PROGETTO DI PURIFICAZIONE DEI FUMI PER IMPIANTO CEMENTIERO, CON SEPARAZIONE E UTILIZZO DEL CO2 COME MATERIA PRIMA: AUTOMAZIONE, STRUMENTAZIONE E CONTROLLO

This thesis presents the design and implementation of an advanced, fully automated fume purification system for a cement plant, with a strong emphasis on automation, instrumentation, and control methodologies. The primary objective is to develop a highly efficient system that not only purifies industrial emissions but also enables the separation and reutilization of carbon dioxide (CO₂) as a valuable raw material. A key aspect of this research is the strategic selection and integration of industrial instrumentation to ensure precise monitoring and regulation of critical process parameters. Essential devices—including transmitters, control valves, gauges, and flow meters—are incorporated to maintain operational stability and safety, reducing human intervention to a monitoring-only role within a fully automated environment. To optimize fume purification and CO₂ recovery, the system employs heat exchangers, centrifugal pumps, reactors, compressors, and other industrial process components, selected for reliability o the process. The study covers multiple engineering aspects, including process component selection, instrumentation strategies for robust and safe operation, hazard mitigation through safety valves and protective measures, and the integration of manual backup instruments for maintenance. Additionally, the research details the development of Piping and Instrumentation Diagrams (P&IDs) using CAD tools, selection of appropriate input/output (I/O) signals aligned with the chosen instrumentation, an Emergency Cause and Effect Diagram (ECED), a Modbus serial communication list, control system architecture, electrical load estimation, cost analysis, graphical HMI (human-machine interface) design, and the implementation of logic using Ladder and Function Block Diagram (FBD). A major contribution of this work is the development of a reliable control system architecture, featuring redundant controllers and the segregation of safety logic solvers from process control logic to ensure maximum safety and operational integrity from both software and hardware. The system is implemented using Programmable Logic Controllers (PLCs), Human-Machine Interfaces (HMIs), and industrial communication protocols such as Modbus and Industrial Ethernet, enabling real-time data acquisition, process monitoring, and automated control for enhanced system performance. This thesis reviews two distinct plant configurations: Main Plant – designed for continuous, uninterrupted CO₂ production, ensuring industrial scalability. Prototype Plant – a modular system composed of four process skids: CO₂ separation unit, also recovering by-products such as oxygen and nitrogen. Production unit for sodium or potassium bicarbonate. Ammonium bicarbonate synthesis skid. Calcium carbonate production skid. While chemical reaction mechanisms and sustainability assessments are beyond the scope of this study, the research provides an in-depth analysis of automation strategies, control logic, and safety implementations in industrial fume purification. The methodologies and technologies presented are engineered with maximum economic efficiency and practical feasibility in mind. All documentation in this thesis adheres to industry standards, ensuring its direct applicability to real-world industrial automation and process control implementations