Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Dust Collector ΔP Monitoring (Baghouse Filter Performance & Explosion Prevention) — ATEX
Prevents dust explosions, ensures ventilation performance
Differential Pressure (ΔP)
Quick Overview
| Problem | Dust collectors and baghouse filters are critical safety systems in mining operations. Progressive filter clogging, torn bags, or airflow restriction can lead to excessive dust accumulation, reduced ventilation efficiency, and increased risk of dust explosions. Manual checks are infrequent and provide no continuous visibility in ATEX dust zones. |
| Solution | Sensa.io’s ATEX-certified differential pressure (ΔP) sensors continuously monitor pressure drop across baghouse filters, enabling early detection of clogging or filter failure and ensuring safe, compliant dust control. |
| Value | Explosion risk reduction • Stable ventilation • Predictable filter maintenance • Regulatory compliance |
| ATEX | Dust Zones 20–22 • Ex ia IIIC T135°C Db certified ΔP sensors |
The Operational Challenge
Dust collectors are used across mining operations:
- Crusher and screening buildings
- Transfer points and conveyor galleries
- Grinding and milling circuits
- Loading, dumping, and processing areas
They must ensure:
- Sufficient airflow to capture airborne dust
- Stable pressure balance across filter media
- Safe operation in combustible dust atmospheres
Common operational issues include:
- Gradual filter clogging increasing ΔP
- Bag rupture causing dust release
- Inefficient cleaning cycles (pulse-jet systems)
- Overworked fans and increased energy consumption
Traditional monitoring relies on:
- Local pressure gauges
- Manual inspection during maintenance rounds
- Fixed filter replacement schedules
These approaches fail to detect rapid degradation or sudden filter failure.
Why Differential Pressure Monitoring Matters
ΔP is the primary indicator of baghouse health.
Continuous ΔP monitoring enables operators to:
- Detect clogging before airflow is compromised
- Identify torn or leaking filter bags
- Optimise pulse-jet cleaning cycles
- Maintain stable airflow and dust capture
Maintaining correct ΔP is essential to preventing dust accumulation and ignition risk.
Sensa.io Solution
Sensa.io delivers a wireless, intrinsically safe ΔP monitoring solution for mining dust collectors.
Core Components
Differential Pressure Sensor (ATEX Ex ia IIIC T135°C Db)
High-resolution ΔP measurement across filter inlet and outlet.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, ideal for large processing plants and remote installations
Installation & Power
Battery-powered installation on existing pressure taps — no wiring, no hot work, no downtime.
Operational Benefits
- Early clogging and failure detection
- Reduced dust explosion risk
- Optimised filter cleaning and replacement
- Lower fan energy consumption
Results and ROI
ATEX Compliance and Safety
All ΔP sensors for dust collector monitoring comply with:
- ATEX Directive 2014/34/EU
- Ex ia IIIC T135°C Db (Dust Zones 20–22)
- IECEx certification for combustible dust
Intrinsically safe design allows continuous monitoring in explosive dust environments without ignition risk.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | Mine SCADA, ventilation control systems, EHS dashboards |
| Deployment | Local or centralised monitoring |
| 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.
Explore Our Sensors
Valve position
The Sensa iO Valve Position Sensor provides real-time open/close feedback for manual and automated valves in oil & gas, chemical, and hydrogen operations.
Pressure
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.
Temperature
Sensa iO’s temperature sensor delivers precise temperature data for process lines, steam systems, heat exchangers, and storage assets.
Differential Pressure (ΔP)
A compact DP solution using dual synchronized pressure inputs to deliver accurate differential pressure data for filters, heat exchangers, separators, and manifolds.
Vibration
A high-resolution vibration sensor built for predictive maintenance of pumps, motors, compressors, and rotating equipment.
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.
