India, the second-largest cement producer in the world, has consistently added capacity at a rate of 119 million tonnes per annum for the past five fiscal years, culminating in a total capacity of 595 MT (Source: Crisil Ratings). In the rapidly expanding Indian cement industry, the demand for innovative solutions to optimize operations and ensure safety is ever-growing. Volar Alta’s drone tech solutions have revolutionized how cement plants approach maintenance and inspections.
Indicating a significant leap towards efficiency and safety, leading cement giants in India, including ACC, Ambuja, Dalmia, and more, are adopting drone technology to inspect critical equipment in cement plants. This strategic shift not only eliminates time-consuming manual labor but also mitigates safety risks for the workforce.
Let's delve into specific use cases where drone technology is transforming the maintenance process within cement plants. Following are the most common equipment where companies are using drones for inspection:
Raw Material Stockpiles:
Efficient management of raw material stockpiles is crucial for uninterrupted cement production. Drones conduct visual and 3D volumetric analysis of stockpile areas, identifying issues such as material segregation, degradation, etc.
Kilns:
Kilns are at the heart of cement production, and any disruptions can have significant consequences. Drones provide a comprehensive view of kiln exteriors and interiors, allowing for precise thermal analysis and identification of hot spots.
Tertiary Air Ducts:
Ensuring the proper functioning of tertiary air ducts is essential for maintaining the required temperature in the kiln. Drones navigate through complex duct systems, capturing high-resolution images and enabling early detection of potential issues such as leaks or blockages, preventing disruptions in the production process.
Cyclones:
Cyclones play a crucial role in the cement manufacturing process, and any malfunction can lead to inefficiencies. Drones provide a detailed view of cyclone interiors, facilitating early detection of abrasion, corrosion, or blockages.
Cement and Clinker Silos:
Drones, equipped with high-resolution cameras and sensors, enable thorough inspections of silos without the need for human entry. This enhances safety and allows for quicker and more accurate identification of potential issues such as material buildup or structural damage.
Conveyor Belts:
Smooth operation of conveyor belts is vital for the movement of raw materials and finished products. Drones inspect conveyor belts for wear, misalignment, or other issues, preventing unexpected breakdowns.
Chimneys:
Drones inspect chimneys for structural integrity and anomalies in a fraction of time as compared to traditional methods, ensuring safer and efficient maintenance practices.
Captive Power Plants:
Captive power plants provide electricity for internal consumption within cement plants. Drones conduct inspections of boilers, turbines, cooling towers, etc., to identify issues such as equipment wear, corrosion, or overheating, ensuring uninterrupted power supply and minimizing downtime.
Volar Alta's drone inspection services have proven instrumental in transforming the maintenance process of the Indian cement industry. By leveraging advanced technology to inspect critical equipment, our clients have achieved a remarkable ROI along with enhanced safety and improved operational efficiency. Cement plants partnering with Volar Alta experience reduced downtime, increased productivity, and a proactive approach to maintenance, ultimately contributing to the sustainable growth of the industry.
As the cement industry embraces innovation and advancements, drone inspections are set to revolutionize its future trajectory. Discover how our services can empower your operations by contacting us at info@volaralta.com. Let's cement the future together!