The proposed pilot project, in collaboration with CELSA, aims to improve the operational efficiency and sustainability of two Celsa facilities located in Spain (Barcelona and Vizcaya) through the deployment of innovative industrial IoT sensors. The project includes the installation of 30 InduEye vibration IoT devices with LoRaWAN connectivity for predictive maintenance in complex rotating machinery, and 1 additional IoT devices to monitor temperatures caused by faulty preheating and postheating furnaces
(Furthermon).
What makes this solution unique is its disruptive technology: batteryless, maintenance-free sensors powered by residual heat, eliminating the need for wiring or battery replacement. The devices use longrange LoRaWAN communications, operate in real-time, and are connected to a dedicated cloud platform hosted on AWS called DAEVIS, which is included in the proposal. This cloud platform enables remote monitoring and advanced data analytics for efficient and informed decision-making.
InduEye vibration sensors can be easily attached to a wide variety of rotating equipment, including pumps, compressors, mixers, and combustion fans. The failure detection method is based on RMS vibration velocity analysis according to ISO 10816, combined with spectral FFT analysis. These measurements are obtained through a triaxial vibration sensor and a temperature sensor, allowing early
identification of imbalance, misalignment, bearing wear, and other mechanical faults. For furnaces temperature monitor, the system targets up to 8 different temperature thermocouple monitoring over preheating and postheating furnaces and outlet temperatures.
This pilot will deliver tangible economic benefits by minimizing unplanned downtime, optimizing maintenance schedules, and reducing energy losses. It also contributes to emission reduction goals by preventing continuous heat lose, thus supporting CELSA digitalization and sustainability roadmap.
Furthermore, the project serves as a scalable and replicable model of how heat-powered IIoT systems can modernize critical infrastructure in energy-intensive industries.
