Identifying chimney tower faults with the Elios 3 at a cement plant
Identifying Chimney Tower Faults With The Elios 3 At A Cement Plant
A cement plant faced a critical issue when a visible fault was spotted on its 120-meter-high chimney stack. To assess the damage, the Elios 3 drone was deployed, capturing 4K video footage and performing a LiDAR scan in just one hour. This provided detailed data for thorough 3D analysis, enabling quick decision-making.
Key Benefits
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Access Inspecting a structure at 120 meters is risky and usually requires complex equipment like cranes. The Elios 3 offered a safer, faster solution with a single-hour flight, eliminating the need for heavy machinery. |
Speed Traditional inspections can take an entire day, but the Elios 3 completed this task in just one hour. Drones are up to eight times faster than conventional methods, reducing downtime significantly. |
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Cost Savings Using a drone saved over 30,000 euros that would have been spent on setting up and dismantling a crane. Additionally, the quick deployment minimized production downtime, further cutting costs. |
Visualization The 3D model generated from the Elios 3’s data allowed for fast, informed decisions and served as a valuable record for internal use and future reference. |
Introduction
In 2022, 4.1 billion tons of cement were produced globally. As a vital construction material, any disruption in supply could lead to serious consequences. Cement plants must maintain high output while managing complex, high-temperature machinery that requires regular care.
Cement production involves heating limestone in a kiln to produce calcium oxide, which is then used in cement. The hot gases from this process are released through industrial chimney stacks. These structures are crucial to the workflow and typically don’t require frequent maintenance. However, unexpected issues can cause major disruptions, halting production entirely.
How A Chimney Stack Works And What The Customer Needed
The chimney stack at this site connected two kilns, each undergoing annual maintenance to avoid simultaneous shutdowns. The stack itself stood 120 meters tall with a 4-meter diameter, designed to withstand extreme temperatures from the kilns.
In February 2023, an engineer noticed a slight tilt at the top of the chimney. Immediate inspection was needed, as delays could result in costly repairs or even structural failure. Shutting down the entire production line for an inspection was a necessary but expensive step.
Solution: Inspecting A Cement Chimney Stack With The Elios 3
A trained drone pilot quickly deployed the Elios 3, an enclosed-space drone capable of flying out of sight. The goal was to gather both visual and LiDAR data to create a 3D model of the chimney’s condition. Unlike traditional methods that required a crane setup taking days and costing tens of thousands of euros, the Elios 3 completed the inspection in just one hour.
The internal space of the chimney was tight and hard to access, making the Elios 3 an ideal choice. After the inspection, the data was processed to identify structural issues, revealing significant damage to the inner sleeve of the stack.
Results Of A Cement Stack Inspection With A Drone
Using GeoSLAM Connect 2.3, the LiDAR data was processed into a high-density point cloud, which was then analyzed in CloudCompare. The results showed that the inner sleeve had subsided by 150mm, causing the top 7.5 meters of the stack to lean at a 4-degree angle.
This discovery led to a swift maintenance plan. Engineers used the 3D model to determine the exact dimensions and location of the damaged section. The repair involved removing the faulty part, cleaning the area, and replacing the inner tube within two weeks.
Drone Programs In Cement Plants
The use of the Elios 3 not only saved the plant a significant amount of money but also reduced the time required for inspections by nearly three days. The smooth operation of the drone, combined with its advanced LiDAR SLAM system, ensured accurate and reliable data collection.
This project will serve as a case study for other cement plants, highlighting the importance of early detection and rapid response to potential structural issues. Thanks to the efficiency of the Elios 3 and the skill of the pilot, the plant resumed operations within two weeks, minimizing the impact on overall production.
Discover more about the Elios 3 and how it can revolutionize your inspection processes today.
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