Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Biogas Digester Pressure & Temperature Monitoring (Process Stability & Safety) — ATEX
Increases yield, ensures safety
Pressure
Temperature
Quick Overview
| Problem | Anaerobic digesters operate under narrow pressure and temperature windows. Undetected pressure instability or thermal drift can reduce biogas yield, damage membranes, trigger safety incidents, or force unplanned shutdowns in ATEX-classified environments. |
| Solution | Sensa.io’s ATEX-certified pressure and temperature sensors continuously monitor digester conditions, providing real-time visibility of process stability and early warning of abnormal behaviour. |
| Value | Stabilised gas production • Reduced safety risk • Lower maintenance cost • Improved plant availability |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified pressure & temperature sensors |
The Operational Challenge
Anaerobic digesters are the core of biogas production facilities, converting organic feedstock into methane-rich gas through biological processes that are highly sensitive to operating conditions.
Key constraints include:
- Pressure stability to protect membranes and gas holders
- Temperature control to maintain bacterial activity
- Gas-tight integrity to avoid methane losses
- Limited tolerance for process excursions
Typical operational issues include:
- Progressive pressure drift due to membrane fouling or valve malfunction
- Temperature fluctuations caused by heating loop failure or feedstock variability
- Undetected micro-leaks leading to gas losses and safety exposure
- Manual measurements performed too infrequently for real-time control
Traditional instrumentation often provides only partial visibility or requires intrusive installation incompatible with ATEX constraints.
Why Pressure & Temperature Monitoring Matters
Pressure and temperature are the two most critical indicators of digester health.
Continuous monitoring enables operators to:
- Detect abnormal pressure rise before membrane stress occurs
- Identify pressure drops indicating leaks or gas holder issues
- Maintain optimal mesophilic or thermophilic temperature ranges
- Correlate biological performance with process conditions
Stable pressure and temperature directly impact:
- Methane yield and energy production
- Digester lifetime and membrane integrity
- Safety of personnel and surrounding infrastructure
Early detection prevents minor deviations from escalating into costly failures.
Sensa.io Solution
Sensa.io delivers a wireless, intrinsically safe monitoring solution designed specifically for anaerobic digesters.
Core Components
Pressure Sensor (ATEX Ex ia IIC T4 Gb)
High-accuracy measurement of digester and gas holder pressure, suitable for low-pressure biogas environments.
Temperature Sensor (ATEX Ex ia IIC T4 Gb)
Continuous monitoring of digester temperature to detect heating failures or biological instability.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, enabling integration with biogas SCADA, EMS, and process optimisation platforms.
Installation & Power
Battery-powered threaded or clamp-on installation on digester nozzles or piping — no cabling or shutdown required.
Operational Benefits
- Continuous visibility of digester health
- Early detection of abnormal process behaviour
- Reduced risk of membrane damage and gas loss
- Improved biological process stability
Results and ROI
ATEX Compliance and Safety
All sensors for digester monitoring comply with:
- ATEX Directive 2014/34/EU
- Ex II 2 G Ex ia IIC T4 Gb (Zones 0–2)
- IECEx certification
The intrinsically safe design enables installation on live digesters without process interruption.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | Biogas SCADA, EMS, CMMS |
| Vendors | Schneider Electric, Siemens, ABB, Honeywell |
| Cybersecurity | AES-128 encrypted communication with secure transport |
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.
What does the Sensa.io Valve Position Sensor actually measure?
The device detects real-time valve position states—open, closed, or intermediate—with high accuracy. It continuously sends this information wirelessly to your monitoring dashboard.
Can this sensor detect partial valve movement or stuck valves?
Yes. The sensor identifies irregular patterns such as partial movement, delayed response, or stuck valves, enabling early maintenance before failure occurs.
Is this sensor suitable for manual, motorized, and actuated valves?
Yes. It supports a wide range of valve types including ball, gate, butterfly, actuator-driven, and manual valves.
How fast does it update the valve position?
You can configure the reporting interval—from seconds to minutes—depending on your operational and battery needs.
How long does installation take?
Most installations take under 10 minutes. The sensor mounts using brackets or clamps without modifying existing valves.
Explore Our Sensors
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A rugged, industrial-grade pressure sensor designed for high-demand oil & gas applications. Provides continuous gas and liquid pressure monitoring, with ATEX intrinsic safety, IP67 housing, and LoRaWAN® connectivity.
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Differential Pressure (ΔP)
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Vibration
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Acoustic
The Sensa iO acoustic sensor identifies ultrasonic leak signatures, gas escape, steam trap failures, and flare noise anomalies.
Trusted by a Worldwide Network
With partners in over 20 countries, Sensa IO delivers rugged sensor solutions to the toughest environments — everywhere.
