Industrial accidents triggered by lightning: causes and consequences

Natural hazards affecting industrial installations could directly or indirectly cause an accident or series of accidents with serious consequences for the environment and for human health. Accidents initiated by a natural hazard or disaster which result in the release of hazardous materials are commonly referred to as Natech (Natural Hazard Triggering a Technological Disaster) accidents. The conditions brought about by these kinds of events are particularly problematic, the presence of the natural event increases the probability of exposition and causes consequences more serious than standard technological accidents. Despite a growing body of research and more stringent regulations for the design and operation of industrial activities, Natech accidents remain a threat. This is partly due to the absence of data and dedicated risk-assessment methodologies and tools. Even the Seveso Directives for the control of risks due to major accident hazards do not include any specific impositions regarding the management of Natech risks in the process industries. Among the few available tools there is the European Standard EN 62305, which addresses generic industrial sites, requiring to take into account the possibility of lightning and to select the appropriate protection measures. Since it is intended for generic industrial installations, this tool set the requirements for the design, the construction and the modification of structures, and is thus mainly oriented towards conventional civil building. A first purpose of this project is to study the effects and the consequences on industrial sites of lightning, which is the most common adverse natural phenomenon in Europe. Lightning is the cause of several industrial accidents initiated by natural causes. The industrial sectors most susceptible to accidents triggered by lightning is the petrochemical one, due to the presence of atmospheric tanks (especially floating roof tanks) containing flammable vapors which could be easily ignited by a lightning strike or by lightning secondary effects (as electrostatic and electromagnetic pulses or ground currents). A second purpose of this work is to implement the procedure proposed by the European Standard on a specific kind of industrial plant, i.e. on a chemical factory, in order to highlight the critical aspects of this implementation. A case-study plant handling flammable liquids was selected. The application of the European Standard allowed to estimate the incidence of lightning activity on the total value of the default release frequency suggested by guidelines for atmospheric storage tanks. Though it has become evident that the European Standard does not introduce any parameters explicitly pointing out the amount of dangerous substances which could be ignited or released. Furthermore the parameters that are proposed to describe the characteristics of the structures potentially subjected to lightning strikes are insufficient to take into account the specific features of different chemical equipment commonly present in chemical plants.

Toxicity assessment of industrial- and sunscreen-derived ZnO nanoparticles

Lo scopo della presente tesi è l’analisi della tossicità di nanoparticelle di ossido di zinco (nano-ZnO) verso gli organismi acquatici. In particolare, il presente studio valuta per la prima volta l'inibizione della crescita della diatomea Thalassiosira pseudonana indotta sia da nanoparticelle di dervazione industriale, che da nanoparticelle auto-estratte in laboratorio da un filtro solare. Gli esperimenti, condotti presso il Laboratorio di Ingegneria dell'Università di Miami, hanno mostrato che la tossicità indotta dalle nanoparticelle di ossido di zinco è influenzata dal tipo di nanoparticelle, nonché dalla loro concentrazione nella soluzione acquosa e dal tempo di esposizione. In particolare le nanoparticelle di derivazione industriale, più piccole rispetto alle nanoparticelle estratte dal filtro solare, hanno indotto un’inibizione della crescita superiore, specialmente a concentrazioni inferiori. Questo andamento suggerisce che ad alte concentrazioni la tossicità di nano-ZnO potrebbe essere influenzata dall’aggregazione di nanoparticelle (indipendentemente dalle dimensioni di partenza delle nanoparticelle), mentre a concentrazioni inferiori la tossicità potrebbe essere influenzata dalle dimensioni di partenza delle nanoparticelle, così come dal tipo di nanoparticelle e dal tempo di esposizione.

Integration of ROS for the control of industrial robotic systems in a proprietary environment

The paper deals with the integration of ROS, in the proprietary environment of the Marchesini Group company, for the control of industrial robotic systems. The basic tools of this open-source software are deeply studied to model a full proprietary Pick and Place manipulator inside it, and to develop custom ROS nodes to calculate trajectories; speaking of which, the URDF format is the standard to represent robots in ROS and the motion planning framework MoveIt offers user-friendly high-level methods. The communication between ROS and the Marchesini control architecture is established using the OPC UA standard; the tasks computed are transmitted offline to the PLC, supervisor controller of the physical robot, because the performances of the protocol don’t allow any kind of active control by ROS. Once the data are completely stored at the Marchesini side, the industrial PC makes the real robot execute a trajectory computed by MoveIt, so that it replicates the behaviour of the simulated manipulator in Rviz. Multiple experiments are performed to evaluate in detail the potential of ROS in the planning of movements for the company proprietary robots. The project ends with a small study regarding the use of ROS as a simulation platform. First, it is necessary to understand how a robotic application of the company can be reproduced in the Gazebo real world simulator. Then, a ROS node extracts information and examines the simulated robot behaviour, through the subscription to specific topics.

Towards the sustainable production of methyl methacrylate: A comparative analysis of industrial chemical production processes using life cycle assessment methodology

Increasing environmental awareness has been a significant driving force for innovations and process improvements in different sectors and the field of chemistry is not an outlier. Innovating around industrial chemical processes in line with current environmental responsibilities is however no mean feat. One of such hard to overhaul process is the production of methyl methacrylate (MMA) commonly produced via the acetone cyanohydrin (ACH) process developed back in the 1930s. Different alternatives to the ACH process have emerged over the years and the Alpha Lucite process has been particularly promising with a combined plant capacity of 370,000 metric tonnes in Singapore and Saudi Arabia. This study applied Life Cycle Assessment methodology to conduct a comparative analysis between the ACH and Lucite processes with the aim of ascertaining the effect of applying principles of green chemistry as a process improvement tool on overall environmental impacts. A further comparison was made between the Lucite process and a lab-scale process that is further improvement on the former, also based on green chemistry principles. Results showed that the Lucite process has higher impacts on resource scarcity and ecosystem health whereas the ACH process has higher impacts on human health. On the other hand, compared to the Lucite process the lab-scale process has higher impacts in both the ecosystem and human health categories with lower impacts only in the resource scarcity category. It was observed that the benefits of process improvements with green chemistry principles might not be apparent in some categories due to some limitations of the methodology. Process contribution analysis was also performed and it revealed that the contribution of energy is significant, therefore a sensitivity analysis with different energy scenarios was performed. An uncertainty analysis using Monte Carlo analysis was also performed to validate the consistency of the results in each of the comparisons.

Axis control optimization: autotuning techniques and frequency response analysis of industrial mechatronic systems

In the field of industrial automation, there is an increasing need to use optimal control systems that have low tracking errors and low power and energy consumption. The motors we are dealing with are mainly Permanent Magnet Synchronous Motors (PMSMs), controlled by 3 different types of controllers: a position controller, a speed controller, and a current controller. In this thesis, therefore, we are going to act on the gains of the first two controllers by going to find, through the TwinCAT 3 software, what might be the best set of parameters. To do this, starting with the default parameters recommended by TwinCAT, two main methods were used and then compared: the method of Ziegler and Nichols, which is a tabular method, and advanced tuning, an auto-tuning software method of TwinCAT. Therefore, in order to analyse which set of parameters was the best,several experiments were performed for each case, using the Motion Control Function Blocks. Moreover, some machines, such as large robotic arms, have vibration problems. To analyse them in detail, it was necessary to use the Bode Plot tool, which, through Bode plots, highlights in which frequencies there are resonance and anti-resonance peaks. This tool also makes it easier to figure out which and where to apply filters to improve control.

Recognition of human activities through eSteps insoles

Recognition of everyday human activity through mobile personal sensing technology plays a central role in the field of pervasive healthcare. The Bologna-based American company eSteps Inc. addresses the growing motor disability of the lower limbs by offering pre-, during and post-hospitalisation monitoring solutions with biomechanics and telerehabilitation protocol. It has developed a smart, customised and sustainable device to monitor motor activity, fatigue and injury risk for patients and a special app to share data with caregivers and medical specialists. The objective of this study is the development of an Artificial Intelligence model to recognize the activity performed by a person with Multiple Sclerosis or a healthy person through eSteps devices.

Catalytic reduction of organic pollutants using supported metal nanoparticles

Metal nanoparticle catalysts have in the last decades been extensively researched for their enhanced performance compared to their bulk counterpart. Properties of nanoparticles can be controlled by modifying their size and shape as well as adding a support and stabilizing agent. In this study, preformed colloidal gold nanoparticles supported on activated carbon were tested on the reduction of 4-nitrophenol by NaBH4, a model reaction for evaluating catalytic activity of metal nanoparticles and one with high significance in the remediation of industrial wastewaters. Methods of wastewater remediation are reviewed, with case studies from literature on two major reactions, ozonation and reduction, displaying the synergistic effects observed with bimetallic and trimetallic catalysts, as well as the effects of differences in metal and support. Several methods of preparation of nanoparticles are discussed, in particular, the sol immobilization technique, which was used to prepare the supported nanoparticles in this study. Different characterization techniques used in this study to evaluate the materials and spectroscopic techniques to analyze catalytic activities of the catalyst are reviewed: ultraviolet-visible (UV-Vis) spectroscopy, dynamic light scattering (DLS) analysis, X-ray diffraction (XRD) analysis and transmission electron microscopy (TEM) imaging. Optimization of catalytic parameters was carried out through modifications in the reaction setup. The effects of the molar ratio of reactants, stirring, type and amount of stabilizing agent are explored. Another important factor of an effective catalyst is its reusability and long-term stability, which was examined with suggestions for further studies. Lastly, a biochar support was newly tested for its potential as a replacement for activated carbon.

Modeling and Model Predictive Control of an Industrial Hydraulic System

This thesis aims to illustrate the construction of a mathematical model of a hydraulic system, oriented to the design of a model predictive control (MPC) algorithm. The modeling procedure starts with the basic formulation of a piston-servovalve system. The latter is a complex non linear system with some unknown and not measurable effects that constitute a challenging problem for the modeling procedure. The first level of approximation for system parameters is obtained basing on datasheet informations, provided workbench tests and other data from the company. Then, to validate and refine the model, open-loop simulations have been made for data matching with the characteristics obtained from real acquisitions. The final developed set of ODEs captures all the main peculiarities of the system despite some characteristics due to highly varying and unknown hydraulic effects, like the unmodeled resistive elements of the pipes. After an accurate analysis, since the model presents many internal complexities, a simplified version is presented. The latter is used to linearize and discretize correctly the non linear model. Basing on that, a MPC algorithm for reference tracking with linear constraints is implemented. The results obtained show the potential of MPC in this kind of industrial applications, thus a high quality tracking performances while satisfying state and input constraints. The increased robustness and flexibility are evident with respect to the standard control techniques, such as PID controllers, adopted for these systems. The simulations for model validation and the controlled system have been carried out in a Python code environment.