The Challenge
- Massive Scale: The vast area of the coal yard made traditional manual surveying time-consuming and prone to human error.
- Zero Visibility: Coal dust during stacking and reclaiming operations “blinded” optical sensors, causing frequent data loss.
- Inventory Drift: Inaccurate volume data led to fuel shortages and difficulties in managing “First-In, First-Out” (FIFO) logic to prevent spontaneous combustion.
- Harsh Weather: Outdoor exposure required sensors to withstand wind, rain, and extreme temperature fluctuations without losing calibration.
The Solution
- Multi-Scanner Synchronization: Multiple 3DPro2300 units were linked to provide seamless, full-surface coverage of the entire coal yard.
- Dust-Penetrating Radar: The 3DPro2300’s radar technology maintains a stable signal through the thickest coal dust clouds during active reclaiming.
- Automated 3D Mapping: The system generates a real-time digital surface model, accounting for the complex peaks and craters of the coal piles.
- Pro Inventory Dashboard: Centralized software provides live volume, weight, and density estimates accessible from the control room.
The Result
- 98% Precision: Reconciled inventory discrepancies, providing audit-ready data for monthly fuel consumption reports.
- Optimized Storage: Improved yard utilization by 20% through precise mapping of available space.
- Enhanced Safety: Eliminated the need for surveyors to navigate hazardous terrain around heavy reclaiming machinery.
- Smart Logistics: Real-time visibility enabled better coal blending and prevented non-planned outages due to fuel shortage.