Northstar Bluescope Steel Boosts Production and Cuts Costs with Emerson’s Smart Wireless Technology

Emerson Process Management’s Smart Wireless technology has transformed furnace control at Northstar Bluescope Steel’s mini‑mill in Delta, Ohio. The upgrade has increased daily output by up to one batch, cut annual maintenance costs by $200,000, and bolstered worker safety.

Using a self‑organizing wireless mesh based on the IEC 62591 (WirelessHART) standard, Emerson’s system gathers real‑time data on cooling‑panel and water‑cooled‑burner temperatures. Accurate temperature monitoring is critical; an overheated panel can rupture, costing up to $20,000 to repair and forcing costly downtime.

“Better temperature control through wireless has allowed us to add up to one additional batch per day,” said Rob Kearney, maintenance supervisor. “Each batch is worth roughly $200,000, so the impact is significant.”

The wireless network replaced a hard‑wired monitoring system that relied on hundreds of cable junctions. In the mill’s harsh environment—high electromagnetic interference, flying slag, vibration, moisture, and temperatures up to 3,000 °F—the wired system suffered frequent measurement failures.

“Between nine and 12 measurement points failed each week due to extreme temperatures or physical damage to sensors, cable, or conduit,” Kearney explained. “When a point failed, the furnace had to shut down. The new wireless solution eliminated almost 100 % of the cable and conduit, slashing maintenance costs by $200,000 annually. It’s been running for four months without a single failure.”

The network comprises 32 Rosemount wireless temperature transmitters—28 dedicated to control and four for monitoring. Their data are relayed to a Smart Wireless Gateway that interfaces with the mill’s transformer‑regulation and burner‑control systems.

“Safety has improved as well,” Kearney added. “Cooling panels now operate consistently at safe temperatures, and there’s less maintenance required around the furnace shell, where ambient temperatures can reach 140 °F.”

Buoyed by these results, Northstar Bluescope plans to deploy a similar wireless solution on a second electric arc furnace.