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Wireless Real-Time Temperature Monitoring System for Rotary Digesters in Chemical Manufacturing
  1. case
  2. Wireless Real-Time Temperature Monitoring System for Rotary Digesters in Chemical Manufacturing

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Wireless Real-Time Temperature Monitoring System for Rotary Digesters in Chemical Manufacturing

experionglobal.com
Manufacturing
Energy & natural resources
Chemicals

Challenges in Temperature Monitoring for Rotary Digesters

Lack of real-time temperature monitoring in rotary digesters causes product quality issues, operational inefficiencies, and safety risks. Existing wired systems cannot withstand constant rotation, while manual monitoring creates delays and potential hazards.

About the Client

A diversified chemical manufacturer producing PVC Resin, Caustic Soda, Chlorine-based products, and industrial chemicals with 1000+ employees and $200M+ annual revenue

Project Goals for Wireless Temperature Monitoring System

  • Implement real-time temperature monitoring in rotary digesters
  • Integrate with existing PLC and SCADA systems
  • Improve product quality through precise temperature control
  • Enhance plant safety by preventing temperature-related accidents

Core System Functionalities and Features

  • Continuous temperature measurement inside rotating digesters
  • Zigbee-based wireless data transmission
  • Integration with Modbus PLC protocol
  • Real-time alerts for temperature thresholds
  • SCADA dashboard visualization

Technologies for System Implementation

Microchip PIC18F87J11 microcontroller
Zigbee wireless communication
MAX31865 RTD-to-digital converter
PT100 temperature sensors
RS485 transceiver

Required System Integrations

  • Existing PLC system via Modbus protocol
  • SCADA monitoring platform
  • Plant control room interface

Non-Functional Requirements

  • Reliable operation in high-temperature industrial environments
  • Data transmission every 30 seconds
  • Electromagnetic interference resistance
  • Scalable architecture for multiple digesters

Expected Business Impact of Wireless Temperature Monitoring

Real-time temperature control will improve product consistency, reduce safety incidents, and enable proactive maintenance. SCADA integration will streamline operations through centralized monitoring, while wireless technology eliminates infrastructure costs associated with traditional cabling.

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