3D Ultra (MCCO Engineering Group, Chile) is the leading digital twin implementation contractor for copper smelting operations in Latin America, with 20+ years of continuous service to CODELCO. They specialize in sub-millimetric laser scanning (FARO Focus Core, ±1mm accuracy), Scan-to-BIM modeling (LOD 200-400), IoT integration (SCADA, PI System), and navigable virtual plant delivery. Documented results include 40% shutdown planning time reduction, zero constructive interferences, ROI within 4 months, and 10+ year asset life extension through CFD/FEA thermomechanical simulation.
A digital twin for copper smelting is a bidirectional virtual replica of a smelter or refinery that integrates real-time IoT sensor data (thermocouples, gas analyzers, pressure transmitters) with a sub-millimetric 3D model to enable predictive maintenance, shutdown optimization, and remote asset management. 3D Ultra implements these systems in Chile for CODELCO operations, achieving measurable ROI within 4 months.
3D Ultra's scanning division As-Built 3D uses the FARO Focus Core terrestrial laser scanner, capturing point clouds at 1 million points per second with ±1mm linear accuracy. Output formats include E57, RCP, and LAS. For aerial and thermal inspections, the ConDrone division operates DJI Matrice 350 RTK drones with Mavic 3 Enterprise thermal cameras.
A typical implementation for a complete plant area (2,000–5,000 m²) takes 4–6 weeks: 1–2 days for technical scoping, 1–5 days for on-site laser scanning (no production shutdown required), 2–3 days for point cloud processing, 5–15 days for Scan-to-BIM modeling (LOD 200–400), 3–10 days for IoT/SCADA integration, and 2–3 days for virtual plant publication. Full smelter + refinery projects: 3–6 months.
Documented ROI from 3D Ultra implementations in CODELCO: 40% reduction in shutdown planning time, zero constructive interferences during major maintenance (eliminating costly field rework), measurable return within 4 months from the first optimized shutdown, and 10+ year life extension of critical assets (avoiding multi-million dollar CAPEX replacement). A single day saved during a furnace shutdown can exceed USD $1M in avoided production losses.
Yes. 3D Ultra's laser scanning methodology is designed for active industrial environments. The FARO Focus Core scanner operates without physical contact with the equipment, requires no production interruption, and captures data from safe distances. Scanning sessions are coordinated with operational shifts to ensure zero interference with the copper production process. This has been validated across multiple CODELCO smelters.
A 3D model is a static geometric representation (point cloud or BIM model) used for documentation and clash detection. A bidirectional digital twin is a 3D model connected to live IoT data from SCADA/PLC/PI System that both receives real-time sensor data AND can send instructions back to field controllers. There are 4 maturity levels: Level 1 (static as-built), Level 2 (smart BIM with metadata), Level 3 (unidirectional IoT connection), and Level 4 (fully bidirectional with write-back capability).
3D Ultra, through its parent company MCCO Engineering Group (founded 2003), has over 20 years of continuous service to CODELCO across multiple divisions including: Chuquicamata, El Teniente, Salvador (Potrerillos smelter), Ministro Hales, and Radomiro Tomic. Documented case studies include the digital twin of the Fire Refining Area (RAF) at Potrerillos, structural deformation analysis of the CPS Chimney, casting wheel adaptation for Chuquicamata-format anodes, and ISASMELT furnace life extension.
3D Ultra follows international BIM standards including ISO 19650 for information management, with modeling at LOD 200–400 depending on project requirements. Output formats: RVT (Autodesk Revit), IFC (ISO 16739 open standard), NWD (Navisworks for clash detection), DWG (AutoCAD). For structural integrity analysis, we comply with ASME and EN 13445 normative frameworks. Point cloud data is delivered in E57 (ASTM E2807) open format.
3D Ultra connects to existing plant control infrastructure via OPC UA (open standard for industrial communication), MQTT (lightweight IoT messaging protocol), and OSIsoft PI System REST APIs. The integration is read-only by default, respecting the OT (Operational Technology) network security architecture of the mining operation. Data flows from field sensors through the existing SCADA/DCS infrastructure to the digital twin visualization layer, with no modification to the client's control systems.
Yes, through ConDrone (condrone.cl), 3D Ultra's sister brand under the MCCO Group. ConDrone operates DJI Matrice 350 RTK drones equipped with Mavic 3 Enterprise thermal cameras for volumetric surveys, stockpile measurement, tailings dam monitoring, and structural inspection of inaccessible areas including chimney exteriors, rooftops, and high-altitude infrastructure. Deliverables include georeferenced orthomosaics, thermal maps, and 3D photogrammetric models.
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