In the middle of the Atacama Desert, 59km (37 miles) from Calama in northern Chile, the Cerro Dominador Solar Plant rises as a symbol of renewable energy innovation. Its 230m (755ft) receiver tower, the second tallest structure in the country, concentrates sunlight in order to heat molten salt to more than 560°C (1040°F). To maintain efficiency and protect the system, the receiver tubes that form the tower’s outer surface must be cleaned and repainted every two years.
This project required the preparation of 1,200m² (12,917ft² ) of Alloy 625 tubing at an extreme height. The tubes, previously coated with paint, needed to be restored to an SSPC SP-5 "White Metal Blast Cleaning" with a consistent 50μm (2 mils) profile to ensure coating adhesion and a reliable thermal transfer. Completing this remote access work at this height in the harsh desert environment presented significant technical, safety, and environmental challenges.
Abrasive blasting with steel grit or copper slag was evaluated but quickly rejected. These abrasives could not deliver the specified profile on the hard alloy and presented safety risks due to the project's unique staging. Rebounding abrasive particles common with these types of blasting threatened to cut suspension ropes, while dust pollution posed a serious environmental hazard in one of the world’s cleanest desert regions. From an economic standpoint, the inefficiency and cleanup demands of these systems made them unviable.
The solution came in the form of
Sponge-Jet Silver 60 Sponge Media™, an abrasive capable of profiling metals as hard as Alloy 625 while dramatically reducing dust and rebound. Average production rates reached 3-5m² (32-54ft²) per hour, balancing precision with efficiency. The pliant sponge particles reduced rebound, lowering the risk to operators working 230m (755ft) above ground, while the near-dustless process protected the environment and surrounding power generation equipment.
The results were a complete success. The team achieved SSPC SP-5 cleanliness across all 1,200m² (12,917ft² ), with a uniform profile that ensured strong coating adhesion. The prepared tubes now provide maximum thermal transfer, essential for efficiently heating molten salt to operating temperature. Compared with traditional abrasives, Sponge-Jet delivered faster results, improved safety, and virtually eliminated negative environmental impact.
The Cerro Dominador maintenance project illustrates the clear advantages of Sponge-Jet over other blasting methods. It enabled reliable surface preparation under extreme conditions, safeguarded workers at high altitude, and protected the Atacama’s pristine environment. By combining technical performance with environmental responsibility, Sponge-Jet Silver 60 has once again proven to be the preferred choice for complex and high-risk infrastructure. At one of the world’s most advanced solar power plants, this technology played a critical role in sustaining efficiency and supporting Chile’s growing leadership in renewable energy production.