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Elios 3 Selected for Internal 3D Mapping in Nuclear Waste Removal Project at DOE Site
This article is part of a series exploring how the Elios 3 is being utilized in a project led by the Idaho Environmental Coalition (IEC), which is working under a contract with the U.S. Department of Energy (DOE). Their mission involves developing a safe method to extract approximately 220 cubic meters (720 cubic feet) of highly radioactive waste, known as calcine, from underground storage bins at the Idaho National Laboratory site. The project is referred to as the Calcine Retrieval Project (CRP).
Key points:
- The IEC, under DOE contract, aimed to remove calcine waste stored in bins within a concrete vault built in the 1950s.
- Before beginning the removal process, the IEC needed to conduct a thorough 3D mapping of the vault's interior to fully understand the operational environment.
- After evaluating five potential solutions for 3D mapping, the IEC found that Flyability’s Elios 2 and Elios 3 drones were the optimal tools for the task.
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The Challenge: 3D Mapping an Irradiated Vault
As part of the larger Idaho Cleanup Project at the Idaho National Laboratory site, the Idaho Environmental Coalition (IEC) faced the complex challenge of safely removing 220 cubic meters (720 cubic feet) of radioactive waste stored underground for over six decades. This waste, known as calcine, is kept in 6.1-meter-tall (20-foot) bins housed inside a concrete vault constructed in the 1950s. The original design of the vault and bins did not anticipate future waste removal, complicating the task significantly.
The CRP team devised an innovative method for removing the calcine:
1. Drill several 25-centimeter (10-inch) diameter holes through the thick concrete roof of the vault where the bins are located.
2. Lower 6.1-meter (20-foot) "access risers" through these holes to the tops of the bins.
3. Weld the access risers securely to the bins' tops.
4. Cut openings in the tops of the bins.
5. Install equipment through the access risers to pneumatically extract the calcine.
However, before executing these steps, the team had to understand the interior layout of the vault thoroughly. Operators needed to identify any obstructions above the bins, such as conduits, piping, or structural supports, to ensure precise drilling and smooth installation of the retrieval equipment.
To achieve this, the CRP decided to create a 3D model of the vault's interior. They considered both LiDAR and photogrammetry systems, with LiDAR being the preferred choice due to its higher precision. Whichever system proved effective in the confined, high-radiation environment would be chosen for the actual operation.
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Evaluating Delivery Mechanisms for LiDAR and Photogrammetry Systems
In 2019, workers attempted to lower a handheld LiDAR sensor through the sole hatch in the vault roof to create a 3D map. While they managed to capture some data, the sensor’s limited range resulted in a partial map with significant shadow areas or blind spots.
To generate a complete 3D map, the CRP team needed a mobile delivery mechanism capable of reaching multiple vantage points (VP1–VP4) inside the vault. However, the single entry point made it impossible to position a handheld system effectively.
The team evaluated five potential solutions:
1. Modifying an existing articulating arm
2. Designing a new articulating arm
3. Using a helium-filled blimp
4. Drilling additional access holes in the vault roof
5. Employing a commercially available inspection drone
A qualitative cost and technical risk assessment considered factors such as project data, technical feasibility, program complexity, vendor feedback, schedule, and budget constraints. Ultimately, the CRP selected the Elios 2 as the most promising option due to its technical success rate, manageable costs, and schedule feasibility. Later, upon the Elios 3’s release, the team upgraded their choice, recognizing its enhanced capabilities.
The CRP cited several reasons for preferring the Elios 2 and 3:
- **Design**: Collision-resistant and agile, allowing it to navigate tight spaces effectively.
- **Nuclear Experience**: Over 80% of North American nuclear facilities rely on the Elios 2 for inspections, with the Elios 1 proving radiation-resistant during tests.
- **Data Quality**: High-resolution visual, thermal, and point cloud data suitable for creating detailed 3D maps.
- **Safety**: Deployable remotely and operable in Beyond Visual Line of Sight (BVLOS) conditions, ensuring operator safety.
- **Cost**: More economical than alternative solutions.
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Testing the Elios 2
Following the decision to use the Elios 2, the CRP scheduled a test with Flyability to confirm its suitability for the 3D mapping task. The test took place at a replica vault site constructed specifically for the calcine removal project. The simulation confirmed the Elios 2’s effectiveness in capturing the necessary data.
After the Elios 3’s launch, the CRP recognized its superior capabilities, particularly its LiDAR sensor, which promised a more comprehensive 3D model of the vault. The final decision solidified the Elios 3 as the ideal tool for this critical phase of the project.