Identifying Chimney Tower Faults With The Elios 3 At A Cement Plant
A chimney stack at a cement plant had a visible fault, but it stood an intimidating 120 meters high. Using the Elios 3, engineers were able to inspect the structure with high-resolution 4K video and LiDAR scanning in just one hour, capturing detailed data for in-depth 3D analysis.
Key Benefits In A Nutshell
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Access Inspecting a 120-meter-high chimney is risky and traditionally requires crane operations. The Elios 3 provided safe and efficient access, completing the inspection in just one hour without the need for heavy machinery. |
Speed The Elios 3 completed the inspection in one hour, while traditional methods usually take a full day. Drones like the Elios 3 can be up to eight times faster than conventional techniques. |
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Cost Savings Using the Elios 3 saved over 30,000 euros that would have been spent on setting up a crane. The drone was ready to fly within minutes, significantly reducing downtime and saving both time and money. |
Visualization The 3D model generated by the Elios 3 enabled quick decision-making and served as a valuable record for internal use, helping teams better understand and plan repairs. |
Introduction
In 2022 alone, 4.1 billion tons of cement were produced globally. As one of the most essential construction materials, any disruption in supply could lead to serious consequences. This makes regular maintenance and timely inspections crucial for cement plants, especially for critical infrastructure like chimney stacks.
Cement production involves heating limestone in large kilns at temperatures between 1300°C and 1450°C. The resulting hot gases are released through chimney stacks, which are vital to the process. These structures are rarely maintained, making unexpected issues potentially catastrophic.
When an engineer noticed a slight tilt in the top of a 120-meter chimney stack, immediate action was necessary. Any delay could lead to costly shutdowns or even structural failure. The challenge was to inspect the stack quickly and safely without disrupting ongoing production.
How A Chimney Stack Works And What The Customer Needed
This particular chimney stack connected two kilns, each undergoing annual maintenance during different seasons. This schedule helped keep production running smoothly. However, any inspection of the stack required a complete shutdown, as it was impossible to access from the outside.
The stack, measuring 120 meters tall and 4 meters in diameter, was designed to withstand extreme heat from the kilns. It consisted of an inner and outer concrete sleeve, working together to protect the structure. But when the engineer spotted a slight angle, they knew an inspection was urgent.
The internal space was narrow and difficult to access, making a standard drone unsuitable. That’s why the Elios 3 was chosen — its enclosed design and LiDAR capabilities made it ideal for this kind of inspection.
Solution: Inspecting A Cement Chimney Stack With The Elios 3
A trained drone pilot from the plant quickly deployed the Elios 3 to conduct the inspection. Unlike traditional methods that required a crane and days of setup, the drone completed the task in just one hour.
After the flight, the LiDAR data was processed using GeoSLAM Connect 2.3, creating a high-density point cloud. This data was then analyzed in CloudCompare, revealing significant damage to the inner sleeve of the stack.
The results showed that the inner concrete tube had subsided, causing the top 7–10 meters of the stack to lean 4 degrees. If left unchecked, this could lead to further structural damage, partial collapse, or even safety hazards.
The 3D model allowed the team to plan repairs efficiently. The inner tube needed replacement, and the maintenance team used the model to determine the exact dimensions and location of the damaged section.
Results Of A Cement Stack Inspection With A Drone
The repair process took about two weeks. The old section of the inner tube, weighing 7 tons, was carefully removed over five days. The outer tube was then cleaned and inspected, followed by the installation of a new concrete segment in four days.
Thanks to the drone's fast and accurate inspection, the plant avoided a major production halt. The entire process was not only faster but also more cost-effective than traditional methods.
The Elios 3 proved to be a game-changer, offering a safer, quicker, and more efficient way to inspect critical infrastructure. This experience has now become a case study for other cement plants looking to adopt similar drone-based solutions.
Drone Programs In Cement Plants
Using the Elios 3 saved the plant significant time and money. Not only did it eliminate the need for expensive crane setups, but it also reduced the overall inspection timeline by nearly three days.
The pilot praised the smooth operation of the Elios 3, noting how the LiDAR SLAM system helped navigate the tight interior of the stack. Despite being 110 meters above ground, the drone maintained a stable signal and delivered clear, actionable data.
Looking ahead, this project will serve as a benchmark for other facilities in the cement industry. By leveraging drone technology, companies can improve safety, reduce costs, and maintain production continuity even in the face of unexpected structural issues.
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