Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Reactor Temperature Monitoring (Batch Control & Product Quality) — ATEX
Quality control, energy efficiency
Temperature
Quick Overview
| Problem | In chemical and process industries, reactor temperature is the most critical parameter for reaction kinetics, product quality, and safety. Temperature deviations can trigger runaway reactions, off-spec batches, or emergency shutdowns—especially in ATEX-classified environments where manual intervention is risky and slow. |
| Solution | Sensa.io’s ATEX-certified temperature sensors provide continuous, high-accuracy monitoring of reactor temperature, delivering real-time visibility for safe batch control and process optimisation. |
| Value | Improved batch quality • Reduced safety risk • Lower scrap rate • Stable, repeatable processes |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified temperature sensors |
The Operational Challenge
Chemical reactors are used for:
- Batch and semi-batch reactions
- Continuous chemical synthesis
- Polymerisation, neutralisation, and mixing processes
Temperature directly affects:
- Reaction speed and yield
- Selectivity and by-product formation
- Pressure generation inside the reactor
- Safety margins during exothermic reactions
Common challenges include:
- Localised overheating or hot spots
- Sensor drift or loss of signal from wired probes
- Limited measurement points on legacy reactors
- Delayed operator response to rapid temperature rise
Traditional temperature monitoring often relies on:
- Single wired thermocouples
- Periodic manual verification
- Reactive alarms after thresholds are exceeded
These approaches can be insufficient in fast-changing reaction conditions.
Why Continuous Temperature Monitoring Matters
Temperature is the primary control variable in most chemical reactions.
Continuous monitoring enables operators to:
- Detect deviations before runaway conditions develop
- Maintain tight temperature control during critical phases
- Improve repeatability between batches
- Reduce thermal stress on reactor walls and seals
Accurate, real-time temperature trends support safer operation and higher product consistency.
Sensa.io Solution
Sensa.io delivers a wireless, intrinsically safe temperature monitoring solution for chemical reactors.
Core Components
Temperature Sensor (ATEX Ex ia IIC T4 Gb)
High-accuracy sensor (±0.2 °C) suitable for direct reactor surface or process measurement.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, enabling integration with DCS, SCADA, and batch control systems.
Installation & Power
Battery-powered clamp-on or threaded installation — no wiring, no hot work, no process interruption.
Operational Benefits
- Early detection of thermal deviations
- Reduced risk of runaway reactions
- Improved batch repeatability
- Enhanced operator confidence
Results and ROI
ATEX Compliance and Safety
All temperature sensors for reactor 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 reactors without shutdown or hot work permits.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | DCS, SCADA, batch management systems |
| Vendors | Siemens, Schneider Electric, ABB, Emerson |
| 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.
