae illustrate the broad and impactful applications of simulation technologies. As the industry continues to embrace digital transformation, further research and development in simulation methodologies will be critical to addressing the complex challenges of modern mining operations.

Read the article online at: https://www.globalminingreview.com/mining/10022025/advanced-engineering-simulation-for-the-global-mining-and-extractive-industries/