Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
< Industries/
mining-quarrying
Smart Monitoring for Mining & Quarrying — Wireless Sensors for Harsh, High-Risk Industrial Environments
Quick Overview
| Problem | Mining and quarrying operations run in extreme mechanical, thermal, and environmental conditions. Equipment failures, dust explosions, structural risks, or ventilation issues can lead to catastrophic downtime and severe safety incidents. |
| Solution | Sensa.io provides wireless sensors for vibration, pressure, differential pressure, temperature, acoustic, and valve position monitoring — engineered for heavy machinery, dust-rich zones, and high-vibration industrial sites. |
| Value | ↑ Equipment uptime • ↓ Maintenance cost (−30–40 %) • ↓ Safety incidents • ROI < 12 months |
| ATEX | Dust Zones 21–22 & Gas Zones where applicable • Ex ia IIIC T85°C Db / Ex ia IIC T4 Gb options |
The Mining Reliability Challenge
Mining is one of the world’s most demanding environments for equipment and instrumentation:
- 75 %+ of equipment failures are mechanical.
- Dust, vibration, shock, and humidity degrade sensors rapidly.
- Ventilation and dust extraction systems are safety-critical.
- Downtime costs can exceed €50,000 per hour (conveyors, mills, crushers).
- Regulations require strict monitoring of air quality, dust levels, methane, explosive storage, and heavy machinery.
Traditional instrumentation is often:
- Wired → expensive cabling runs, conduit, junction boxes.
- Manual → operators making rounds in dangerous locations.
- Reactive → failures detected after loss of production.
- Incompatible → legacy SCADA or ageing PLCs.
Mining operations need continuous, real-time, robust sensing that works flawlessly in:
- High vibration
- Extreme dust (ATEX hazards)
- High-temperature areas
- Shock-prone environments (crushers, conveyors, mills)
- Underground tunnels with ventilation constraints
Sensa.io delivers intrinsically safe, maintenance-free sensors built for mining realities.
Why ATEX & Continuous Monitoring Matter in Mining
Mining presents a unique combination of hazards:
1. Dust Explosion Risk (ATEX Zone 21/22)
Ore dust, coal dust, and fine particulates can ignite from:
- overheated motors
- mechanical friction
- bearing failures
- electrical faults
ATEX-certified sensors eliminate ignition sources.
2. Catastrophic Mechanical Failures
When a conveyor, crusher, or pump fails:
- production halts
- maintenance teams mobilise
- safety incidents escalate
- multi-hour downtime quickly becomes extremely costly
3. Worker Safety in Underground Operations
Rockfall, structural movement, ventilation issues or methane emissions must be detected immediately.
4. Harsh Environmental Conditions
High vibration, high dust, chemicals, humidity, and physical shock destroy standard instrumentation.
A single conveyor belt failure can cost €50,000–200,000 in lost production.
Continuous monitoring reduces downtime by 30–60 %.
Core Use Cases for
Mining & Quarrying
Use Case
Sensor Type
ATEX
ROI/Value
Gas Vent Line Acoustic & Pressure Anomaly Detection (Methane Hazard Early Warning)
Acoustic
Pressure
Early detection of dangerous methane releases
Hydraulic System Pressure & Temperature Monitoring (Excavators, Drills & Heavy Equipment)
Pressure
Temperature
Prevents breakdowns, extends machine life
Acoustic & Vibration Detection of Rockfall or Structural Movement (Early Warning & Worker Protection)
Acoustic
Vibration
Early warning to protect workers underground
Explosive Storage Temperature & Door Vibration Monitoring (ATEX Compliance & Security)
Temperature
Vibration
Ensures compliance, detects unauthorized access
Slurry Pipeline Pressure & Differential Pressure (ΔP) Monitoring (Blockage & Rupture Prevention)
Pressure
Differential Pressure (ΔP)
Detects blockages, prevents pipe rupture
Mobile Equipment Engine Vibration Monitoring (Haul Trucks & Loaders)
Vibration
Reduces maintenance costs for haul trucks & loaders
Silo Temperature & Acoustic Anomaly Detection (Fire, Blockage & Structural Risk Prevention) — ATEX
Temperature
Acoustic
Prevents fires & structural failures in ore silos
Hoist Motor Vibration & Brake Temperature Monitoring (Shaft Safety & Uptime Protection)
Vibration
Temperature
Prevents hoisting failures — critical safety system
Fuel Storage Pressure & Temperature Monitoring (ATEX Safety & Compliance)
Pressure
Temperature
Avoids overpressure, improves safety in fuel areas
Pump Station Pressure & Vibration Monitoring (Mining Dewatering Pumps)
Pressure
Vibration
Prevents flooding incidents, reduces pump failures
Ventilation Airflow, ΔP & Fan Vibration Monitoring (Underground Safety & Energy Efficiency)
Differential Pressure (ΔP)
Vibration
Temperature
Ensures worker safety, regulatory compliance, reduces energy use
Dust Collector ΔP Monitoring (Baghouse Filter Performance & Explosion Prevention) — ATEX
Differential Pressure (ΔP)
Prevents dust explosions, ensures ventilation performance
Crusher & Mill Vibration Analysis (Predictive Maintenance & Catastrophic Failure Prevention)
Vibration
Early detection of imbalance & wear → reduces catastrophic damage
Conveyor Belt Vibration & Bearing Temperature Monitoring (Failure Prevention & Production Continuity)
Vibration
Temperature
Prevents belt failure, avoids production stoppages costing +50k€/h
Conveyor Belt Vibration & Bearing Temperature Monitoring (Failure Prevention & Production Continuity)
Crusher & Mill Vibration Analysis (Predictive Maintenance & Catastrophic Failure Prevention)
Dust Collector ΔP Monitoring (Baghouse Filter Performance & Explosion Prevention) — ATEX
Ventilation Airflow, ΔP & Fan Vibration Monitoring (Underground Safety & Energy Efficiency)
Pump Station Pressure & Vibration Monitoring (Mining Dewatering Pumps)
Fuel Storage Pressure & Temperature Monitoring (ATEX Safety & Compliance)
Hoist Motor Vibration & Brake Temperature Monitoring (Shaft Safety & Uptime Protection)
Silo Temperature & Acoustic Anomaly Detection (Fire, Blockage & Structural Risk Prevention) — ATEX
Mobile Equipment Engine Vibration Monitoring (Haul Trucks & Loaders)
Slurry Pipeline Pressure & Differential Pressure (ΔP) Monitoring (Blockage & Rupture Prevention)
Explosive Storage Temperature & Door Vibration Monitoring (ATEX Compliance & Security)
Acoustic & Vibration Detection of Rockfall or Structural Movement (Early Warning & Worker Protection)
Hydraulic System Pressure & Temperature Monitoring (Excavators, Drills & Heavy Equipment)
Gas Vent Line Acoustic & Pressure Anomaly Detection (Methane Hazard Early Warning)
Vibration
Acoustic
Differential Pressure (ΔP)
Temperature
Pressure
Valve position
How Sensa.io Technology Works
| Open Wireless Architecture | All sensors are compatible with mining control systems:
Compatible with:
|
| Sensor Engineering for Harsh Environments | 🌡️ Extreme Temperature & Dust
🔧 High Vibration & Mechanical Shock
🔥 ATEX Environments (Optional)
🔋 Ultra-Long Battery Life
🧠 Advanced Data Analytics
|
Proven ROI and Field Results
Operators who deployed Sensa.io in upstream fields typically achieved:
−30 to −60 %
Downtime reduction:
−25 to −40 %
Maintenance savings:
+15–25 %
Conveyor uptime improvement:
Case Example
Acoustic & Vibration Detection of Rockfall or Structural Movement (Early Warning & Worker Protection)
Early warning to protect workers underground
Case Example
Gas Vent Line Acoustic & Pressure Anomaly Detection (Methane Hazard Early Warning)
Early detection of dangerous methane releases
ATEX Compliance and Safety
All Sensa.io sensors for upstream operations comply with:
Mining combines dust, methane, vibration, mechanical wear, and high temperatures — a perfect storm for ignition risks.
Sensa.io provides:
✔ ATEX Dust Zones 21–22
Ex II 2 D Ex ia IIIC T85°C Db
For:
- baghouses
- ore silos
- crushing areas
- conveyor transfer towers
✔ ATEX Gas Zones (if methane present)
Ex II 2 G Ex ia IIC T4 Gb
For:
- methane vent lines
- underground workings
- explosive storage areas
✔ IECEx compliant
✔ Delivered with all certificates:
- Declaration of Conformity
- Calibration certificates
- Maintenance-free design
FAQ - Common Questions
Are Sensa.io sensors compatible with any gateway or network?
What ATEX certifications apply to Sensa.io devices?
All hazardous-area models are certified Ex II 2 G Ex ia IIC T4 Gb and IECEx approved for Zones 0–2.
What is the typical battery life?
Up to 10 years at 15-minute intervals, depending on signal strength and environment.
How are the sensors integrated into existing systems?
Through standard protocols — LoRaWAN, Modbus, MQTT, REST API — no proprietary middleware needed.
How does predictive maintenance reduce OPEX?
Early anomaly detection reduces emergency interventions by 30–40 %, extends equipment life and lowers energy costs.
General & Functionality
What is the typical ROI when deploying sensors in upstream production?
Depending on asset criticality and scope, operators generally achieve payback within 6 to 12 months, driven by reduced downtime, lower maintenance overhead, and improved safety compliance.
How are calibration and maintenance handled in ATEX zones?
Sensors are factory-calibrated and include internal digital calibration tables. No field recalibration is required for 5–10 years; visual inspection every 3 years is sufficient.
How are data transmissions secured in remote fields?
All data packets are encrypted end-to-end with AES-128, and communication can run over private LoRaWAN or VPN-secured 4G networks. This guarantees industrial-grade cybersecurity and compliance with IT/OT segmentation policies.
Can Sensa.io sensors monitor hydrate or wax formation in flowlines?
Yes. Temperature sensors placed along the flowline detect critical cooling patterns leading to hydrate or wax build-up. Real-time data allows proactive heating or chemical injection, avoiding costly blockages.
How does acoustic leak detection work in upstream applications?
Acoustic sensors detect high-frequency sound anomalies generated by gas or fluid leaks. When combined with pressure readings, they localise the leak within ±10 m, reducing detection time from hours to minutes.
Can sensors remain active during well interventions or shutdowns?
Yes. Thanks to intrinsically safe (Ex ia) design, sensors can operate continuously in Zone 0 even during interventions, without hot-work permits or risk of ignition.
How do pressure sensors resist sand abrasion and high vibration in wellheads?
Each pressure module uses 316L stainless-steel diaphragms and vibration-proof electronics (rated up to 20 g RMS) with conformal coating. This ensures long-term stability in abrasive and high-shock environments typical of wellhead zones.
How does predictive maintenance with Sensa.io actually reduce OPEX?
By analysing vibration, pressure, or ΔP trends, the system detects anomalies before they escalate. This reduces emergency interventions by 30–40 %, extends equipment lifetime, and lowers energy consumption by 10–15 %.
How can Sensa.io sensors be integrated into our SCADA or DCS system?
Integration is immediate through standard industrial protocols: LoRaWAN, Modbus RTU/TCP, MQTT, or REST API. Data can feed directly into Honeywell, Emerson, Schneider, or ABB SCADA platforms without middleware.
How long do the batteries last in upstream operations?
Up to 10 years depending on the transmission interval and signal quality. The adaptive power management system automatically adjusts the sending frequency according to the measured parameter’s variability.
What ATEX certifications cover Sensa.io sensors?
All hazardous-area models are certified Ex II 2 G Ex ia IIC T4 Gb (Gas Zones 0–2) and Ex ia IIIC T135°C Db (Dust Zones 20–21). They are also IECEx approved and comply with the European Directive 2014/34/EU.
Are Sensa.io sensors compatible with any LoRaWAN gateway or network?
Yes. Sensa.io sensors are fully gateway-agnostic and connect seamlessly to any LoRaWAN or MQTT-compatible infrastructure — including Kerlink, Cisco, Milesight, MultiTech, or private industrial networks. This ensures flexible integration with existing SCADA or IoT systems.
Specific Technical Questions/
Mining & Quarrying
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