Product category:
Wireless process sensors
News Release from: Honeywell Field Solutions | Subject: Nucor mill
Edited by the Processingtalk Editorial
Team on 16 November 2007
Wireless temperature sensors in steel
mill upgrade
Wireless access to new temperature readings on the Nucor steel mill in Alabama has allowed an upgrade to the furnace, allowing improved processes and a 15 percent expansion in production
Nucor Corporation faced the challenge of improving process operations in an extreme environment at its steel recycling mill in Tuscaloosa, Alabama With the support of the Honeywell wireless solutions, the Nucor mill has been able to increase production performance and lay the groundwork for future advances in production efficiency
This article was originally published on Processingtalk on 30 Nov 2007 at 8.00am (UK)
Related stories
Process control at Kronos Leverkusen
Experion to streamline operations, reduce waste and improve environmental efficiency for Kronos, the major German pigment manufacturer, of Leverkusen
New OneWireless equipment health monitoring
OneWireless equipment health monitoring is the first wireless product to send complete spectral information for more efficient maintenance
The mill was able to realize the following benefits:.
* Increased production of 15 percent through furnace upgrade.
* Improved production efficiency through more accurate data.
Further reading
Wireless transmitters integrated with Experion
Roche has integrated Honeywell wireless transmitters with Experion Process Knowledge System for improved temperature monitoring performance
OneWireless starter kit from Honeywell
Get started on the road to a more efficient and safer plant with the Honeywell universal, simple, and efficient OneWireless network and industrial start-up evaluation kit
Choosing the right industrial Wireless Network
The questions to address when making the decision to implement wireless technology in your industrial facility are reviewed by Honeywell, a leader in the supply of wireless sensors and networks
* Improved safety through greater ability to measure process status.
* Faster, more reliable access to data.
* Improved quality of data to enable better decision making.
* Reduced maintenance requirements compared to wired transmitter alternative.
* Provided foundation to expand wireless efforts across the mill and enhance process reliability.
The Nucor Corporation is the largest steel producer in the United States and had net sales of USD12.7 billion in 2005.
Nucor is also the nation's largest recycler.
In 2004, Nucor recycled approximately 17 million tons of scrap steel, with 5 million of those tons being automobiles.
The Nucor steel mill in Tuscaloosa is a hot rolled coil and cut-to-length plate mill that manufacturers carbon and high-strength low alloy steels for structural and pressure vessel applications.
The Nucor Tuscaloosa steel mill was faced with the challenge of improving process operations on one of its furnaces used to melt and recycle steel: to do this improved temperature measurement and control was needed To help support an increase in production levels, operations staff searched for a reliable way to monitor temperatures around the furnace in areas not previously monitored.
The ability to gather this data would facilitate a furnace upgrade and subsequent increase in production.
A key requirement was to be able to instantaneously know what temperatures were in the furnace, which can reach more than 1,000 degrees Fahrenheit, to protect from a production upset if temperatures were to get too high.
Another concern was the huge magnetic field that exists around the furnace, a result of running over 120,000 amps to the furnace, and its impact on transmitter functionality.
The Nucor mill turned to Honeywell to help overcome the challenge of obtaining accurate and reliable temperature readings on its furnace.
The use of wireless technology was seen as the better way to get these readings given the extreme environment.
Nucor worked with Honeywell to come up with a solution that included the placement of wireless transmitters just a few feet from the base of furnace flames.
The transmitters were installed on the cooling circuits for the furnace and encased on specially built protective boxes to withstand the extreme heat.
"With the use of wireless transmitters, we were able to start monitoring a part of the mill that was previously not possible, which has allowed us to completely upgrade the furnace and increase production," said the Melt Shop Electrical Supervisor.
As a result of the positive experience with the wireless solution from Honeywell, Nucor has decided to pursue the installation of wireless devices throughout the entire mill.
"We believe the potential for wireless technology at our mill is huge", said the Nucor supervisor.
"We are looking at extending wireless coverage right across the mill - eventually facilitating the removal of hard wires and significantly improving equipment reliability and overall mill performance.
With wireless technology, we'll be able to focus efforts on more efficient means of collecting the data we need from the field".
Nucor is planning to use wireless technology to increase the amount of preventive maintenance performed by enabling field staff quick access to real-time information such as online maintenance checklists and drawings.
"Right now, field employees have to print out this maintenance information and walk around with it," said the Nucor supervisor.
"With wireless technology in place, the field will have everything electronically at their fingertips.
• Honeywell Field Solutions: contact details and other news
• Email this article to a colleague
• Register for the free Processingtalk email newsletter
• Processingtalk Home Page
Search the Pro-Talk network of sites
