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
Early mechanical degradation detection
Vibration
Quick Overview
| Problem | Mixer performance inside anaerobic digesters is not continuously monitored, limiting visibility on mechanical degradation or abnormal operation. |
| Solution | SENSAiO vibration sensors monitor mechanical vibration behavior of digester mixers. |
| Value | Improved detection of abnormal vibration patterns, supporting earlier identification of mechanical issues or process imbalance. |
| ATEX | Designed for biogas environments, compliant with ATEX / IECEx requirements for explosive gas atmospheres. |
The Operational Challenge
In biogas and waste-to-energy plants, digesters rely on mixers to:
- Maintain homogeneous substrate conditions
- Prevent sedimentation and crust formation
- Ensure efficient biological activity
From a physical perspective:
- Mixers generate rotational motion transmitted through shafts and blades
- This motion produces characteristic vibration signatures
- Vibration levels depend on load, fluid viscosity, and mechanical condition
Typical operational stresses include:
- Variable substrate density and composition
- Gas accumulation within the digester
- Continuous or cyclic operation
- Mechanical wear over time
Common issues include:
- Imbalance due to uneven load or buildup
- Bearing wear or degradation
- Shaft misalignment
- Increased resistance from sludge thickening
Detection challenges include:
- Equipment located in sealed or hazardous environments
- Limited direct inspection capability
- Lack of continuous instrumentation
- Difficulty identifying gradual degradation
As a result, mechanical issues may develop without early indication.
Why Vibration Monitoring Matters
Vibration is a direct indicator of mechanical behavior.
By continuously monitoring vibration:
- Changes in mechanical condition can be observed
- Abnormal operating conditions can be detected
- Long-term degradation trends can be tracked
Typical interpretations include:
- Increased vibration amplitude may indicate imbalance or wear
- Changes in frequency patterns may correlate with mechanical faults
- Irregular vibration may indicate process disturbances
Vibration data reflects how the mixer interacts with both mechanical components and the digester medium.
SENSAiO Solution
SENSAiO deploys wireless vibration sensors installed on:
- Mixer housings
- Drive systems
- External accessible mounting points
Sensors measure vibration signals and transmit data via LoRaWAN to a centralized monitoring platform.
The system provides:
- Continuous vibration monitoring
- Trend analysis over time
- Alerts on abnormal vibration behavior
It is important to clarify that:
- SENSAiO is a monitoring-only system
- It does not control mixer operation
- It does not adjust process conditions
- It does not perform automatic diagnostics
The system supports maintenance and operational awareness.
Results and ROI
ATEX Compliance and Safety
Digesters operate in environments containing flammable biogas. SENSAiO sensors:
- Are available with ATEX / IECEx certification
- Are suitable for explosive gas atmospheres
- Are designed for hazardous industrial environments
All equipment is delivered with appropriate certification documentation.
SENSAiO systems are not safety systems and do not replace protective systems, emergency shutdown systems, or regulatory safety requirements.
Integration and compatibility
| Protocols | LoRaWAN, MQTT, REST API |
| Gateways | Compatible with standard LoRaWAN gateways (Kerlink, Multitech, Cisco, etc.) |
| Systems | Integration with maintenance and monitoring platforms |
| Deployment | Suitable for retrofit on existing mixer equipment |
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, SENSAiO delivers rugged sensor solutions to the toughest environments — everywhere.
