Options
Optimizing raw material composition to increase sustainability in porcelain tile production: A simulation-based approach
Citation Link: https://doi.org/10.15480/882.8938
Publikationstyp
Journal Article
Date Issued
2024-04
Sprache
English
Author(s)
TORE-DOI
Volume
107
Issue
4
Start Page
2110
End Page
2127
Citation
Journal of the American Ceramic Society 107 (4): 2110-2127 (2024)
Publisher DOI
Scopus ID
Publisher
Wiley
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.
Subjects
digitalization
optimization
porcelain tile
simulation
DDC Class
620: Engineering
Publication version
publishedVersion
Loading...
Name
Journal of the American Ceramic Society - 2023 - Alves - Optimizing raw material composition to increase sustainability in.pdf
Type
Main Article
Size
5.35 MB
Format
Adobe PDF