Wireless Real-Time Temperature Monitoring System for Rotary Chemical Reactors

The client faces difficulties in implementing real-time temperature monitoring within rotary digesters due to their continuous rotation and the limitations of wired measurement systems. This leads to increased operational overheads, compromised product quality, and heightened safety risks because temperature buildups cannot be detected promptly, potentially causing accidents.

A mid-sized chemical manufacturing company operating multiple plants that requires precise temperature control in rotating processing vessels to ensure product quality and safety.

• Develop and deploy a wireless temperature monitoring system capable of continuous, real-time data acquisition inside rotary digesters.
• Integrate the monitoring system with existing plant control systems to facilitate seamless data flow and operational oversight.
• Enhance safety by enabling early detection of temperature anomalies to prevent accidents.
• Improve product quality by maintaining precise temperature control through real-time monitoring.
• Reduce operational overheads associated with traditional wired systems and manual temperature checks.

• Wireless temperature sensors capable of operating in rotating environments inside the digesters.
• Integration with existing Programmable Logic Controller (PLC) systems using standard protocols such as Modbus.
• Wireless communication module (e.g., Zigbee or equivalent) supporting reliable data transmission.
• Hardware hardware solution includes temperature sensors (e.g., RTD/PT100), digital converters, and transceivers suitable for industrial environments.
• Firmware designed for continuous, periodic temperature measurement and secure wireless data transfer.
• Connectivity to a centralized SCADA or control room dashboard for real-time visualization and alarm management.

• Existing PLC systems via protocols such as Modbus
• SCADA or plant supervisory control dashboards
• Alarm management systems for safety alerts

• System should transmit temperature data every 30 seconds with minimal latency
• Robust wireless connectivity suitable for industrial environments with rotation and potential interference
• Secure data communication to prevent unauthorized access
• Hardware durability to operate reliably in harsh chemical plant conditions
• Scalability to deploy additional sensors or expand to other units

Implementation of the wireless temperature monitoring system is expected to significantly enhance product quality by enabling better temperature control, reduce safety risks through early detection of critical temperature deviations, and improve operational efficiency by replacing wired systems. The solution aims for a marked reduction in plant downtime and oversight, leading to increased overall productivity and safety assurance.