A 120-meter-tall chimney stack at a cement plant showed visible signs of damage. To inspect the structure, the Elios 3 drone was deployed, capturing 4K video and LiDAR data in just one hour, enabling detailed 3D analysis for maintenance planning.

Key Benefits In One Go

Introduction

In 2022, 4.1 billion tons of cement were produced globally, making it one of the most essential construction materials. Any disruption in production can lead to serious consequences. Cement plants must balance high demand with the need for regular maintenance of complex machinery, ensuring that maintenance doesn’t interfere with output.

Cement production involves heating limestone in a kiln to create calcium oxide, a key component of cement. The hot gases from this process are released through large chimney stacks. These structures are critical to the workflow but rarely require routine maintenance. However, unexpected issues can cause major delays and safety risks.

When an engineer noticed a slight tilt in the top of a chimney stack, immediate action was needed to prevent potential shutdowns and ensure safety.

How A Chimney Stack Works And What The Customer Needed

This chimney stack was connected to two kilns, each undergoing annual maintenance—one in winter and one in summer. This schedule ensured continuous production. The stack itself stood 120 meters tall with a 4-meter diameter, designed to handle hot gases from the kilns.

During February 2023, the engineer noticed a subtle misalignment at the top of the stack. An inspection was urgently required, as any delay could lead to costly production halts. Traditional methods would have involved a crane, which is both time-consuming and expensive.

Solution: Inspecting A Cement Chimney Stack With The Elios 3

The site had a trained drone pilot who quickly initiated the inspection. Since the stack’s interior was narrow and hard to reach, an enclosed-space drone like the Elios 3 was the ideal choice. It captured both visual and LiDAR data simultaneously, allowing for a comprehensive 3D model of the structure.

Unlike cranes, which can take days to set up and cost tens of thousands of euros, the Elios 3 completed the inspection in just one hour. The chimney only needed a short cooldown period before being used again, minimizing downtime.

Results Of A Cement Stack Inspection With A Drone

After processing the LiDAR data with GeoSLAM Connect 2.3, the team created a high-density point cloud. Using CloudCompare, they analyzed the data and discovered that the inner sleeve of the stack had subsided, causing the top 7-10 meters to lean by 4 degrees. A section of concrete had shifted 150mm to the east, posing significant risks if left unaddressed.

The 3D model allowed engineers to plan repairs accurately. The inner tube was replaced in a timely manner, with the entire repair process taking just two weeks, far faster than traditional methods.

Drone Programs In Cement Plants

The use of the Elios 3 not only saved the plant a significant amount of money but also improved efficiency. The drone’s ease of use and rapid deployment allowed the team to save nearly three days compared to traditional inspection methods.

The pilot noted that the flight was smooth and reliable, even at 110 meters above ground. The LiDAR SLAM system helped navigate the tight space inside the stack with precision.

This project will serve as an internal case study, highlighting the importance of early detection and fast response in maintaining the integrity of critical infrastructure. Thanks to the Elios 3, the plant avoided major disruptions and resumed production within two weeks.

Discover more about the Elios 3 and its applications in industrial inspections.

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