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 under a contract with the Department of Energy (DOE). The initiative, called the Calcine Retrieval Project (CRP), aims to safely remove several hundred cubic meters of highly radioactive waste from underground storage bins in Idaho. This story dives into the challenges and solutions involved in mapping a complex, irradiated environment.

Key points:

  • The IEC was tasked with removing radioactive calcine waste from a vault built in the 1950s.
  • Before any removal could begin, the team needed to create a detailed 3D map of the vault’s interior.
  • After evaluating multiple options, the IEC chose Flyability’s Elios 2 and later the Elios 3 for their ability to navigate tight spaces and collect accurate data.

The Challenge: Mapping a High-Radiation Vault

The Idaho Cleanup Project at the Idaho National Laboratory involves one of the most complex environmental remediation efforts in the U.S. One of its key components is the Calcine Retrieval Project (CRP), which seeks to safely extract 220 cubic meters of radioactive waste—known as calcine—from underground storage bins that have been in place for over six decades.

The waste is stored inside 6.1-meter-high concrete bins housed within a vault constructed in the 1950s. These structures were never designed for future retrieval, making the task extremely difficult. To address this, the CRP team developed a multi-step process involving drilling, robotic welding, and pneumatic extraction. However, before any physical work could begin, they needed a clear understanding of what lay inside the vault.

Creating a 3D model of the vault was essential. It allowed the team to identify obstructions like pipes, conduits, and structural supports that could interfere with the placement of access holes. Without this information, the retrieval process would be risky and inefficient.

LiDAR and photogrammetry were considered as methods for creating the 3D model. LiDAR offered higher detail, but both technologies had to work within the confined and hazardous space of the vault.

Evaluating Solutions for a Complex Environment

In 2019, the CRP team attempted to use a handheld LiDAR sensor lowered through the only hatch in the vault roof. Unfortunately, this method produced a partial 3D map with significant blind spots. To fully map the area, they needed a way to collect data from four different vantage points, all while working in a high-radiation zone with limited access.

Five potential solutions were evaluated:

  • Modifying an existing articulating arm
  • Designing a new articulating arm
  • Using a helium-filled blimp
  • Drilling multiple access holes
  • Using a commercially available inspection drone

After a thorough cost and risk assessment, the Elios 2 was chosen as the best option. At the time, the Elios 3 was still in development, but once it launched, the CRP team quickly upgraded to it due to its integrated LiDAR sensor, which provided more accurate and detailed 3D mapping capabilities.

The Elios 2 and 3 stood out for their durability, radiation resistance, and ability to operate in confined, high-risk environments. They could maneuver around obstacles, collect high-resolution visual and thermal data, and even operate beyond visual line of sight when necessary.

Testing the Elios 2 and Transitioning to the Elios 3

To confirm the Elios 2’s suitability, the CRP team conducted a test at a simulated vault site. The test was successful, proving that the drone could navigate the space and collect reliable photogrammetry data.

Following the release of the Elios 3, the CRP team recognized its advantages, particularly the inclusion of a LiDAR sensor. This upgrade allowed for more precise and comprehensive 3D modeling of the vault, significantly improving the accuracy of the planning and execution phases of the project.

With the Elios 3 now in use, the CRP is well on its way to safely retrieving the radioactive waste, demonstrating how advanced robotics and drone technology can play a crucial role in some of the most challenging environmental cleanup efforts today.

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