Mining Plant DIY ANY Sensor OR INSTRUMENTATION Concepts/IDEAS

I need a set of original, build-from-scratch ANY SIMPLE SENSOR OR INSTRUMENTATION-system concepts that can realistically be deployed in a mining process plant for ongoing monitoring duties. Rather than off-the-shelf suggestions, I’m after practical DIY projects that a small in-house team could prototype with commonly available components, then scale up for rugged, on-site use.

Each idea should come with enough technical depth for immediate action: a clear purpose in the plant, an outline of the sensing method, rough schematic or block diagram, critical component list with part numbers, and notes on calibration and environmental hardening (dust, vibration, temperature, moisture). Safety and maintainability are important, so please highlight any intrinsically safe approaches or enclosure considerations when relevant.

Please deliver a short portfolio of distinct concepts—ideally three to five—that demonstrate variety in what they monitor around the mill, crusher, flotation or tailings areas. Include estimated build cost, integration tips for PLC/SCADA or simple data-logging setups, and any open-source firmware references if microcontrollers such as Arduino, ESP32 or Raspberry Pi are involved.

I’ll review the concepts for feasibility, cost, and clarity, so structure each one the same way and keep explanations concise but technically solid.