Identifying Chimney Tower Faults With The Elios 3 At A Cement Plant
A 120-meter-tall chimney stack at a cement plant showed visible signs of damage, but its height made traditional inspection methods risky and time-consuming. Using the Elios 3, engineers were able to conduct a thorough inspection in just one hour using 4K video footage and LiDAR scanning, capturing detailed data for 3D analysis.
Key Benefits In One Go
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Access Inspecting structures over 120 meters high is typically dangerous and requires complex equipment like cranes. The Elios 3 provided quick and safe access without the need for heavy machinery, allowing the team to complete the inspection in under an hour. |
Speed Traditional inspections can take an entire day, but the Elios 3 collected all necessary data in just one hour. This makes drone-based inspections up to eight times faster than conventional methods. |
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Cost Savings By avoiding the need for a crane, the plant saved around 30,000 euros in setup and operation costs. Plus, the fast deployment minimized downtime, reducing overall operational losses. |
Visualization The 3D model created from the Elios 3's data allowed for accurate decision-making and served as a valuable reference for future maintenance. It also helped document the issue for internal use. |
Why Inspection Matters in Cement Plants
In 2022, over 4.1 billion tons of cement were produced globally. As one of the most essential construction materials, any disruption in production could lead to serious consequences. Cement plants must maintain their kilns and other critical infrastructure, including chimney stacks, which are vital to the process but rarely inspected due to their height and complexity.
Chimney stacks in cement plants are designed to handle hot gases from the kilns. They are built with inner and outer concrete sleeves to withstand extreme temperatures. However, if a fault occurs, it can bring the entire production line to a standstill. That’s why timely and accurate inspections are crucial.
The Problem and the Need for Action
In February 2023, an engineer noticed that the top of the 120-meter chimney appeared slightly tilted. Immediate action was needed to prevent potential failures that could halt production or even cause structural collapse. Traditionally, inspecting such a structure would require setting up a crane, which is both costly and time-consuming.
Instead, the plant used the Elios 3, an enclosed-space drone capable of flying beyond visual line of sight. Its LiDAR and camera system allowed for a detailed inspection of the chimney’s interior, providing real-time data and a full 3D model of the structure.
How the Elios 3 Helped
The Elios 3 was deployed quickly, and within one hour, the pilot had gathered enough data to analyze the chimney’s condition. Unlike traditional methods that could take days, the drone’s speed and precision enabled the team to act fast.
After processing the LiDAR data, the team discovered that the inner sleeve of the chimney had shifted by 150mm, causing the top 7.5 meters to lean at a 4-degree angle. This was a serious issue that required immediate attention to prevent further damage or safety risks.
Results and Next Steps
With the 3D model in hand, the maintenance team planned the repair efficiently. They replaced the damaged section of the inner tube, cleaned the affected area, and installed a new part in less than two weeks. The whole process was completed with minimal disruption to production.
This case study highlights how drones like the Elios 3 can revolutionize maintenance practices in the cement industry. They offer a safer, faster, and more cost-effective way to inspect critical infrastructure, ensuring continuous and safe operations.
Looking Ahead
This project will serve as a valuable case study for other cement plants looking to adopt drone technology. The Elios 3 not only saved time and money but also demonstrated the power of real-time data and 3D visualization in modern industrial maintenance.
Discover more about the Elios 3 and how it can transform your inspection workflows today.
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