DEM-based modelling framework for spray-dried powders in ceramic tiles industry. Part III: Validation procedure

This is the third and final paper in a series presenting a DEM-based modelling framework for simulating the spray-dried powder rheology in ceramic tiles industry. Part I described the characterization of the spray-dried powder. Part II detailed the implementation of a new dedicated solver for simulating demanding scenarios. In this part, the validation procedure of the framework is presented through 2 validation series: a partial mould filling and a complete mould filling equivalent to industrial filling. A pilot-scale powder feeder was built expressly for this purpose. Powder dynamics was accurately reproduced in series 1, with a maximum relative error of 10%. Surface density in the mould was adequately reproduced in series 2 (maximum absolute error < 4 kg/m2). The formation of defects is accurately predicted. Some discrepancies in the surface density values are observed. The DEM-based modelling framework proves as a valid tool to design and optimize spray-dried powder handling equipment. [Display omitted] •Two mould filling series are proposed to perform the validation.•A pilot-scale powder feeder is designed and constructed to validate the framework.•Powder dynamics during the mould filling is accurately reproduced (error < 10%).•Surface density of the powder bed is adequately reproduced (absolute error < 4 kg/m2).•Modelling framework developed is valid for use in ceramic tile manufacturing.