Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Silo Temperature & Acoustic Anomaly Detection (Fire, Blockage & Structural Risk Prevention) — ATEX
Prevents fires & structural failures in ore silos
Temperature
Acoustic
Quick Overview
| Problem | Ore and material silos in mining operations are exposed to fire, blockage, and structural risks caused by friction, material bridging, compaction, or abnormal flow. These events often develop silently and can escalate into smouldering fires, dust ignition, or sudden discharge failures before operators are aware. |
| Solution | Sensa.io’s ATEX-certified temperature and acoustic sensors continuously monitor silos to detect abnormal heating, friction noise, and flow anomalies—enabling early intervention without manual inspection in hazardous zones. |
| Value | Fire & explosion risk reduction • Early blockage detection • Safer operations • Reduced unplanned downtime |
| ATEX | Dust Zones 20–22 • Ex ia IIIC T135°C Db certified temperature & acoustic sensors |
The Operational Challenge
Mining silos are used to store and buffer:
- Crushed ore and concentrate
- Coal, aggregates, and fines
- Process intermediates feeding mills or conveyors
They operate under conditions that create hidden risks:
- Material compaction and arching
- Friction between material and steel walls
- Uneven discharge and flow interruptions
- Accumulation of combustible dust
Common failure scenarios include:
- Localised heating and smouldering material
- Sudden blockage requiring emergency intervention
- Structural stress due to uneven load distribution
- Dust ignition during discharge events
Traditional monitoring relies on:
- Visual inspection during filling or emptying
- Operator experience and audible cues
- Reactive shutdown after flow stops or alarms trigger
These methods expose personnel to dust hazards and often detect problems too late.
Why Temperature & Acoustic Monitoring Matter
Temperature and acoustic signals are early indicators of abnormal silo behaviour.
Continuous monitoring enables operators to:
- Detect friction-related heating before ignition
- Identify abnormal flow sounds indicating bridging or collapse
- Detect impacts or structural resonance
- Intervene safely before blockages or fires occur
Acoustic monitoring captures dynamic events that temperature sensors alone may miss.
Sensa.io Solution
Sensa.io delivers a wireless, intrinsically safe monitoring solution for mining silos and bulk material storage.
Core Components
Temperature Sensor (ATEX Ex ia IIIC T135°C Db)
Monitors silo wall or internal temperature to detect abnormal heating and smouldering material.
Acoustic Sensor (ATEX Ex ia IIIC T135°C Db)
Detects friction noise, abnormal flow patterns, and impact events inside the silo.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, suitable for remote and hazardous mining areas.
Installation & Power
Battery-powered clamp-on installation — no wiring, no hot work, no silo entry.
Operational Benefits
- Early fire and ignition risk detection
- Safer blockage identification
- Reduced emergency interventions
- Improved silo availability and reliability
Results and ROI
ATEX Compliance and Safety
All sensors for silo 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 enables monitoring without increasing ignition risk.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | Mine SCADA, safety monitoring, EHS platforms |
| Deployment | Silo clusters or central control rooms |
| 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.
