Integrated Process Simulation applied to the Optimization of Porcelain Tile Manufacturing

,

• Publisher: Cuvillier Verlag
• Year: 2024
• eBook ISBN:
  9783689520601
• Print ISBN:
  9783689520595
• Edition: 1

This thesis introduces a comprehensive simulation methodology for modeling and optimizing the manufacturing process of porcelain tiles. The implementation of an integrated analysis and process simulation methodology for porcelain tile manufacturing has demonstrated its effectiveness in accurately predicting the results of modified process parameters and raw material composition at every stage of the process sequence. This methodology enables the prediction of outcomes at each step of the process, including the quality of the end product, thereby eliminating the requirement for extensive experimentation or trial-and-error methods. The simulations can function as a decision-making tool to propose modifications that optimize productivity and foster sustainability in the process. This emphasizes the considerable potential of the suggested tool for digitalizing the complete process sequence and creating a digital twin of the ceramics production chain.

Table of contents

• Abstract
• Acknowledgments
• Contents
• Nomenclature
• 1 Introduction
• 1.1 General description of manufacturing sequence
• 1.2 Motivation
• 1.3 Outline
• 2 Fundamentals of numerical simulations
• 2.1 Flowsheet simulations
• 2.2 DEM-BPM simulations
• 3 Models development and numerical background
• 3.1 Implement models for macroscale flowsheet simulation
• 3.2 Energy consumption modelling
• 3.3 Numerical background of DEM-BPM simulations forcompaction
• 3.4 Numerical background of DEM-BPM simulations for heattransfer analysis
• 4 Material and methods
• 4.1 Macroscale flowsheet simulation
• 4.2 Uniaxial compaction experimentation methodology
• 4.3 Experimental investigation of heat transfer analysis in particlebeds
• 5 Optimization methodology
• 5.1 Case studies 1 & 2
• 5.2 Case study 3
• 5.3 Case study 4
• 6 Validation of macroscale flowsheet simulation
• 6.1 Sensitivity analysis
• 6.2 Summary
• 7 Energy consumption validation
• 7.1 Electrical energy consumption validation
• 7.2 Thermal energy consumption validation
• 7.3 Summary
• 8 Optimization case studies
• 8.1 Case study 1 and 2
• 8.2 Case study 3
• 8.3 Case study 4
• 9 DEM-BPM simulations for improved correlations ofcompactions tages
• 9.1 Correlation between bond properties and final porosity
• 9.2 Summary
• 10 Investigation of heat transfer analysis of packed beds
• 10.1 Validation of the DEM-BPM heat transfer models
• 10.2 Heat transfer analysis during storage on silos
• 10.3 Summary
• 11 Conclusions
• 12 References
• Appendix A
• Appendix B
• Appendix C
• Appendix D
• Appendix E
• Appendix F
• Appendix G
• Appendix H