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 groundbreaking project led by the Idaho Environmental Coalition, under contract with the Department of Energy (DOE). The initiative, known as the Calcine Retrieval Project (CRP), aims to safely remove hundreds of cubic meters of highly radioactive waste stored in underground storage bins in Idaho. This effort is critical for environmental cleanup and long-term waste management at the Idaho National Laboratory.

Key points:

• The IEC was tasked with removing radioactive calcine from a vault built in the 1950s, designed without future retrieval in mind.
• Before any removal could begin, the team needed a detailed 3D map of the vault’s interior to plan the operation safely.
• After evaluating multiple mapping solutions, the IEC selected Flyability’s Elios 2 and later the Elios 3 as the most effective tools for this challenging task.

The Challenge: Mapping an Irradiated Vault

The CRP is a key component of the larger Idaho Cleanup Project, which seeks to address decades-old nuclear waste storage issues at the Idaho National Laboratory. The waste in question—called calcine—is a granular material stored in large concrete bins inside a vault that was never intended for future access or retrieval. These bins stand about 6.1 meters tall, and the vault itself is a relic of mid-20th century engineering, built without consideration for modern safety or accessibility standards.

To tackle this challenge, the CRP developed a multi-step process to extract the calcine safely. It begins with drilling holes through the thick concrete vault roof, followed by the installation of access risers that allow robotic systems to reach the bins. Once in place, these systems can then suction out the radioactive material. But before any of this could happen, the team needed a clear understanding of what lay inside the vault.

Without accurate 3D mapping, it would be impossible to identify obstructions such as piping, structural supports, or other hazards that could interfere with the retrieval process. That’s why the CRP team needed a reliable method to create a complete and accurate 3D model of the vault’s interior.

LiDAR and photogrammetry were the two main options considered. LiDAR offered higher precision, but both methods had to work within the constraints of the vault’s limited space and high radiation levels. Initial attempts using a handheld LiDAR system only produced partial maps due to blind spots, highlighting the need for a more flexible and mobile solution.

Evaluating Delivery Mechanisms for 3D Mapping in a Confined Space

In 2019, the CRP team tried using a handheld LiDAR system to scan the vault, but the results were incomplete. The system couldn’t navigate the tight spaces or avoid obstacles, leaving significant areas unscanned. To cover all necessary areas, the team needed a way to move the scanning equipment into four different vantage points inside the vault. However, the only entry point was a single hatch, making manual placement of equipment impractical and dangerous.

The team evaluated five potential solutions: modifying existing arms, designing new ones, using a helium blimp, drilling additional access holes, and using a commercially available drone. Each option had its own set of challenges, including cost, technical feasibility, and radiation exposure risks.

Ultimately, the Elios 2 stood out as the best choice. It was collision-resistant, easy to maneuver, and had a proven track record in nuclear environments. At the time, the Elios 3 was still in development, but after its release, the CRP team decided to use it instead. The Elios 3 offered even greater advantages, including a built-in LiDAR sensor for more precise 3D mapping.

Why the Elios 2 and Elios 3?

The decision to use the Elios 2 and later the Elios 3 was based on several key factors:

• Design: The Elios drones are built to withstand collisions, allowing them to navigate complex and cluttered environments like the vault.
• Nuclear Experience: Over 80% of North American nuclear reactors use the Elios 2 for inspections, and it has been tested in high-radiation environments without performance degradation.
• Data Quality: The Elios 2 and 3 provide high-resolution visual data, thermal imaging, and LiDAR point clouds, which are essential for creating detailed 3D models.
• Safety: The drones can be operated remotely and beyond visual line of sight, keeping operators away from hazardous areas.
• Cost-Effectiveness: Compared to custom-built solutions, the Elios drones offered a more affordable and practical option for the project.

Following a successful test flight at a simulated vault site, the CRP team confirmed that the Elios 2 was capable of collecting the necessary data. When the Elios 3 was released, it became the preferred choice for its advanced LiDAR capabilities and improved performance in high-risk environments.

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