For a circular future with lower CO₂ emissions and manageable costs, smart and efficient use of raw materials is indispensable. Heros Sluiskil, a leader in the circular economy, plays a key role in this. By sustainably processing bottom ash into secondary raw materials, the company minimises waste and maximises reuse.
A crucial link in this process are the heavy industrial screening plants that process the bottom ashes. Heros processes 1 million tonnes of AEC bottom ash annually, a quantity that continues to increase. To achieve these ambitious targets, the plants must continue to operate reliably. Especially the heavily loaded bearings in the screening plants are a risk factor; their failure often leads to unexpected and costly downtime.
Cause of bearing failure and the solution
Most premature bearing damage occurs due to material fatigue as a result of continuously varying loads. Research shows that 60% of bearing failures are caused by this. This results in unexpected downtime and loss of productivity.
To tackle this problem, Heros, in collaboration with Muller Beltex, has developed an advanced system for wireless monitoring of bearing temperatures. This enables technicians to spot anomalies early and intervene before damage occurs.
Wireless monitoring system
The system uses PT1000V3C bearing temperature sensors. These sensors measure temperature directly on the outer bearing through the grease nipple, which is much more accurate than surface temperature measurements. The wireless transmitters are built into industrial junction boxes to ensure robustness. This is essential on Heros’ vast premises, where wired systems are impractical due to the mass of ferrous and non-ferrous materials.
The PT1000 sensors were chosen for their low power consumption and long lifetime of 7 to 10 years. They transmit a temperature reading every three minutes over a 4G network. In case of anomalies, the system automatically generates a notification with specific location data and a work order, allowing the maintenance team to take targeted and efficient action.
Benefits of wireless monitoring system
- Preventive maintenance: Early detection of temperature anomalies prevents unexpected downtime.
- Reliability: The wireless network functions excellently on large industrial sites without complex cabling.
- Cost savings: Avoided downtime and targeted repairs reduce operational costs.
- Longevity: The sensors require minimal maintenance, contributing to stable and efficient production.
Innovative technology
The PT1000V3C sensor is designed for a wide range of industrial applications, from block and flange bearings to motors and pumps. Its corrosion-resistant housing meets stringent ATEX standards for explosive environments, making the sensor suitable for challenging industrial conditions.
Conclusion
The successful application at Heros illustrates how wireless monitoring can contribute to a more sustainable and efficient industry. The monitoring system that technology plays a key role in the circular economy. Real-time insight into bearing temperatures minimises downtime, increases efficiency and contributes to a more sustainable production process. This can also be applied in other sectors, such as mining, steel production and recycling industries. Continuous innovation in wireless technology and sensors can further optimise processes.
