IoT Monitoring for
Mining & Metallurgy
ROSSMA wireless sensors for furnace automation, conveyor product tracking, equipment vibration diagnostics and temperature/pressure monitoring at ferrous and non-ferrous metallurgy plants, open-pit mines and processing facilities
Mining & Metallurgy Challenges
High temperatures, heavy equipment and kilometer distances challenge automation
Furnace Temperature Control
Smelting, roasting and reheating furnaces operate at 800-1,600 °C. A 50 °C deviation causes product defects, energy waste or lining damage. Manual checks: 2-4 per shift.
Unplanned Equipment Downtime
Conveyors, crushers, mills, rolling mills and compressors operate in dusty, high-vibration conditions. Conveyor belt failure stops the entire process chain. Downtime cost: hundreds of thousands per hour.
Cable Runs Are Impractical
Open-pit quarries, plant territory, transport galleries span kilometers. Cable installation is economically unfeasible, especially in quarries with moving equipment.
Manual Periodic Inspections
Inspectors check equipment 1-2 times per shift with portable instruments. Between rounds, critical vibration, temperature or pressure changes go undetected.
Product Tracking on Conveyors
Without automatic counting of slabs, billets and ore batches on conveyor belts, real-time productivity monitoring is impossible. Manual counting causes errors and reporting delays.
No Data for Process Optimization
Without continuous data from furnaces, conveyors and auxiliary equipment, operating decisions rely on experience rather than analytics.
ROSSMA Capabilities for Metallurgy
From furnace automation to conveyor tracking — wireless solution for the entire plant
Furnace Automation
1-Wire Ex and ANALOG Ex X4 monitor lining, crown and flue gas temperatures. Multiple thermocouples and 4-20 mA sensors connect to one wireless transmitter. Data every 30-60 sec. Alarms on profile deviation.
Conveyor Product Tracking
Pulse Ex and Tilt Counter Ex register slab, billet and ore batch passage on conveyor belts. Automatic real-time counting. Data via LoRaWAN to ROSSMA.NETS for productivity analysis.
Vibration Diagnostics
ANALOG Ex X4 measures vibration acceleration, velocity and bearing temperature on conveyors, mills, crushers and rolling mills. Early wear detection 2-8 weeks before failure. 30-50% unplanned downtime reduction.
Pressure & Hydraulics
P-METER Ex monitors pressure in press hydraulics, rolling mills and quarry equipment. Pulse Ex measures cooling fluid and water flow. Autonomous battery operation.
Wireless Infrastructure
LoRaWAN covers quarry, workshop or plant territory up to 15 km. NB-IoT for remote areas. Battery 10 years at −55 to +85 °C. IP66/IP67, dust and vibration resistant.
ROSSMA.NETS HMI — Unified Center
Web SCADA: furnace and conveyor mimics, temperature trends, ISA-18.2 alarms (5 levels). Productivity, runtime and energy reports. Integration via Modbus TCP, OPC UA, MQTT.
Architecture: From Furnace & Conveyor to Control Room
Wireless sensors on equipment — LoRaWAN — unified plant SCADA
Metallurgy & Mining Equipment
Furnace temperature, vibration, pressure and conveyor tracking sensors
Autonomous Measuring and Switching Device ROSSMA® IIOT-AMS ANALOG Ex X4
Autonomous Switching Device ROSSMA® IIOT-AMS 1-Wire Ex (Temperature Sensor)
Autonomous Measuring and Switching Device ROSSMA® IIOT-AMS TILT COUNTER Ex (Tilt Counter)
Autonomous Wireless Pressure Transmitter ROSSMA IIOT-AMS P-METER
Autonomous Measuring and Switching Device ROSSMA® IIOT-AMS Pulse
Measuring and Switching Device ROSSMA® IIOT-AMS MODBUS Ex Stand Alone
Autonomous Measuring and Switching Device ROSSMA® IIOT-AMS Dry Contact
Autonomous Kit for Combustible Gas Concentration Monitoring (Gas Analyzer with LoRaWAN/NB-IoT)
Economics: Wired SCADA vs ROSSMA IoT
Cost of adding monitoring points to an operating plant
| Parameter | Wired SCADA | ROSSMA IoT |
|---|---|---|
| Additional point | $800-1,500 (cables + install) | $150-1,000 (sensor) |
| Sensor installation | 2-3 days | 15-30 minutes |
| Conveyor tracking | Photo sensors + cables + PLC | Wireless Pulse Ex |
| Vibration diagnostics | Portable analyzer (walk-around) | ANALOG Ex X4 online 24/7 |
| Furnace temperature | Fixed thermocouples + cables | 1-Wire Ex / ANALOG Ex wireless |
| Scaling | New project + approvals | Add sensor in 15 min |
Key Economic Advantages
Frequently Asked Questions
What tasks does ROSSMA solve at a metallurgy plant?
How does conveyor product tracking work?
Can sensors withstand temperatures near furnaces?
How to monitor quarry equipment?
Compatible with existing SCADA?
Ex certification for foundries?
Battery life on plant site?
Implementation cost?
Ready to Digitize Your Plant?
Get a wireless monitoring system quote — from furnaces and conveyors to quarry equipment