Major Cement Company Enhances Stockpile Measurement with Elios 3

A leading cement plant in France has successfully implemented the Elios 3 drone equipped with LiDAR technology to improve the accuracy and safety of clinker stockpile measurements. This innovative approach has transformed the traditional, manual inventory process into a faster and more reliable operation.

Key Benefits at a Glance

Introduction

Clinker is a crucial raw material used in the production of various types of cement. It is ground into a fine powder and then used as a binding agent. Clinker is typically stored in large silos, and accurate inventory tracking is essential for efficient production planning.

Traditionally, plant operators have relied on a manual method to measure clinker levels. This involves standing on a platform inside the silo and using a long pole to estimate the amount of clinker present. However, this method is time-consuming, imprecise, and poses significant safety risks, especially when working at heights.

Customer Needs

Clinker silos are known for being dusty, dark, and potentially hazardous environments. At one French cement plant, employees had to stand on a small, unstable platform located 25 meters (82 feet) above the ground to take manual measurements. This not only exposed them to the dangers of working at height but also resulted in inaccurate data.

Recognizing the need for improvement, the plant sought out new technologies that could enhance both the accuracy and safety of their inventory process.

Solution

The plant decided to test the Elios 3, a LiDAR-equipped drone designed for challenging environments. The device's ability to collect precise 3D data while flying made it a promising solution for clinker inventory management.

Using GeoSLAM Connect, the collected LiDAR data was processed to create an accurate 3D model of the clinker stockpile. The Elios 3’s real-time 3D Live Map allowed pilots to navigate even in low-visibility conditions, making it ideal for use inside dusty silos.

Results

The implementation of the Elios 3 proved to be highly successful. The drone enabled fast, accurate, and safe clinker inventory measurements, replacing the previous manual method.

Some key benefits included:

• Speed: The entire process took only 30 minutes, including flight time and post-processing.
• Accuracy: The measurements were far more precise than those obtained through manual methods.
• Dusty Environment Capability: The 3D Live Map allowed safe operation even in extremely dusty conditions.
• Safety: No personnel needed to climb onto high platforms, reducing the risk of accidents.
• Full Coverage: The 3D map ensured complete coverage of the stockpile area for accurate measurements.

Additional Visual Inspection of a Filter Shaft

Beyond inventory, the Elios 3 was also used to inspect a filter shaft. Inspectors discovered severe damage to several beams, which helped the maintenance team plan necessary repairs quickly and avoid potential shutdowns.

Conclusion

The success of the Elios 3 in improving clinker stockpile measurements has led the plant to consider adopting the technology permanently for its inventory needs. Additionally, they are exploring its use for regular visual inspections of other plant assets.

With its ability to operate effectively in dusty and confined spaces, the Elios 3 offers a versatile and reliable solution for industrial applications where visibility and safety are critical concerns.

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