Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Digester Mixer Vibration Monitoring (Agitator Reliability & Process Stability) — ATEX
Prevents motor failures, maintains homogeneity
Vibration
Quick Overview
| Problem | Digester mixers (agitators) are essential to maintain homogeneous temperature, substrate distribution, and gas release. Bearing wear, shaft misalignment, or blade fouling can degrade mixing efficiency, reduce methane yield, and trigger unplanned shutdowns—often without early warning in ATEX-classified environments. |
| Solution | Sensa.io’s ATEX-certified vibration sensors continuously monitor mixer mechanical behaviour, detecting early signs of wear or imbalance to ensure stable digestion and predictable maintenance. |
| Value | Stable biogas yield • Reduced mixer failures • Lower maintenance cost • Improved digester availability |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified vibration sensors |
The Operational Challenge
Mixers and agitators are installed in anaerobic digesters to:
- Maintain uniform temperature and bacterial activity
- Prevent sedimentation and floating layers
- Ensure efficient gas release from the substrate
- Avoid localised overheating or dead zones
These components operate under harsh conditions:
- Continuous or cyclic operation
- High torque and variable load
- Corrosive and abrasive media
- Limited access for inspection
Common failure modes include:
- Bearing degradation due to moisture ingress
- Shaft misalignment or imbalance
- Blade fouling increasing torque demand
- Progressive mechanical fatigue
Traditional monitoring often relies on:
- Motor current observation
- Visual inspection during maintenance
- Reactive repair after performance loss
This results in late detection and avoidable process instability.
Why Vibration Monitoring Matters
Vibration is the earliest and most reliable indicator of mechanical degradation in rotating equipment.
Continuous vibration monitoring enables operators to:
- Detect bearing defects weeks before failure
- Identify imbalance caused by fouling or damage
- Monitor changes in load and operating regimes
- Correlate mixer health with digestion performance
Stable mixing directly impacts:
- Methane yield and gas quality
- Digester thermal uniformity
- Lifetime of mechanical components
Early detection prevents sudden mixer stoppage and costly digester downtime.
Sensa.io Solution
Sensa.io delivers a wireless, intrinsically safe vibration monitoring solution for digester mixers and agitators.
Core Components
Vibration Sensor (ATEX Ex ia IIC T4 Gb)
Measures acceleration, RMS velocity, and frequency patterns to identify bearing wear, imbalance, and misalignment.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, enabling integration with biogas SCADA, EMS, and maintenance platforms.
Installation & Power
Battery-powered clamp-on installation on mixer bearing housings or motor frames — no cabling, no process interruption.
Operational Benefits
- Early fault detection on mixers
- Reduced risk of sudden mixing failure
- Stable digestion and gas production
- Optimised maintenance scheduling
Results and ROI
ATEX Compliance and Safety
All vibration sensors for digester mixer 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 allows installation on live digesters without shutdown or hot work.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | Biogas SCADA, EMS, CMMS |
| Vendors | Siemens, Schneider Electric, ABB, Honeywell |
| Cybersecurity | AES-128 encrypted communication |
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.
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Trusted by a Worldwide Network
With partners in over 20 countries, Sensa IO delivers rugged sensor solutions to the toughest environments — everywhere.
