Fast, Safe and Accurate: Biomass Separator Inspections Using the Elios 3 Drone
At DJM Aerial Solutions, we recently completed a series of internal inspections on four biomass separators using our Elios 3 confined space drone. These critical assets, integral to the operation of biomass and energy from waste (EfW) facilities, often present significant challenges when it comes to safe, accurate condition assessment — particularly when refractory wear or tube exposure is suspected.
Our solution: a rapid, non-entry inspection method that reduces downtime, eliminates confined space risks, and delivers exceptional data clarity.
Why Biomass Separator Inspections Are Critical
Biomass separators are exposed to extreme thermal cycling, ash particulate, and process gases — all of which can lead to:
Refractory wall degradation
Exposed or worn boiler tubes
Erosion or abnormal wear patterns
Cracking, spalling, or delamination
Localised structural deformation
Identifying these defects early prevents costly shutdowns, catastrophic failure, and unnecessary exposure to hazardous working conditions.
Inspection Objectives
During this project, our inspection brief included:
Close visual examination of refractory walls for cracking, spalling, and structural wear
Identification of exposed or thinning tubes, often early indicators of insulation failure
Review of general wear patterns to detect anomalies that might affect separator performance or lifespan
Generation of a full visual defect report, complete with annotated video and still imagery for each separator
Why Use the Elios 3?
The Elios 3 is designed specifically for confined space and GPS-denied environments. Its features include:
4K stabilised camera with precision flight control
360° LED lighting to illuminate dark internal structures
Onboard LiDAR sensor for spatial awareness and optional 3D modelling
Collision-tolerant cage, allowing safe flight inside complex assets
Operated by confined-space certified pilots, minimising operational risks
Results and Deliverables
Each of the four biomass separators was inspected in a fraction of the time compared to traditional methods. We provided the client with:
High-resolution 4K inspection footage
Annotated still images of all areas of interest
Summary defect reports per separator
Maintenance recommendations based on visual condition
Advantages Over Traditional Methods
| Drone Inspection | Traditional Inspection |
|---|---|
| No confined space entry | Requires manned entry, scaffold, or rope access |
| Completed in hours | Often requires multiple shifts or full shutdown |
| Minimal disruption to site operations | Significant operational downtime |
| Clear, high-resolution defect visuals | Limited visibility due to lighting and angles |
| Cost-effective and scalable solution | Labour intensive and expensive |
Applications Across the Biomass and EfW Industry
Drone inspection of biomass plant infrastructure extends beyond separators. We regularly carry out:
Boiler inspections (gas pass 1, 2 and 3)
Refractory condition surveys
Ash separator and hopper inspections
Scrubber and stack assessments
Pre- and post-outage visual reporting
Our Elios 3 inspections are used by maintenance planners, integrity engineers, and outage managers across the UK energy sector.
Frequently Asked Questions About Drone Surveys
It’s a visual and structural assessment of biomass separators used to handle high-temperature process residues in energy facilities.
Damaged refractory can expose structural metal, leading to corrosion, inefficiency, or failure of the separator.
Cracks, spalling, delamination, exposed tubes, and irregular wear patterns.
Drones eliminate the need for confined space entry and deliver rapid, high-quality results.
We use the Flyability Elios 3, specifically designed for confined space industrial inspection.
Each unit can typically be inspected within 1–2 hours, depending on complexity.
Minimal — the drone can be deployed as soon as the asset is isolated and safe to enter.
Thermal surveys are typically conducted externally using other platforms; Elios 3 provides high-resolution visual and spatial data.
We deliver 4K video, annotated image sets, and optional LiDAR point clouds in LAS or OBJ format.
Yes — we provide nationwide coverage and rapid mobilisation to all biomass and EfW sites.
Summary: Biomass Drone Inspection That Works
Whether inspecting separators, boilers, or associated assets, the Elios 3 platform is redefining how internal biomass inspections are conducted. By eliminating confined space entry and delivering fast, precise data, we’re helping plant operators make smarter decisions, reduce maintenance risks, and stay operational.
Ready to Book Your Biomass Drone Inspection?
We provide rapid mobilisation across the UK and Europe with full CAA approvals, confined space training, and a track record of delivering industry-leading inspection data.
📍 Nationwide coverage
✅ Experienced with EfW and biomass sites
📊 Actionable data in hours, not days
Contact DJM Aerial Solutions today to book your inspection.