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1.
  • Bhadani, Kanishk, 1991, et al. (author)
  • Application of Structural Optimization for an Early Stage Product Development
  • 2017
  • In: NAFEMS World Congress 2017, A World of Engineering Simulation, Stockholm, Sweden. - 9781910643372 ; , s. 13-
  • Conference paper (peer-reviewed)abstract
    • In today’s automotive industry there is a growing demand for more fuel efficient vehicles and reduced development times. These trends are driven by stricter environmental regulations, a growing environmental awareness, and increasing technological development and competitiveness. Finding an optimized and balanced component that fulfils the requirements in an early phase of the product development is a prerequisite for enabling more competitive lead times, costs, weights and minimizing the risk for late design changes. The aim with this paper is to show a process capturing CAE driven development for an early stage development of components in a complex system. The process utilizes structural optimization techniques to generate knowledge, optimize and balance packaging volumes of adjacent components in complex systems. The paper also highlight the organizational challenges and technical challenges involving the use of structural optimization for realizing the process completely. The paper will illustrate the simultaneous use of topology and shape optimization to generate knowledge for the optimized design volume for multiple adjacent components linked together. The linking of the multiple component is carried out using morphing technique and the design space between the multiple components is dynamic in nature during simulation. The mesh in one component is allowed to change according to the mesh of the other component during the simulation. The result from the simultaneous topology and shape optimization simulation generates the knowledge if it is feasible to change design volume to meet the weight and performance targets. The process also indicates how much performance increase is possible if the design volume is allowed to change and thus generating a trade-off between the components performance.The new process has a potential to be extended to other conflicting scenarios in adjacent components which exists in early stages of development process especially, cases involving conflicting structural requirements in various industries.
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2.
  • Asbjörnsson, Gauti, 1985, et al. (author)
  • Application of Design of Experiments (DoE) in Evaluating Crusher Circuit Performance
  • 2023
  • Conference paper (other academic/artistic)abstract
    • The configuration and the interaction between the crushers and screens enable aggregate producers to produce products that are in accordance with the applicable product certification. However, the performance of the system is seldom optimized for the given conditions and market demand. This paper aims to describe the experimental work and the results of quantifying the crusher and screen performance by applying design of experiments in a full-scale tertiary crushing process of an aggregate production plant with both standard belt-cut sampling as well with continuous processes monitoring. The research output is able to demonstrate that there exists an interaction effect between the crusher closed side setting and eccentric speed that previously has not been identified with traditional methods. The quantification of interaction between crusher and screen individual performance to the process performance have been demonstrated with both belt-cut samples and continuous process monitoring.
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3.
  • Asbjörnsson, Gauti, 1985, et al. (author)
  • Continuous Assignment Development on Topology Optimization in Engineering Design
  • 2022
  • Conference paper (other academic/artistic)abstract
    • An engineering course assignment needs to be designed as a stimulating and challenging task for actively engaging students. It is typically required to be solved in an iterative approach using lectures, reading materials, software tools and supervision sessions. Assignments allow for a practical application of a theory to enhance the students’ understanding of the topic with active learning activities to gain continuous engagement in the course. In the Engineering Design and Optimization course at the Chalmers University of Technology, there is a good balance of theoretical lectures and practical aspects in the assignments. One of these assignments is called the cantilever beam challenge. The students are given an iterative task of designing a cantilever beam based on their previous engineering know-how in the first iteration and applying Topology Optimization on a defined design space to minimise compliance and mass in the second set of iterations. This paper aims to examine the students’ performance, from the start of the course, concerning the development that has happened regarding the different software solutions and different additive manufacturing techniques, and to provide the students’ opinions on the assignment. Each year, this particular assignment ranks high in the course evaluation due to its framework, competitiveness and instant feedback on the proposed design solutions with computer analysis and physical experiments with 3D printed models. However, the interesting questions are whether more advanced tools and algorithms support students learning and whether the beams’ performance improves.
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4.
  • Asbjörnsson, Gauti, 1985, et al. (author)
  • Development of production and environmental platforms for the European aggregates and minerals industries
  • 2024
  • In: Minerals Engineering. - 0892-6875. ; 206:2024
  • Journal article (peer-reviewed)abstract
    • Both quantification and communication of environmental impacts can create the foundation for improved sustainable production and decision-making. Without widespread information about site-specific environmental impacts, stakeholders cannot make a well-informed decision based on the local system boundaries. With organization-wide digital platforms, different aspects of production and management can be integrated and customized based on the organization's needs. This paper aims to give an overview of the development of three different process and environmental platforms, their purposes, system structure, system constraints and the applied framework. These respective platforms are being developed separately for the Swedish aggregates industry, the European aggregates industry and the European critical raw materials sector. The initial demonstrator can integrate site-specific information with a simulation-based allocation of resources and generate Life-Cycle Assessment and Environmental Product Declaration reports harmonized with the EN 15804 standard and the associated Product Category Rules.
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5.
  • Asbjörnsson, Gauti, 1985, et al. (author)
  • Improving Students Engagement with Active Learning in Engineering Optimization Lectures
  • 2021
  • In: Proceedings of the International CDIO Conference. - 2002-1593. - 9786164076167 ; 1:1, s. 535-545
  • Conference paper (peer-reviewed)abstract
    • In optimisation, as for learning, the synthesises of previous knowledge and current information is essential to achieve defined objectives. The students' objectives are to fulfil the course's intended learning outcomes and possibly, at the same time, develop their knowledge, skills, and attitudes within the subject. The purpose of this work is to incorporate a more collaborative learning environment with active learning activities in the classroom to improve student learning opportunities, their perception of the course and their interest in the subject of optimisation. Within the CDIO initiative, active learning or experiential learning is stated as a key factor in engaging students directly in thinking and problem-solving activities. This can apply to different teaching activities such as assignments, lectures, and assessments. With active learning, the purpose is to involve students more actively in the learning process instead of relying on passive information transfer. Active learning methods aim to facilitate the students' process of creating their understanding of the topic by reflecting, questioning, conjecturing, evaluating and make connections between ideas whilst drawing on ideas, experiences and knowledge of others. In this work, diverse activities for incorporating more interactive learning in the classroom have been implemented in different course lectures, activities such as think pair-share, mind maps, multiple-choice questions, incomplete hands and more. An evaluation of the students' perception of the course and the various activities was carried out at the end of the course. The most considerable improvement was with the overall impression of teaching. That improved between the years from 3.10 to 3.57. The most appreciated activity was the think-pair-share approach, which gave the students a cognitive break from the lecture slides to discuss the topic. However, the response rate was limited but did indicate the students' perspective and what was appreciated. The results will provide a good base for future development.
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6.
  • Bhadani, Kanishk, 1991, et al. (author)
  • Application of design of experiments (DoE) in evaluating crushing-screening performance for aggregates production
  • 2024
  • In: Minerals Engineering. - 0892-6875. ; 209
  • Journal article (peer-reviewed)abstract
    • The configuration and the interaction between the crushers and screens enable aggregate producers to produce products that are in accordance with the applicable product certification. However, the performance of the system is seldom optimized for the given conditions and market demand. This paper aims to describe the experimental work and the results of quantifying the crusher and screen performance by applying the design of experiments (DoE) in a full-scale tertiary crushing process of an aggregate production plant with both standard belt-cut sampling as well with continuous processes monitoring. The results show the application of a simplified modelling approach using the design of experiments for the evaluation of crusher performance and circuit performance using experimental data. The research output is able to demonstrate that there exists an interaction effect between the crusher closed side setting and eccentric speed that previously has not been identified with traditional methods. The quantification of interaction between crusher and screen individual performance to the process performance has been demonstrated with both belt-cut samples and continuous process monitoring. Using a DoE, digital experiments can be planned for mapping and quantifying the performance of aggregate production.
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7.
  • Bhadani, Kanishk, 1991, et al. (author)
  • Application of Multi-Disciplinary Optimization Architectures in Mineral Processing Simulations
  • 2018
  • In: 11th International Comminution Symposium. - 9781510883789
  • Conference paper (peer-reviewed)abstract
    • Optimization is a pivotal point in distinguishing the competitiveness between industries that are developing, designing and operating products and processes. Mineral processing is an industry which operates various sub-processes and produces one or several products. The sub-processes involved are dynamic in nature and differs in discipline of operation. These dynamic sub-processes are sequentially integrated forming a mineral processing system. Currently, the developed simulations for the mineral processing systems have the potential to be used to design, operate and control mineral processing plants to an increased extent, but need broader optimization strategies to integrate multiple sub-processes involved. The scope of this research is to demonstrate application of multi-disciplinary optimization (MDO) architectures into a mineral processing simulation. A case study consisting of two sub-processes of comminution and classification circuits to produce aggregate products is used to demonstrate the application of MDO architectures. The MDO architectures are compared based on problem formulation, computational resources required and validity of the results. The optimization results using MDO architectures can be used to illustrate trade-offs between different sub-processes within the considered scope. The application of MDO architectures can facilitate the linking mathematical models of various disciplines such as comminution, and liberation in mineral processing simulation.
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8.
  • Bhadani, Kanishk, 1991, et al. (author)
  • Application of multi-disciplinary optimization architectures in mineral processing simulations
  • 2018
  • In: Minerals Engineering. - : Elsevier BV. - 0892-6875. ; 128, s. 27-35
  • Journal article (peer-reviewed)abstract
    • Optimization is a pivotal point in distinguishing the competitiveness of industries that are developing, designing and operating various products and processes. Mineral processing is an industry which operates various sub-processes and produces one or several products. The sub-processes involved are dynamic in nature and differ in the discipline of operation. These dynamic sub-processes are sequentially integrated forming a mineral processing system. Currently, the developed simulations for the mineral processing systems have the potential to be used to design, operate and control mineral processing plants to an increased extent, but need broader optimization strategies to integrate multiple sub-processes involved. The scope of this research is to demonstrate application of multi-disciplinary optimization (MDO) architectures into a mineral processing simulation. A simulation study consisting of two sub-processes of comminution and classification circuits to produce aggregate products is used to demonstrate the application of MDO architectures. The MDO architectures are compared based on problem formulation, computational resources required and validity of the results. The optimization results using MDO architectures can be used to illustrate trade-offs between different sub-processes within the considered scope. The application of MDO architectures can facilitate the linking mathematical models of various disciplines such as comminution, and liberation in mineral processing simulation.
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9.
  • Bhadani, Kanishk, 1991, et al. (author)
  • Application of Optimization Method for Calibration and Maintenance of Power-Based Belt Scale
  • 2021
  • In: Minerals. - : MDPI AG. - 2075-163X. ; 11:4
  • Journal article (peer-reviewed)abstract
    • Process optimization and improvement strategies applied in a crushing plant are coupled with the measurement of such improvements, and one of the indicators for improvements is the mass flow at different parts of the circuit. The estimation of the mass flow using conveyor belt power consumption allows for a cost-effective solution. The principle behind the estimation is that the power draw from a conveyor belt is dependent on the load on the conveyor, conveyor speed, geometrical design, and overall efficiency of the conveyor. Calibration of the power-based belt scale is carried out periodically to ensure the accuracy of the measurement. In practical implementation, certain conveyors are not directly accessible for calibration to the physical measurement as these conveyors have limited access or it is too costly to interrupt the ongoing production process. For addressing this limitation, a better strategy is needed to calibrate the efficiency of the power-based belt scale and maintain the reliability of such a system. This paper presents the application of an optimization method for a data collection system to calibrate and maintain accurate mass flow estimation. This includes calibration of variables such as the efficiency of the power-based belt scale. The optimization method uses an error minimization optimization formulation together with the mass balancing of the crushing plant to determine the efficiency of accessible and non-accessible conveyors. Furthermore, a correlation matrix is developed to monitor and detect deviations in the estimation for the mass flow. The methods are applied and discussed for operational data from a full-scale crushing plant.
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10.
  • Bhadani, Kanishk, 1991, et al. (author)
  • Applied Calibration and Validation Method of Dynamic Process Simulation for Crushing Plants
  • 2021
  • In: Minerals. - : MDPI AG. - 2075-163X. ; 11:9
  • Journal article (peer-reviewed)abstract
    • There is a need within the production industry for digitalization and the development of meaningful functionality for production operation. One such industry is aggregate production, characterized by continuous production operation, where the digital transformation can bring operational adaptability to customer demand. Dynamic process simulations have the ability to capture the change in production performance of aggregate production over time. However, there is a need to develop cost-efficient methodologies to integrate calibrations and validation of models. This paper presents a method of integrating an experimental and data-driven approach for calibration and validation for crushing plant equipment and a process model. The method uses an error minimization optimization formulation to calibrate the equipment models, followed by the validation of the process model. The paper discusses various details such as experimental calibration procedure, applied error functions, optimization problem formulation, and the future development needed to completely realize the procedure for industrial use. The validated simulation model can be used for performing process planning and process optimization activities for the crushing plant's operation.
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11.
  • Bhadani, Kanishk, 1991, et al. (author)
  • CDIO Course Development for Faculty in Raw Materials Programmes
  • 2017
  • In: The 13th International CDIO Conference Proceedings, Calgary, Canada. - 1796-9964. - 9780889533998 ; , s. 315-326
  • Conference paper (peer-reviewed)abstract
    • In Europe, the existing MSc programmes which are linked to the thematic Raw Material content often focus mainly on technical knowledge in itself, and students graduate as professionals who know how to solve pre-defined technical problems. Students in such programmes seldom practice entrepreneurial, communication and innovation skills at a level that is needed in working life. On the other hand, the CDIO Initiative has developed a framework for modernizing engineering education by introducing such skills and thinking into the technical programmes and courses. It is widely discussed in the CDIO community that one of the constraints in implementing CDIO is faculty staff professional development. CDIO standards 9 and 10 focus on the faculty development and competencies both in terms of pedagogic as well as learning methods to deal with personal and interpersonal skills, and product, process, and system building skills. In order to bring a change and implement CDIO into the Raw Materials programmes in Europe, a modular course for training in CDIO was developed and delivered for the faculty member in the Raw Materials sector. This paper accounts for the development of the faculty training course, and provides a unique perspective on the implementation of CDIO into raw materials related programmes capturing the different models of implementation from different universities’ programmes and courses. The various universities involved provide programmes and courses across the entire value chain of raw materials from mining and minerals processing to materials design, sustainability and recycling. This paper will serve as a reference for the educators to develop and implement CDIO education methods in specific disciplines as illustrated here in the field of raw materials related programmes.
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12.
  • Bhadani, Kanishk, 1991, et al. (author)
  • Comparative Study of Optimization Schemes in Mineral Processing Simulations
  • 2019
  • In: IMPC 2018 - 29th International Mineral Processing Congress. ; 2019, s. 464-473
  • Conference paper (peer-reviewed)abstract
    • Modelling and simulations for mineral processing plants have been successful in replicating and predicting predefined scenarios of an operating plant. However, there is a need to explore and increase the potential of such simulations to make them attractive for users. One of the tools to increase the attractiveness of the simulations is through applying optimization schemes. Optimization schemes, applied on mineral processing simulations, can identify non-intuitive solutions for a given problem. The problem definition itself is subjective in nature and is dependent on the purpose of the operating plant. The scope of this paper is to demonstrate two optimization schemes: Multi-Objective Optimization (MOO) using a Genetic Algorithm (GA) and Multi-Disciplinary Optimization (MDO) using an Individual Discipline Feasible (IDF) approach. A two stage coarse comminution plant is used as a case plant to demonstrate the applicability of the two optimization schemes. The two schemes are compared based on the problem formulations, types of result and computation time. Results show that the two optimization schemes are suitable in generating solutions to a defined problem and both schemes can be used together to produce complementary results.
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13.
  • Bhadani, Kanishk, 1991, et al. (author)
  • Development and implementation of key performance indicators for aggregate production using dynamic simulation
  • 2020
  • In: Minerals Engineering. - : Elsevier BV. - 0892-6875. ; 145
  • Journal article (peer-reviewed)abstract
    • Continuous process improvements are needed to maintain and run an industrial operation at a profitable state. An aggregates production plant consists of multiple process operations such as blasting, primary crushing, followed by secondary and tertiary crushing stages with an intermediate screening of products. Each of these processes can be operated with multiple objectives in mind of operators and plant managers. These objectives can be defined by varying terms like generating required throughput of the plant, maintaining equipment’s health, meeting customers’ demands, etc. The use of the term key performance indicators is recurrent in industry to formalise and represent these objectives of operation. Currently, the KPIs defined by the ISO 22400 standards are widespread for continuous improvements in the manufacturing industry and they are viewed as a support tool to measure improvements. The scope of this paper is to calculate relevant KPIs for an aggregates production plant using dynamic simulations. Further, the KPIs are implemented in a three-stage aggregate production plant using both real-time plant data and dynamic process simulation. The KPIs developed are useful for operators and plant managers to make decisions. The results show the relationship and dependencies of various equipment and process KPIs. The dynamic simulation has potential to be used as an exploration tool to identify the opportunities of improvement in aggregates processing using KPIs as a measure. The KPIs presented in the paper are based on ISO 22400 standard and have potential to be extended to similar processing operations such as coarse and fine comminution for minerals processing. Apart from the diagnostics application, the KPIs implemented in the dynamic simulation platform can be used to explore and optimize a crushing plant’s design and operations.
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14.
  • Bhadani, Kanishk, 1991, et al. (author)
  • Experimental and simulation-driven improvements for coarse comminution circuit using Plantsmith process simulator - A case study of Geita Gold Mine, Tanzania
  • 2021
  • Conference paper (other academic/artistic)abstract
    • Continuous improvements are a key aspect of driving an industrial process plant at a profitable state. The performance of the crushing plant is driven by each equipment’s (crusher, screen conveyors, bin, etc.) operation, raw material properties, operational strategies, control system, maintenance, and so on. To bring improvements for full-scale industrial units, a thorough investigation is needed. In the considered case study, a need was posed by the industry operating coarse and fine comminution circuit to investigate the opportunities for upscaling and downscaling of the plant capacity along with evaluating the performance of the existing circuit. The need is driven by the change in ore characteristics from the mining segment. As the decision’s in the industry is driven by the cost, it is important to find opportunities which will increase the profitability and produces a viable solution(s). The paper presents a methodological approach for evaluating the performance of the crushing plant by carrying out: • Physical investigation and observation • Experimental survey and laboratory data analysis • Evaluating historical production data • Simulation configuration and calibration in Plantsmith process simulator • Evaluating alternative concepts using Plantsmith process simulator The evaluation presents possible improvements in the existing plants, and alternative concepts with their opportunities and pitfalls. The results show that a methodological approach can bring a wide understanding of the plant operations and simulation tool is useful for evaluating operational scenarios. Also, multiple practical aspects are presented concerning the investigation process.
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15.
  • Bhadani, Kanishk, 1991 (author)
  • Optimization Capabilities for Crushing Plants
  • 2022
  • Doctoral thesis (other academic/artistic)abstract
    • Responsible production and minimal consumption of resources are becoming competitive factors in the industry. The aggregates and minerals processing industries consist of multiple heavy mechanized industrial processes handling large volumes of materials and are energy-intensive. One such process is a crushing plant operation consisting of rock size reduction (comminution) and particle size separation (classification) processes. The objective of the crushing plant operation for the aggregates industry is to supply specific size fractions of rock material for infrastructure development, while the objective in minerals processing is to maximize material ore throughput below a target size fraction for the subsequent process. The operation of a crushing plant is complex and suffers variabilities during the process operation, resulting in a drive for optimization functionality development. Process knowledge and understanding are needed to make proactive decisions to enable operations to maintain and elevate performance levels. To examine the complex relationships and interdependencies of the physical processes of crushing plants, a simulation platform can be used at the design stage. Process simulation for crushing plants can be classified as either steady-state simulation or dynamic simulation. The steady-state simulation models are based on instantaneous mass balancing while the dynamic simulation models can capture the process change over time due to non-ideal operating conditions. Both simulation types can replicate the process performance at different fidelities for industrial applications but are limited in application for everyday operation. Most companies operating crushing plants are equipped with digital data-collection systems capturing continuous production data such as mass flow and power draw. The use of the production data for the daily decision-making process is still not utilized to its full potential. There are opportunities to integrate optimization functions with the simulation platform and digital data platforms to create decision-making functionality for everyday operation in a crushing plant. This thesis presents a multi-layered modular framework for the development of the optimization capabilities in a crushing plant aimed at achieving process optimization and process improvements. The optimization capabilities for crushing plants comprise a system solution with the two-fold application of 1) Utilizing the simulation platform for identification and exploration of operational settings based on the stakeholder’s need to generate knowledge about the process operation, 2) Assuring the reliability of the equipment model and production data to create validated process simulations that can be utilized for process optimization and performance improvements. During the iterative development work, multiple optimization methods such as multi-objective optimization (MOO) and multi-disciplinary optimization (MDO) are applied for process optimization. An adaptation of the ISO 22400 standard for the aggregates production process is performed and applied in dynamic simulations of crushing plants. A detailed optimization method for calibration and validation of process simulation and production data, especially for mass flow data, is presented. Standard optimization problem formulations for each of the applications are demonstrated, which is essential for the replicability of the application. The proposed framework poses a challenge in the future development of a large-scale integrated digital solution for realizing the potential of production data, simulation, and optimization. In conclusion, optimization capabilities are essential for the modernization of the decision-making process in crushing plant operations.
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16.
  • Bhadani, Kanishk, 1991 (author)
  • Optimization Framework for Crushing Plants
  • 2019
  • Licentiate thesis (other academic/artistic)abstract
    • Optimization is a decision-making process to utilize available resources efficiently. The use of optimization methods provide opportunities for continuous improvements, increasing competitiveness, trade-off analysis and as a support tool for the decision-making process in industrial applications. One of such industrial applications where optimization methods are needed is coarse comminution and classification processes for aggregates and minerals processing industries. The coarse comminution and classification process, consisting of crushing and screening, is a heavy industrial process characterized by continuous operations. The processes handle large material volumes, are energy intensive, and suffer large variabilities during process operations. To understand the complexity and to replicate the process performance of the coarse comminution and classification processes, process simulation models have been under development for the past few decades. There are two types of process simulation models: steady-state simulation and dynamic simulation. The steady-state simulation models are based on instantaneous mass balancing while the dynamic simulation models are capable of capturing the process change over time due to non-ideal operating conditions. Both simulation types are capable of capturing the process performance, although the dynamic process simulations have been proven to have a higher fidelity for industrial applications. Both the steady-state and dynamic simulation models lack the capability of optimization methods which can potentially increase the utilization of the developed process simulation models. The optimization capabilities can further increase the functionality of the process simulation models and provide decision-making support. The thesis presents a modular optimization framework for carrying out process optimization and process improvements in a coarse comminution and classification process using process simulation models. The thesis describes the results of explorative studies carried out for developing the application of optimization methods and key performance indicators for the coarse comminution and classification process. The application of the optimization methods can generate new insights about the process performance with respect to the operating parameters, and non-intuitive results. The application of the key performance indicators can be used to carry out process diagnostics and process improvement activities. As a conclusion, a conceptual framework for carrying out optimization procedure within the coarse comminution and classification process is presented. The development of the optimization system and performance measuring system can be useful for process optimization and process improvements for industrial applications.
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17.
  • Bhadani, Kanishk, 1991, et al. (author)
  • Simulation-Driven Development for Coarse Comminution Process - A Case Study of Geita Gold Mine, Tanzania using Plantsmith Process Simulator
  • 2021
  • In: Proceedings of the Design Society. - : Cambridge University Press (CUP). - 2732-527X. ; 1, s. 2681-2690
  • Conference paper (peer-reviewed)abstract
    • A comminution process is a material size reduction and separation process which is primarily used in the aggregates and the minerals processing industry. Knowledge related to equipment’s operation, raw material properties, operational strategies, control system, maintenance, etc. is needed to design a capable plant. New needs are arising from the industry for existing operational crushing plants such as investigation for improvements, upscaling, and downscaling of the capacity. The paper presents an application of simulation-driven development for a crushing plant in an existing gold processing plant. Due to the change in ore characteristics and the need for optimizing the cost of operation, it is required to investigate the opportunities for improvement and alternative options for downscaling the capacity of the plant. A systematic process for configuring, developing, and evaluating alternative concepts using a process simulation tool is presented. The results show the process of generating knowledge for alternative crushing plant operation settings and how the choices can be selected and eliminated using boundary conditions. The evaluation presents possible improvements and alternative concepts with their opportunities and pitfalls.
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18.
  • Bhadani, Kanishk, 1991, et al. (author)
  • State of the Art in Application of Optimization Theory in Minerals Processing
  • 2017
  • In: European Symposium on Comminution and Classification, Izmir, Turkey.
  • Conference paper (other academic/artistic)abstract
    • There has been continuous development going over the past 40 years related to the creation of models and simulation techniques to predict the behaviour of equipment and processes in minerals processing. At the same time, application of optimization theory into such modelling and simulation schemes has been applied to generate knowledge to improved performances of the equipment and processes.Different optimization techniques have been applied to design and configure different equipment and processes, yet there are no well-established formulations to reproduce the results. The research is scattered and focused on the need and application of the specific equipment or process not utilizing the optimization’s full potential.The aim of this paper is to highlight the trends in development of optimization schemes in minerals processing. By understanding the state of the art in application of optimization theory into mineral processing will further pave the possibility to develop utility in this field. The paper presents two classification schemes: State of Development Stage and State of Application Area as a basis to classify research within optimization related to mineral processing. In order to make smart and strategic decisions in minerals processing operations, it is required to further develop optimization techniques into modelling and simulation schemes to extract the relevant information. The classification schemes can be useful in defining the future focus area for research and development.
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19.
  • Bhadani, Kanishk, 1991, et al. (author)
  • Student Perspectives on Video-Based Learning in CDIO-Based Project Courses
  • 2017
  • In: The 13th International CDIO Conference Proceedings, Calgary, Canada. - 1796-9964. - 9780889533998 ; , s. 689-704
  • Conference paper (peer-reviewed)abstract
    • This paper aims at demonstrating the applicability of video learning in CDIO based project courses and at evaluating to what extent it benefits students. The courses are Machine Elements (PPU210), Product Planning - Needs and Opportunities (PPU085) and Engineering Design and Optimization (PPU190) in the Mechanical Engineering programme at Chalmers University of Technology. The research was carried out by first creating a set of videos for selected topics in three courses. In total, 22 videos were created including topics such as “Benchmarking”, “SWOT”, and “Prototype lab equipment instructions”. The learning outcomes of the video lectures were mapped to the CDIO syllabus. A blended learning environment was developed, i.e. the videos were utilised as additional support alongside existing learning activities. The videos were then used in the courses and the students’ feedbacks collected through a dedicated questionnaire, the regular course evaluation survey, and in student-teacher group meetings during and after the courses. The collected data was analysed to produce inferences about the applicability and utility of the video lectures. The resulting analysis shows the students’ preferences regarding the evaluated video lectures and instructions. The students find videos more appealing compared to traditional lectures. One of the main benefits highlighted is the possibility of watching the videos in parallel to the design-build-test project execution rather having the classroom lecture only. This helps in reinforcing concepts, and results in less dependency on supervisors during the project execution. Videos proved to be suitable for creating a blended learning environment and improved the perceived learning experience for the students. In order to maximize student satisfaction and interaction with the videos, the videos should be short and closely aligned to the other learning activities. The paper also suggests future improvements to be carried out for video-based learning in the courses, and proposes an easy adaptable way for teachers to develop video material.
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20.
  • Bhadani, Kanishk, 1991, et al. (author)
  • Trade-Off Curves for Performance Optimization in a Crushing Plant
  • 2023
  • In: Minerals. - 2075-163X. ; 13:10
  • Journal article (peer-reviewed)abstract
    • Operational flexibility in an aggregate production process is required to adapt to changes in customer demands. Excessive demand for a particular product fraction can lead to operational alteration wherein re-crushing of the existing larger-sized product fraction is necessary. The choice of re-crushing existing product fractions results in feed condition changes to the crusher. One common approach to producing the desired product is by varying the operation settings of a crusher in a crushing plant. However, knowledge of differences in operational performance for changing feed conditions in the circuit is required. This potentially leads to a problem of performance optimization based on the desired target product, available feed material and capability of the crusher. The paper presents an application of a multi-objective optimization method to generate multiple operational settings for the dynamic change in the operation condition in a crushing plant. Controlled experimental survey data with varying feed conditions are used to calibrate the crusher model using an unconstrained optimization problem solved using a gradient-based algorithm (Quasi-Newton method). Trade-off curves between various performance indicators of the crushing plant using a dynamic simulation platform are generated using multi-objective optimization using a non-gradient-based algorithm (genetic algorithm). The results of the application can help the operators and plant managers to make proactive decisions to steer the operation of the crushing plant towards the desired needs of the operation.
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21.
  • Herbert, Juan Herrera, et al. (author)
  • Implementation of CDIO Initiative In New European Education Programs in Raw Materials
  • 2017
  • In: EDULEARN17 Proceedings. - 2340-1117. - 9788469737774 ; , s. 6518-6526
  • Conference paper (other academic/artistic)abstract
    • EIT Raw Materials, one of the six Knowledge and Innovation Communities (KICs) initiated by the EIT (European Institute of Innovation and Technology) and funded by the European Commission, has the mission to boost competitiveness, growth and attractiveness of the European raw materials sector via radical innovation and guided entrepreneurship. It aims to significantly enhance innovation in the raw materials sector by the sharing of knowledge, information and expertise. This must generate a significant impact on European competitiveness and employment by driving and fostering innovation and empowering students, entrepreneurs and education partners driving toward the circular economy.To reach the vision, where the European Union’s industrial strength is based on a cost-efficient, secure, sustainable supply and use of raw materials, a new generation of skilled people entering industry, universities and research needs to be developed. Today’s technical MSc graduates in raw materials and especially primary resources (i.e. exploration, extraction, mining and mineral processing and metallurgy) meet the technical standards required by the raw materials industry across the full raw materials value chain and best suits large companies where they often act as specialists and experts. For small to medium enterprises as well as for our future engineers, other skills than technical are necessary.EIT Raw Materials will educate people that will have an intra- and entrepreneurial mind-set and will be able to develop their functions in new working environments, fostering the entrepreneurial and innovation skills, knowledge and attitudes needed for the entre- and intrapreneurs of tomorrowThe CDIO™ INITIATIVE is an innovative educational framework for producing the next generation of engineers. The framework provides students with an education stressing engineering fundamentals set in the context of Conceiving — Designing — Implementing — Operating (CDIO) real-world systems and products. There are no academic institutes in Europe that have yet applied CDIO for primary resource related MSc programs. Within the KIC EIT Raw Materials Academy, the overarching brand of all the KIC’s education activities are created in order to stimulate education activities and foster new ways of learning and teaching; an approved education project is focusing on the implementation of the CDIO methodology in primary resources linked programs. The project started in 2016 and focuses on faculty and pilot case development and the contributing partners are from academia, industry and research institutes. This project focuses on faculty development for an active and experimental learning by teaching the “technical” faculty through CDIO linked courses (entrepreneurship, business, etc.), communicative workshops, inspiration lectures and by involving the “business and entrepreneurial” faculty in exploration, mining, mineral processing and metallurgy related issues also through curriculum and pilot cases developed together with the industry.This paper describes how this education project is being developed within the EIT Raw Materials and will give an overview of the needed skillset of future engineers demanded in the Raw Materials primary sector. It presents key outputs about already developed and implemented activities in mining engineering and metallurgy related programs.
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22.
  • Nerenst, Tim Brix, et al. (author)
  • Probabilistic Performance Evaluation and Optimization of Medical Plastic Moulded Components Subject to Large Scale Production
  • 2021
  • In: ASME International Mechanical Engineering Congress and Exposition, Proceedings (IMECE). - 9780791885567
  • Conference paper (peer-reviewed)abstract
    • A new medical device can take years to develop from early concept to product launch. The long development process can be attributed to the severe consequences for the patient if the device malfunctions. Three approaches are often combined to mitigate risks: rigorous simulation and modeling, physical test programs, and Failure Mode Effect Analysis (FMEA) - all of which are time-consuming. Physical test programs are often carried out on prototype components from the same batch and, therefore, limited in revealing the actual distribution of performance. The risk probabilities are subsequently based on educated guesses. Furthermore, simulation and modeling are usually performed on nominal geometry - not accounting for variation - and only provide a safety factor against failure. The traditional use of safety factors in structural analysis versus the probabilistic approach to risk management presents an obvious misfit. Therefore, these three approaches are not ideal for addressing the two key questions that the design engineer has: 1) How often will the design fail, and 2) How should the design be changed to improve robustness and failure rates. The present work builds upon the existing Robust and Reliability-Based Design Optimization (R2BDO) and adjusts it to address the key questions above using finite element analysis. The key feature of the new framework is the focus on minimal use of computational resources while being able to screen feasible design concepts early in the embodiment phase and subsequently optimize their probabilistic performance. A case study in collaboration with a medical design and manufacturing company demonstrates the new framework. The case study includes FEA contact modeling between two plastic molded components with twelve geometrical variables. The optimization focuses on minimizing the failure rate (and improving design robustness) concerning three constraint functions (contact pressure, strain, torque). The study finds that the new framework achieves significant improvements to the component’s performance function (failure rate) with minimal computational resources.
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23.
  • Papadopoulou, Panagiota, 1992, et al. (author)
  • CDIO faculty development course – Built-in implementation
  • 2019
  • In: Proceedings of the International CDIO Conference. - : Chalmers University of Technology. - 2002-1593.
  • Conference paper (peer-reviewed)abstract
    • To successfully implement the CDIO approach in engineering programs, a holistic approach is required, connecting the philosophy of the program with teaching and learning activities in the courses. One influential component in this interaction is faculty members and their competence in providing integrated learning experiences, in using active experiential learning methods, and in assessing student learning (CDIO Standard 10). As an effort to support such faculty development, a group of universities has been conducting activities directly aiming to enable and drive CDIO implementation in the participating universities (mainly within the EIT Raw Materials programme). In this paper, we will continue reporting and critically reflecting on these CDIO-based faculty development endeavours. Initially, a faculty development course was launched in 2016 at Chalmers University of Technology and offered to participants from other universities (Bhadani et al., 2017). The paper starts by outlining the adaptation of the course into its second version, followed by investigating the experiences from the first group in 2018. The course was designed to suit both experienced and novice faculty. It offered a staged introduction to CDIO implementation alternated with sessions in which participants worked on their own course development. The rationale for this design was to increase the direct usefulness for the participants, in that they should feel engaged and involved during learning and be able to immediately apply their learning to their own course. To estimate the impact of the course on participants’ actual course design and implementation, participants’ final presentations and feedback were analysed. Interviews were also conducted to gather information about the changes made in the participants’ own teaching, as well as the perceived influence of the CDIO course on those changes. The paper could be used to support organizers of faculty development courses in other universities, by documenting a model that can be implemented as a standard faculty training course.
  •  
24.
  • Papadopoulou, Panagiota, 1992, et al. (author)
  • Video Development Methods for CDIO-Based Project Courses
  • 2018
  • In: The 14th International CDIO Conference, Kanazawa, Japan. - 1796-9964 .- 2002-1593. - 9784906122530 ; , s. 431-442
  • Conference paper (peer-reviewed)abstract
    • Video utilization can be a powerful tool for teachers to stimulate students’ interest and support flexible and adaptive learning. Successful video-based learning implementation cannot be assured without careful consideration regarding desired quality, learning outcomes and video development methods. The investigation and sharing of experiences considering video development is indispensable and will contribute to spreading a culture of easily made, peer-reviewed videos, which will enhance teaching and learning. For CDIO-based courses, it is required that the video development methods are agile and cost-effective in production as to support continuous update of videos relevant for the course and other course activities. In this paper, we identify and describe video development methods from different CDIO-based project courses. The methods are classified based on the content type, the production style, the required resources and the video characteristics. All presented video development methods follow our general framework of video development process which has been previously published and consists of four interwoven steps - topic selection, learning objectives mapping, content generation and video recording. Based on semi-structured interviews with the course teachers, we present their experiences with those different development methods to create content specific videos pertaining to various Conceive-Design-Implement-Operate topics. As outcome, we suggest our preferable video development method depending on video content category. We conclude that the choice of video development method must consider the audience’s characteristics and needs while video content should be aligned with the course content, other learning activities and the literature. The video development methods suggested and described in this paper will assist educators to choose an appropriate video development method for their own courses and maximize the videos’ contribution to student learning.
  •  
25.
  • Quist, Johannes, 1985, et al. (author)
  • CDIO Based Engineering Design and Optimization Course
  • 2017
  • In: Proceedings of 2017 International CDIO Conference, Calgary, Canada. - 1796-9964. - 9780889533998 ; , s. 298-314
  • Conference paper (peer-reviewed)abstract
    • In order to design competitive products that meet today’s challenges, future engineers need knowledge and experience in applying and integrating optimization theory in the engineering design process. The Chalmers course Engineering Design and Optimization addresses this need and was developed and first offered in the fall semester of 2013. This paper provides a detailed account of the course development experiences, teaching methods and course evaluations using CDIO Standards. It also includes a discussion of the learning objectives, required resources, instructional processes and student assessments. The course is analyzed to see to what extent the course aim is satisfied and highlight areas of improvement. Three projects are carried out in groups of two students. The projects are a cantilever design-build-test exercise, a redesign project that involves material selection, and a multi disciplinary design project of an engine component using multi-physics software. The assignments are assessed with respect to both engineering criteria as well as reporting and communication. The course is believed to be novel in the way optimization theory and tools are taught as an integrated learning experience with engineering design and physical prototyping. The course has had a great impact on the students’ choice of master’s thesis project. The number of optimization-focused master thesis projects has increased from two or three to around 15 annually. Several of these projects are multidisciplinary and joint projects between departments of Applied Mechanics and Product & Production Development. The course has also initiated a valuable partnership with industry on optimization that now has grown to a network with 20 industrial and academic members.
  •  
26.
  • Tim Brix Nerenst, Tim Brix, et al. (author)
  • Sequential Design Process for Screening and Optimization of Robust and Reliability Based on Finite Element Analysis and Meta-Modelling
  • 2022
  • In: Journal of Computing and Information Science in Engineering. - : ASME International. - 1530-9827 .- 1944-7078. ; 22:4
  • Journal article (peer-reviewed)abstract
    • A new medical device can take years to develop from early concept to product launch. Three approaches are often combined to mitigate risks: Failure Modes and Effects Analysis (FMEA), simulation and modeling, and physical test programs. Although widely used, all three approaches are generally time-consuming and have their shortcomings: The risk probabilities in FMEA's are often based on educated guesses, even in later development stages as data on the distribution of performance is not available. Thus, the traditional use of safety factors in structural analysis versus the probabilistic approach to risk management presents an obvious misfit. Therefore, the above three approaches are not ideal for addressing the design engineer's key question; how should the design be changed to improve robustness and failure rates. The present work builds upon the existing Robust and Reliability-Based Design Optimization (R2BDO) and adjusts it to address the key questions above using Finite Element Analysis (FEA). The two main features of the presented framework are screening feasible design concepts early in the embodiment phase and subsequently optimizing the design's probabilistic performance (i.e., reduce failure rates) while using minimal computational resources. A case study in collaboration with a medical design and manufacturing company demonstrates the new framework. The optimization minimizes the failure rate (and improves design robustness) concerning three constraint functions (torque, strain, and contact pressure). Furthermore, the study finds that the new framework significantly improves the design's performance function (failure rate) with limited computational resources.
  •  
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