The Science Behind a Granule: 'A life Story'
Professor Agba D. Salman, The University of Sheffield
Granulation is a size enlargement process where powder particles are
bonded together using a liquid, which can be poured, sprayed or melted
into the powder mass. Granulation is an important processing step in
many industries, perhaps most notably in the, pharmaceutical and food
industries. Historically, process and product development has taken
place on a case by case basis, with significant costly trial and error
required. There is now a move forward to take this ‘black art’ approach
towards a more science based engineering design methodology, with a view
to develop a ‘granulation theory’ and a comprehensive multi-scale
model. In order to do this it is necessary to employ various
experimental techniques across all the length scales; micro-, meso-, and
macro-. Some of the techniques being further developed; such as
particle image velocimetry (PIV), High Speed Imaging, Thermal Imaging,
X-Ray Tomography, Visual On-line sizing (VOS) and DEM modelling, and
their application from drop-powder and drop-granule interaction and
evolution of granule structure at the micro-scale, to intra-granulator
powder motion and collision rates, binder distribution at the
macro-scale, will be introduced.
About: Agba D. Salman is a Professor of Chemical Engineering at the University Sheffield. He
has published more than 300 papers and has led more than 80
collaborative research projects with range of industries; from food,
pharmaceutical, to detergent and fertilisers on understanding the
science behind industrial granulation processes allowing formulators to
design processes, which deliver better products for consumers. He has
also organized 9 international meetings on Granulation and edited 16
special issues of international journals, and two Handbooks on
Granulation and Particle Breakage.
Back to the future: Distillation and other separations in the era of bio, info and process intensification
Professor Andrzej Górak, TU Dortmund University
and absorption are the main work horses of the chemical process
industries, but are highly energy intensive processes: Distillation of
hydrocarbons from crude oil consumes energy equivalent to the total
energy consumption of the United Kingdom in 2014; energy sufficient to
power roughly 40 million homes is needed to separate cyclic hydrocarbons
through distillation worldwide; and the energy sector emits more than
30 gigatons of CO2 worldwide, equivalent to about two thirds of total
CO2 emissions, which must be recovered through efficient
This lecture will show how efficient
distillation and absorption technologies can, and must, contribute to
solving the global challenges we are facing today, but more importantly,
the challenges future engineers will be facing in the coming decades.
Some examples that will be considered:
- enzymes in distillation and absorption
- intensification of absorption and distillation in modular devices or centrifugal fields
- digitalization and additive manufacturing for efficient separations.
About: Professor Andrzej
Górak, chemical engineer by training, obtained his Ph.D. from TU Lodz in
Poland. He worked a researcher at Henkel KGaA in Düsseldorf and became
professor and the Chair of Fluid Separation Processes at TU Dortmund
University, Germany in 1992. He also has been full professor at the
Technical University of Lodz since 2003. In 2014 he was also awarded by
with Kirschbaum-Medaille for his achievements in fluid separations and
one year later with the PROSE award. His scientific activities are
focused on the intensified separation processes like integrated reaction
and separation processes. He is author of about 300 peer reviewed
papers, 15 patents and 10 co-edited books.
Opportunities and Obstacles in Establishing and using Digital Twins
Prof. Dr.-Ing. Rainer Stark, TU Berlin & Fraunhofer IPK
digital Twin technology has been recognized during the last years to
provide new enablers for technical and business processes.
Unfortunately, the term Digital Twin still is used with different
meanings since IT vendors only loosely followed a stricter understanding
and hence partially misused it for marketing purposes.
This presentation will, therefore, deliver a clear definition and
will explain the difference to a Digital Master and a Digital Prototype.
Furthermore, a theoretical foundation will be given for the target
behavior dimensions of Digital Twins as well as a first explanation of
the critical design elements of Digital Twins.
Prof. Stark will also give an insight into the different kind of
Digital Twins which have been established within the research labs and
Industrie 4.0 labs at the IWF of TU Berlin and the Fraunhofer IPK. The
presentation will also tackle the as-is situation in industry and the
outlook for the challenges and opportunities ahead.
About: Prof. Dr.-Ing. Rainer Stark has a background
in mechanical engineering and received his PhD
1994 (thesis: “Development of a mathematical model on tolerance for the
integration in (3D-) CAD systems”). From 1994 to 2008 he worked in
variuos positions within the Ford Motor Company, finishing his
fourteen years of industrial carrier with a position as European Technical Manager regional and global activities in Virtual Product Development and Methods. During
this time he also gave numerous guest lectures and presentations at the
University of Bochum, the Saarland University Saarbrücken and at the
University of Applied Science of Aix-la-Chapelle.
Since February 2008 Prof. Rainer Stark is professor for Industrial
Information Technology at the Technical University of Berlin and
Director of the Virtual Product Creation division of the Fraunhofer
Institute for Production Systems and Design Technology (IPK) and from
April 2011 until March 2013 he was the Managing Director of the
Department for Machine Tools and Factory Management (IWF).
Prof. Stark is member of the German Academy of Technical Sciences
(acatech), the scientific societies WiGeP (Scientific Society for
Product Development), Design Society and CIRP (International Academy for
Production Engineering) and board member of the ProSTEP iViP
He is also an active member of the VDI (Society of German Engineers)
board Product Development and Mechatronics, the Research Board of
Industry 4.0 as well as the expert group National Competence Monitoring.
SESSION 1: Digital twins in manufacturing industry
Digital Twin for geometry assurance in individualized production
Rikard Söderberg, Professor, Department of Industrial and Materials Science, Chalmers and Director for Wingquist Laboratory
This talk will focus on functionality and data models necessary for real-time geometry assurance and how this concept allows moving from mass production to more individualized production.
Simulations of products and production processes are extensively used in the engineering phase. To secure good geometrical quality in the final product, tolerances, locator positions, clamping strategies, welding sequence, etc. are optimized during design and pre-production. Faster optimization algorithms, increased computer power and amount of available data, can leverage the area of simulation toward real-time control and optimization of products and production systems - a concept often referred to as a Digital Twin.
About: Rikard Söderberg is chair professor in Product and Production Development. He received his PhD from Chalmers in 1995. After some years in the IT and consultancy sector he went back to Chalmers to build up his research group within Geometry Assurance and Robust Design. He is head of department of Industrial and Materials Science. He is Director for Wingquist Laboratory since 2001.
Rikard has been scientific advisor for Fraunhofer Chalmers Centre of Industrial Mathematics since the start in 2001 and since some years he is also the Chairman of the Board. He is Fellow of The American Society of Mechanical Engineers (ASME), Fellow of The International Academy for Production Engineering (CIRP) and member of The Royal Swedish Academy of Engineering Sciences (IVA).
His own research focus on minimizing the effect of geometrical variation and includes industrial design aspects, visualization, robust design, statistical variation simulation, optimization, assembly modeling and analysis, inspection preparation and analysis. He has close collaboration with automotive and aerospace industry.
Rikard has more than 200 peer reviewed scientific publications and a number of his scientific results have been transferred into commercial software products and working procedures, today used in daily operation by a large number of engineers in international companies.
Modeling, simulation and optimization as a leading edge in digital product realization
Johan Carlson, Dr., Managing Director, Fraunhofer-Chalmers Centre for Industrial Mathematics
In this talk, we will show how advanced mathematics and algorithms can be used to cut costs, improve quality and save time in product and production development as well as in running production. The focus will be on modelling, simulation, and optimization (MSO) of geometries, process parameters and motions in manual and robotized processes.
The general interest and focus on industrial digitalization and digital twins have boosted the MSO concept: The simulation and optimization algorithms (Thinking) rely on an updated digital model (Sensing) of the physical system to be controlled (Acting). The updates can be of different data types such as massive 3D point clouds, position tracking and robot programs as well as on different time scales ranging from years to real-time. In the presentation we will show examples from traditional as well as emerging applications.
About: Dr. Johan S. Carlson is the Director of the Fraunhofer-Chalmers Research Centre for Industrial Mathematics, FCC, and is heading the department of Geometry and Motion Planning. He received his PhD degree in mathematical statistics on how to reduce geometrical variation in assembled products at Chalmers University of Technology in 2000. His research interest includes methods, algorithms and tools for digital product realization and in particular geometry simulation and assurance. Dr. Carlson has 20 years of experience with industrial development and implementation related to digital product realization and has been a key person or responsible for over hundred industrial and public projects.
He is one of the inventors of the commercial software tool Industrial Path Solutions (IPS) used daily for virtual prototyping by engineers in over 80 companies including global vehicle OEMs in Sweden, Germany, US, Korea, Japan and China. He has published about 100 scientific articles in international conferences and journals.
Joining in non-rigid variation simulation to support a Digital Twin for geometry assurance
Kristina Wärmefjord, Associate professor, Department of Industrial and Materials Science, Chalmers
A digital twin for geometry assurance can be used for real time optimization and improvement of the product and production processes. To be able to rely on the digital twin, as many as possible of the factors affecting the product in reality need to be included in the simulation model. This presentation focuses on how different aspects of joining can be included in a digital twin for geometry assurance and the effects on accuracy. Examples from automotive and aerospace industry will be presented.
About: Dr. Kristina Wärmefjord took her PhD 2011 and works within the research group of “Geometry Assurance & Robust Design”. Her main research focus is on variation simulation for non-rigid parts and methods to decrease the gap between simulated values and the real outcomes, i.e. increase the accuracy of non-rigid variation simulations. With an increased accuracy, quality can be improved, simulations can replace physical prototypes and costs can be reduced.
The work is done in close collaboration with a number of companies, mostly in automotive and aerospace industry.
Kristina is the assistant director of Wingquist Laboratory and project leader for the projects “Smart Assembly” and “Virtual Robust Design and Simulation Methods”.
Digital twins in the engineering tool chain - automatic update of geometrical changes
Knut Åkesson, Professor, Automation, Department of Electrical Engineering, Chalmers
A digital twin needs to updated and synchronized with changes in the production system, this includes changes to both the software and the hardware. This is today largely a manual process and a common situation is that the digital and physical systems are synchronized during the initial virtual commissioning phase but tend to deviate away from each other over time. With synchronized we mean in this context that the digital models of both the software parts and the hardware parts are useful abstractions of the physical system. Not having the systems synchronized significantly, decrease the value of the digital twin and thus it is important to establish new automated methods to keep the physical systems and the digital twin synchronized with each other. In this presentation, we show how recent results from computer vision and artificial intelligence can be used to synchronize geometrical models. This includes approaches to build point-cloud models from multiple camera images, recognizing objects and estimation their 6D-pose. We present some initial results and some challenges that will be addressed in a new research project.
About: Knut Åkesson is a professor in Automation at Chalmers. He received his PhD in Automatic Control from Chalmers in 2002, and his Master of Science in Computer Science and Engineering from Lund University in 1997. His research interest includes formal verification, testing, and planning with applications toward cyber-physical (production) systems. Recently he has also started to do research on machine learning and computer vision techniques with applications for automated production systems.
Digital twins in the engineering tool chain - analysis and optimization of the control functions
Kristofer Bengtsson, Dr., Automation, Department of Electrical Engineering, Chalmers
The engineering work is often about creating different types of models. The current trend when developing automation systems is to create highly detailed and complete virtual models that can be used from early design to final virtual commissioning. However, the developed models are usually not kept up-to-date with the real system or used during production. This talk will therefore present the latest research about reusing the digital models as digital twins to optimize and analyze the running system, for example to reduce the wear and tear or save energy. Automated algorithms to identify changes in the control functions in the real systems that keeps the digital models in sync with the real system, will also be presented.
About: Dr. Kristofer Bengtsson received his Ph.D. degree in Systems and Control from Chalmers University of Technology in 2012. He has a background in developing real-time control and automation systems before starting his academic career. Currently he is working with control and optimization of automation systems, intelligent and collaborative robots as well as AI and IT support for proactive healthcare.
SESSION 2: Simulation as a tool for chemical engineering
Simulations facilitate development of sustainable hygiene products
Charlotta Hanson, Senior scientist, Adjunct professor, Essity Hygiene and Health AB
Simulations can be used in many ways to facilitate the development of sustainable hygiene products. Many hygiene products are made for handling of fluids. An essential element in fluids handling is the absorption of liquids by means of porous structures. Models of fluid transfer in porous structures can be used to properly adjust the function of an absorbent, to optimize the manufacturing process of the porous structure or to investigate how to improve the microclimate of the product for the comfort of the user. Simulations can be used to speed up the development process, to set the proper route in trouble shooting or for efficient knowledge transfer. Models are compact storages of knowledge that can be used in the communication between the many players involved in the complex life cycle of a hygiene product, all acting to optimize the processes involved in the creation of sustainable solutions.
About: Dr. Charlotta Hanson is Senior Scientist, Essity Hygiene and Health AB and Adjunct Professor at Chemistry and Chemical Engineering, Chalmers University of Technology. She has a PhD in Chemical Engineering on the properties and quality of lime from the lime mud reburning process in the sulphate pulp mill. She has been working for twenty five years in industry, specializing in the science behind fluid absorption in hygiene products. The common denominator for the studies at Chalmers and at Essity has been porous structures; their characteristics and properties and how they influence and are influenced by different processes.
Modelling and simulations to optimize the design of polymer coated drug delivery systems
Mariagrazia Marucci, Dr., Associate Principal Scientist, AstraZeneca
Polymer film coating is often used in modified release oral drug delivery systems; several parameters can be varied to obtain a specific drug release profile. This talk will illustrate how the design of a coated system can be optimized by applying the materials science tetrahedron, by using an appropriate model to describe the coated system and the drug release process, and by performing simulations to predict the release from coated systems with different geometries and compositions.
About: Dr. Mariagrazia Marucci is an Associate Principal Scientist in Material Science at AstraZeneca and an Associate Professor in Pharmaceutical Technology at Lund University. She has 12 years of industry experience and has contributed to the development of several immediate and modified release oral formulations. In 2016 she was awarded the AkzoNobel Nordic Prize for Surface and Colloid Chemistry for her contribution to the field of pharmaceutical film coating.
Process engineering modelling and the Center for Chemical Process Engineering (CPE)
Ronnie Andersson, Associate Professor, Department of Chemistry and Chemical Engineering, Chalmers
Recent advances in model development and large computational power allows new insights to chemical engineering processes, faster development, higher quality while using less resources. The center for Chemical Process Engineering (CPE) brings together Chalmers researchers in mathematics, statistics, physics, thermo- and fluid dynamics, and control engineering and a range of chemical engineering areas in a network. The purpose is to conduct fundamental and applied research, professional education and industrial development projects in process technology; design, control, optimization, process analytical technology, energy use, environmental technology and more.
About: Dr. Ronnie Anderssons research centers around physical modelling in chemical engineering, spanning fundamental understanding, development of mathematical models, frameworks for virtual design, technological innovation and engineering practice including training.
Digitalization in process engineering: "old" and "new" challenges
Gaetano Sardina, Assistant Professor, Fluid mechanics, Department of Mechanics and Maritime Sciences, Chalmers
Digital technologies are changing the current business models in the manufacturing industry, providing new revenue and value-producing opportunities.
Numerical simulations aim to reproduce a “digital copy” of a chemical system to improve its efficiency and design. In this talk, we will briefly review the current state of the art of computational models, including the main limitations. New approaches based on Artificial Intelligence will be illustrated to address old problems from a different perspective.
About: Dr. Gaetano Sardina is an Assistant Professor in Sustainable Process Engineering, with emphasis on numerical simulations of multiphase flows. The main focus of his research is the transport of particles, droplets and bubbles in Newtonian and complex flows. His research spans from industrial to environmental and biological applications. Additional areas of specific interest involve transport in porous media and cloud microphysics.