Thermoelectric Generator-Powered Long-Range Wireless Real-Time Steam Leak Detection in Steam Traps

This paper introduces a novel thermoelectric generator (TEG)-powered Industrial Internet of Things (IIoT) device that addresses key limitations in the detection of steam leaks in industrial steam pipelines, particularly in steam traps. Existing solutions often rely on battery-powered or wired sensors, which are limited by high maintenance costs, short lifespans, or significant infrastructure investments. The proposed device operates without batteries, using waste heat to provide continuous power, and leverages LoRaWAN for long-range wireless communication, minimizing reliance on costly internal infrastructure. Additionally, the device integrates temperature differential (ΔT) and ultrasonic sensors with edge computing capabilities to enhance real-time leak detection and reduce dependency on cloud computing. By enabling precise, low-maintenance monitoring of steam systems in energy-intensive industries (e.g., petrochemical, pharmaceutical), this technology can significantly reduce energy losses, operational costs, and greenhouse gas emissions. Initial testing demonstrates the device’s ability to detect leaks accurately under varying industrial conditions, offering a robust, scalable solution for Industry 4.0 applications.