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Item type:Publication, Access status: with files , Optimizing raw material composition to increase sustainability in porcelain tile production: A simulation-based approach(Wiley, 2024-04); ; ; ; Reducing the environmental impact of porcelain tile production while maintaining cost-effectiveness is challenging. This work introduced a novel modeling approach for optimizing a standard composition range comprising kaolinite (15–38 wt.%), illite (0–20 wt.%), quartz (20–40 wt.%), and feldspar (20–45 wt.%) to establish a robust composition interval for porcelain stoneware tiles. The proposed study considers several factors, such as composition impact on the manufacturing sequence, production costs, and CO2 emission. A flowsheet simulation database was generated by coupling the Dyssol framework with MATLAB. This study investigated the influence of raw material composition within the process sequence, the total CO2 emissions, and production costs within the contexts of Spain and Brazil, two of the top five global producers. Granules with a higher proportion of talc and illite exhibit reduced moisture content after spray drying, and these combinations have lower green body porosity after compaction. The addition of talc allowed for decreased porosity content after compaction reduced firing temperature, and lowered costs and CO2 emissions despite the higher prices associated with talc. The proposed simulation methodology offers a powerful decision-making tool for optimizing raw material composition to minimize cost and CO2 emissions in the porcelain tile production. This methodology represents an early stride toward integrating digital twin methodologies within the ceramic tile sector, facilitating improved process regulation, and promoting the adoption of digital technologies.Publicationtype: Journal Article28 151 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: with files , Comparing open-source DEM frameworks for simulations of common bulk processes(Elsevier, 2023-12-19); ; Scopus© Citations 1 13 62 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: without files , Microscale DEM simulation of spray-dried porcelain granules under uniaxial compaction(Elsevier, 2023-10-01); ; ; ; The microscale modeling of spray-dried granules for porcelain tile manufacturing with different moisture contents under uniaxial compaction is investigated in this paper. The Discrete Element Method (DEM) and the Bonded Particle Model (BPM) were applied for the investigation. To describe the mechanical behavior of granules during compression, an elastic-plastic bonded model was implemented, in which the moisture content is linked to the properties of the bonds. A good agreement was reached between experiments and simulations for the second and third stages of compaction. Herein, we obtained a mathematical model that links moisture, bond behavior during rupture, and porosity after compression. Different experimental studies have validated the model with high-achieving correspondence between the experiments and simulations. Thus, the proposed simulation methodology proved effective in predicting the porosity of the particles' bulk after uniaxial compaction.Publicationtype: Journal Article22 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: without files , Linking process-property relationships for multicomponent agglomerates using DEM-ANN-PBM coupling(2022-01); To improve predictivity of macroscale flowsheet models and to establish a link between process conditions, material microstructure and product properties, a data-driven strategy is proposed and applied for continuous particle formulation process. A discrete element method and mesh-free bonded-particle model are used to analyze mechanical behavior of multicomponent agglomerates at uni-axial compression tests. The DEM calculations are performed for varied input parameters to create a database containing information about fracture behavior of agglomerates. The final database is used to build an artificial neural network (ANN) and to link structure-property relationships: from known properties of single components and known microstructure to predict macro-mechanical agglomerate properties. Afterward, the formulated ANN is coupled to the population balance model (PBM) to perform modeling of continuous process where the transient change of particle size distribution in the plant is described. The results demonstrate that the proposed strategy can be efficiently applied to link process-property relationships.Publicationtype: Journal Article47 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: with files , High heating rate sintering and microstructural evolution assessment using the discrete element method(Elsevier, 2021-09-08); ; ; ; Publicationtype: Journal ArticleScopus© Citations 9 163 765 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: with files , Integrated process simulation of porcelain stoneware manufacturing using flowsheet simulation(Elsevier, 2021-05); ; ; ; Integrated simulation of manufacturing plants plays crucial role in development of sustainable processes and optimized products. However, no investigation has been reported for the whole process chain of porcelain stoneware manufacturing. In this contribution, semi-empirical models of porcelain stoneware processing steps have been developed and implemented into Dyssol framework. By validation based on industrial and lab-scale experiments, the simulation has been applied for modeling and sensitivity analysis of the entire process. The simulation results are in a good agreement with experiments showing that the proposed modeling strategy has high potential to be used for future digital transformation in this sector.Publicationtype: Journal ArticleScopus© Citations 8 96 418 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: without files , MUSEN : an open-source framework for GPU-accelerated DEM simulationsThe conceptual design, implementation aspects and main features of an open-source DEM simulation framework MUSEN have been described. MUSEN has been developed for efficient calculations that can be performed on personal computers equipped with general-purpose graphics processing units (GPUs). A very intuitive graphical user interface significantly simplifies usage of the system and reduces learning time. It makes this framework an ideal software tool for educational purposes and for solution of classical problems of solids process engineering. Users without significant experience can easily specify initial scenes, perform simulations and analyse results. In the same time, the modular-based structure of the system allows its extension with new components, calculation algorithms or contact models.Publicationtype: Journal Article222