Professional Documents
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NEW Overall - Report - of - Dangote - Jit Hope
NEW Overall - Report - of - Dangote - Jit Hope
NEW Overall - Report - of - Dangote - Jit Hope
DECLARATION
Internship program is newly adopted in the educational curriculum of Ethiopia for engineering
students. It is given to students of fourth year and in the second semester (for four months). We
have done this internship program for four months in DANGOTE CEMENT (ETHIOPIA) PLC.
We declare that the project work entitled as ‘Design and Modeling of cement dust collector
machine’ is an authentic record of our own work carried out at DANGOTE CEMENT
(ETHIOPIA) P.L.C. as required for the four months internship semester for the award of
‘Internship evaluation’ under the guidance of our advisor Mr.Goftila and Ms.Kuleni from March,
2019 to June, 2019.
ADVISOR NAME: MR.GOFTILA AND MS.KULENI
Date …………………………….
Signature…………………………...
NAME OF STUDENT ID. NO SIGNATURE
ABDISA DIRRIBA..................................RU1751/08___________________________
BAYISA DINKU......................................RU0850/08___________________________
BELAY DEKSISA....................................RU1653/08___________________________
EBBISA AYYELE....................................RU1842/08 __________________________
TESFAYE ASSEFA..................................RU1585/08 __________________________
TESFAYE BEJI………………………….RU1336/08__________________________
ACKNOWLEDGEMENT
First of all, we like to thank GOD for the unlimited favor he has done for us while we were on
internship period. Next to that we thank Jimma University for preparing us and giving us the
knowledge we used on our internship stay. Also we like to thank Dangote Cement (Ethiopia) PLC
for letting us in.
Next to that we like to offer our heart full respect and want to say thank you to our advisor from
university Mr.Goftila and Ms.Kuleni. Also we like to send our special gratitude to Mr.Eyob,
Mr.Habtamu, Mr.Estifanos, our advisor from the company for helping us getting enough
knowledge about the company and there advice also the suggestion that they have been giving us
while we were doing our project. On the other hand, we like to thank our group members, those
have been working with us in the company where, we were assigned and the projects we have
done together for the ideas and knowledge’s we have share.
Finally, we like to thank the workers on DANGOTE CEMENT (ETHIOPIA) PLC for their
sociability in order to show us what they know in the shop. We know we didn’t say enough so we
want to thank everyone who has contributed on our internship stay.
EXCUTIVE SUMMERY
This internship report presents all works which have been done in …… company for the last four
months. At the beginning the report gives brief history of hosting company, the main products and
service, vision and mission of the company; the overall internship experience this includes how
we get in to the company, challenges we faced and measure taken in order to overcome those
challenges; the overall benefit we gained from the internship including improving our practical
skill, upgrading our theoretical knowledge, improving our interpersonal communication and about
work ethics and entrepreneurship skills.
Then the report also discusses about the design and modeling of cement dust collector machine
for easy way to collect cement powder. Cement dust collector machine is a machine that design
for collecting a dust which is very harmful for human to collecting manual or another mechanism.
It consists of many machine element parts and turbo machinery devices. Dust extractors vary
widely in design operation, effectiveness, space requirements, construction, and capital, operating
and maintenance costs. Each type has advantages and disadvantage. Dust collection technology is
taken lightly by the production or maintenance engineers of a manufacturing plant and they try to
fabricate a simplistic collector, which, unfortunately, never works. It is not uncommon for us to
deal with such customers who have either tried their own hands or have taken the services of a
back –yard fabricator for this purpose and have burnt their fingers. A purely
designed/manufactured dust collector might cost less to begin with, but it might cost a lot over a
short/medium term and may achieve absolutely nothing. Manufacturer, supplier of dust collecting
machines including dust extractor machine for collecting loose powder or dust from the polishing
chamber.
Finally, the result and discussion, conclusion, and recommendation for both hosting company
and University have been included in the report.
Contents
DECLARATION ................................................................................................................................................ i
ACKNOWLEDGEMENT ................................................................................................................................... ii
EXCUTIVE SUMMERY ................................................................................................................................... iii
CHAPTER ONE ............................................................................................................................................... 1
1. BACKGROUND ........................................................................................................................................... 1
1.1 History of Dangote cement PLC .......................................................................................................... 1
1.2 Dangote cement Strategy ................................................................................................................... 2
1.3 Vision, Mission and Value of Dangote Cement ................................................................................... 2
1.3.1.Vision............................................................................................................................................ 2
1.3.2. Mission ........................................................................................................................................ 3
1.3.3.Values ........................................................................................................................................... 3
1.4 Dangote cement PLC Products............................................................................................................ 3
1.4.1 Ordinary Portland cement (OPC) ................................................................................................. 4
1.4.2 Portland pozzalana cement (PPC) ................................................................................................ 4
1.5 Company’s Customers ........................................................................................................................ 6
1.6 Company’s Stake Holder ..................................................................................................................... 6
1.7 Organizational Structure of the Company .......................................................................................... 6
CHAPTER TWO .............................................................................................................................................. 7
2. OVERALL ABOUT INTERNSHIP EXPERIENCE .............................................................................................. 7
2.1 How We Get Into the Company .......................................................................................................... 7
2.2 Procedure Used While Performing Our Work Tasks ........................................................................... 7
2.3 The Section of the Company we have been working ......................................................................... 8
2.3.1 Back section ................................................................................................................................. 8
2.3.1.1 The quarry ................................................................................................................................. 8
2.3.2 Middle section............................................................................................................................ 11
2.3.3 End Section: ............................................................................................................................... 20
2.4 Our Performance at the Company .................................................................................................... 23
2.5 Challenges We Faced While Performing Our Work Tasks ................................................................ 24
2.6 Measures taken For the Challenges we faced .................................................................................. 24
CHAPTER THREE .......................................................................................................................................... 25
LIST OF FIGURES
Figure 1.1 Dangote Cement Factory overall view .......................................................................... 2
Figure 1.2 products of Dangote Cement Factory ............................................................................ 4
Figure 1.3 overall organizational structures of the company .......................................................... 6
Figure 2.1 Quarry ............................................................................................................................ 8
Figure 2.2 Hummer Crusher ........................................................................................................... 9
Figure 2.3 Stacker ......................................................................................................................... 10
Figure 2.4 Reclaimer ..................................................................................................................... 10
Figure 2.5 Vertical Roller Mill (VRM)......................................................................................... 12
Figure 2.6 Heat Conditioning Tower ............................................................................................ 12
Figure 2.7 Bag Filter ..................................................................................................................... 13
Figure 2.8 Homogenization Silo ................................................................................................... 14
Figure 2.9 preheater ...................................................................................................................... 17
Figure 2.10 rotary kiln .................................................................................................................. 18
Figure 2.11 hot clinker conveyers ................................................................................................. 19
Figure 2.12 Clinker Storage .......................................................................................................... 20
Figure 2,13 Cement mill ............................................................................................................... 22
Figure 2.14 Cement Silos .............................................................................................................. 23
Figure 2.15 Packing and Loading ................................................................................................. 23
Figure 4.1 Problem We Saw ......................................................................................................... 33
figure 4.2 v-belt pulley and rotary feeder ..................................................................................... 43
Figure 4.3 Shaft ............................................................................................................................. 47
Figure 4.4 Bearing ........................................................................................................................ 48
Figure 4.5 Wheel ........................................................................................................................... 49
Figure 4.6 Container ..................................................................................................................... 50
Figure 4.7 Bolt .............................................................................................................................. 50
Figure 4.8 Nut ............................................................................................................................... 51
Figure 4.9 Hopper ......................................................................................................................... 51
Figure 4.10 Handel........................................................................................................................ 53
CHAPTER ONE
1. INTRODUCTION
1.1 History of Dangote cement PLC
Dangote Cement is a subsidiary of Dangote Industries, which was founded by Aliko Dangote in
1981 as a trading business with an initial focus on importation of bagged cement and other
commodities such as rice, sugar, flour, salt and fish [1].
This cement plant is commenced project of US$ 500 million at Oromia regional state, West Shoa,
Ada’a Berga district, near Mugher town which is 80km from Finfinne. This establishing factory is
planned to produce 3000-5000metric tons per day or 2.5 million ton per annual. The company
began running in June 2015 where lying on 134 hectares of land and employs 1500 workers. It’s
one of the technologies in its nature, especially in mill technology as well as zero dust emitting
technology to the atmosphere. It will soon take its part of supplying cement into local and
international market with OPC and PPC so as to support cement demand to construction industries
[2].
Throughout history, cement materials have played a vital role and where used widely in the ancient
world. The Egyptians used calcined gypsum as cement and the Greeks and Romans used lime
made by heating limestone and added sand to make mortar, with coarser stones for concrete. The
renaissance and age of enlightenment brought new ways of thinking which led to the industrial
revolution. In 18th century Britain, the interests of industry and empire coincided, with the need
to build lighthouses on exposed rocks to prevent shipping losses.
A few years later, in 1845, Isaac Johnson made the first modern Portland cement by firing a
mixture of chalk and clay at much higher temperatures, similar to those used today. At these
temperatures (14000C-15000C), clinkering occurs and minerals form which are very reactive and
more strongly cementations [1].
While Johnson used the same material to make Portland cement as we use now, three important
developments in the manufacturing process led to modern Portland cement:
Development of rotary kilns.
Addition of gypsum to control setting.
Use of ball mills to grind clinker and raw materials.
1.3.2. Mission
To deliver strong returns to our shareholders by selling high-quality products at affordable prices,
backed by excellent customer service.
To help Nigeria and other African countries towards self-reliance and self-sufficiency in the
production of the world’s most basic commodity, by establishing efficient production facilities in
strategic locations close to key growth markets.
To provide economic benefits to local communities by way of direct and indirect employment in
all countries in which we operate.
To lead the way in areas such as governance, sustainability and environmental conservation and
to set a good example for other companies to follow.
1.3.3. Values
Customer Service: As a world-class organization, we understand that we exist to serve and
satisfy our customers. Accordingly, our customer orientation reflects intimacy, integrity and
learning.
Entrepreneurship: We continuously seek and develop new business, employing state-of-the-
art methods to retain our market leadership.
Excellence: We are a large organization, working together to deliver the best products and
services to our valuable customers and stakeholders. To achieve this, we demonstrate
teamwork, respect and meritocracy.
Leadership: We thrive on being leaders in our business, markets and communities. To drive
this we focus on continuous improvement, partnership and professionalism.
4. Raw grinding
The raw materials are very finely grinded in order to produce the raw mix.
5. Burning
The raw mix is preheated before it goes into the kiln, which is heated by a flame that can
be as hot as 2000 °C. The raw mix burns at 1500 °C producing clinker which, when it
leaves the kiln, is rapidly cooled with air fans. So, the raw mix is burnt to produce clinker
the basic material needed to make cement.
6. Grinding
The clinker and the gypsum are very finely ground giving“pure cement”. Other secondary
additives and cementations materials can also be added to make a blended cement.
7. Storage, packing and dispatch
The cement is stored in silos before being dispatched either in bulk or in bags to its final
destination.
CHAPTER TWO
2. OVERALL ABOUT INTERNSHIP EXPERIENCE
2.1 Our way to the Company
We have visited a number of industries which had negative responses before we joined
DANGOTE CEMENT ETHIOPIA. Most of the companies we sent our request letters were said
they have already accepted other students this was totally out of our expectation We get in to the
company by sending a letter, which was given to us by the Department; to the company’s human
resource office Mr. Tariku and he informed us that he will contact us later whether we got accepted
to work there or not. After two months later, we informed that we were accepted and that we may
come and start working with confirming letter from our universities. Then After that we go back
to the university and receiving the confirming letter from the industry linkage office of JIT, we
went to the company on the first weeks of April 2019(2011 E.C.). We were a two week late to start
that time due to some procrastination, and the postponing of our entrance date of JIT. Then we
contacted Training Centre Office manager of company Mr. Tamirat and he gave us a tempo ID
and other neccesary and mandatory material to our practice at the company.
In classifier above the grinding chamber the ground product is separated from the grit which then
falls back onto the grinding track for renewed grinding. This VRM have the capacity to grind
450t/h.
Working principle
The high temperature gas from the preheater are distributed by the gas distributing plates in
conditioning tower, then the gas thoroughly mix with atomizing water sprayed by high pressure
lances. As the high temperature gas flow through conditioning tower, temperature of the gas drops
while humidity of the gas increases and the specific resistivity of dust decreases, then the gas flows
into EP. When the gas is humidified, some clotted dust in exhaust gas deposits to the bottom of
the conditioning tower and then the dust is discharged out of conditioning tower by paddle
conveyor. Two double air-lock valves are set under the paddle conveyor, one valve is to discharge
dry material in normal operating condition and another is used in abnormal operating condition
that there is wet material in conditioning tower. To convenient for inspection, manual gate valves
are set at both the wet material outlet and dry material outlet.
Vibrators are set on the upper part and the lower part of conditioning tower to prevent large
quantity wet material depositing on the wall of shell and hopper.
happen very quickly at the same time in suspended situation. The CaCO3 decomposition of raw
material has already completed before going into the kiln.
Positive displacement compressors include piston type, vane type, diaphragm type and screw type.
But out of those we are mostly concentrates on screw type compressors, because the company
consists of only this type of compressor.
2.3.2.13 Clinker Storage
The clinker is transported by Deep Pan Conveyor from the clinker crusher to the clinker storage.
Deep Pan Conveyor has the ability of transport hot materials. Also under clinker silo there are
three, 3 Deep Pan Conveyor which are used to feeding the clinker to the belt conveyor.
from these silos by special Lorries designed for this interest. Otherwise the powder will be
transported to the packing stations.
CHAPTER THREE
3 THE OVERALL BENEFITS GAINED FROM INTERSHIPS
There are many benefits we have gained while internships. The benefits we have gained are in
terms of many points of view and some of them are as follows.
ask the function of each instrument and appropriate applications of each elements of the plants,
since they are better than us in practical knowledge.
When communication skill is improved, it is not difficult to advance team work skill during any
project work. There may be different problems are faced that cannot be solved with alone. When
this type of problem encountered, it is important and obligatory to communicate with others and
solve the problems easily.
Therefore, to work well together as teamwork with our colleagues, we have decided that to work
on our communication skills and they allow us as a team member to contribute. In doing so, we
have gained an opportunity of improving our team work skills for the remarkable teamwork sprite
(fairy).
In general, Team playing and trust go hand in hand; once a person has earned trust from his/her
colleagues (a person with whom one works in professions ) by being responsible he/she can be
able to build stronger teams by:
Clarifying team goals
Identifying the issues that prevent the team from achieving its goals
Addressing those issues and removing them so that the goals can be achieved
Can-do-approach to work
Money and power should be secondary, creating a great product or service should be
primary
CHAPTER FOUR
4. DESINGING AND MODELING OF CEMENT DUST
COLLECTOR MACHINE
4.1. Brief details about the study
4.1.1. INTRODUCTION
Dust collector machine is a machine that design for collecting a dust which is very harmful for
human to collecting manual or another mechanizim.it consists of many machine element parts and
turbo machinery devices. Dust extractor vary widely in design operation, effectiveness, space
requirements, construction, and capital, operating and maintenance costs. Each type has
advantages and disadvantage. Dust collection technology is taken lightly by the production or
maintenance engineers of a manufacturing plant and they try to fabricate a simplistic collector,
which, unfortunately, never works. It is not uncommon for us to deal with such customers who
have either tried their own hands or have taken the services of a back –yard fabricator for this
purpose and have burnt their fingers. A purely designed/manufactured dust collector might cost
less to begin with, but it might cost a lot over a short/medium term and may achieve absolutely
nothing. Manufacturer, supplier of dust collecting machines including dust extractor machine for
collecting loose powder or dust from the polishing chamber. Our cement dust extractor unit is used
to control the flying dust that is automatically generated during the shuttering of cement bag.
Controlling dust hazards and cross contamination at packing of cement plant, reducing mechanical
strain and balanced air blowing system are some of the ideal features of our dust extraction
machine.
Manual cleaning machine is a better alternative than automated cleaning machine at the time of
power crisis. Pedal operated body is used to achieve dry and wet cleaning concurrently.
The objective of the paper is to propose a machine having multiple benefits with minimum usage
of resources. This is based on basic principle of science; the project is a collusion of mechanical,
electrical and electronic devices. The multipurpose road cleaning machine can be used on different
roads in rural and urban areas. This machine resolves the issue of dusty roads, choked pipeline,
manholes, removal of metal particles from road and obstacles.
Dust collector of four wheeler has been designed keeping in mind the slinging of the road dust due
to vehicle movement. Considerable fraction of PM10 in urban air is usually due to non-exhaust
traffic emissions and sling from the street surfaces. These road non-exhaust emissions are
generally uncontrolled and detail about the productiveness of alleviation measures on paved roads
is still scant. The main objective is to design and fabricate a collector system for high clearance to
reduce the level of non-exhaust emissions to some extent. The model consists of a centrifugal fan
to absorb dust before it open out and pollutes the air, which is to be placed on and above the rear
side of the wheel. This system will help in controlling and reducing the dust concentration behind
the vehicle.
Also transport of pieces of parts and equipment from bottom to top floor and vies versa
for maintenance is difficult.
Most of the time; the roller are cracked at its back edge when it is at the work. Because of
this; the roller are want to maintenance in short period of time. This maintenance makes
the decline business of company.
Many powders and bulk solids that flow through hopper also have a property known as
“cohesion” which means that after they have been subjected to pressure, such powders can
form an “arch” or “rat-hole” or “caking” inside a vessel, preventing discharge and
requiring the action of hammering popularly known as “hammer rash”, vibration, aeration
or other methods to promote flow.
Here we tried our best to overcome the first two problems at once from the listed above by
designing the cement dust extractor machine.
4.1.6 OBJECTIVES
General objective
The main objective of the project is to design dust collecting machine for packing plant area.
Specific objectives
To protect the production equipment from the dust.
To protect the job from the effects of dust.
To design the 3D model of all component of machine and assembly of the completed
machine.
To simulate the machine to show its working principles.
To decrease the operational cost of device by using new mechanism and reduce the price of
machine.
4.1.7. METHODOLOGY
During the design process, several different manual dust collecting mechanisms were considered.
The merits and faults of each approach were examined and some preliminary analysis was done.
In the end the automatic dust collector mechanism was chosen as the most fitting for the scope of
this particular project. The data’s we use in our calculation are collected by different methods of
data collection. These are:
1. Primary source
Direct observation
Interviewing employees of different expert
2. Secondary source
Reference
Different websites
3. Data analysis tool
SOLID WORKS software
Mostly we concentrate on the primary source of data to achieve our design appropriately by;
Asking technicians about problems of the company
Identifying the problems in the company
Understanding operation principles of the machine
Identifying part components which are needed for the machine
4.1.9.APPLICATION
This dust collecting machine have many application area those are:-
Cement Industry
Asphalt Industry
Quarry and Minerals Industry
Pharmaceutical Industry
In the cement Industry it used to: -
To remove dust powder from the packing area
To suck a small particles of dust which have high pollution for environment
It can collect other solid trashes.
To produced partly pressurized and purified air.
To store the dust
To transport the material.
4.1.10. Advantages
•Modular design provides optimum field flexibility and short manufacturing lead time -
have it your way fast
•Heavy duty carbon steel construction for long life.
•Due to the filtration bag small Dust also can be collect
Due to bag house we will get pure air from inlet air for environment
•Available in standard unitary type models & custom based specially designed models for
CDE
•All the units are designed & manufactured as per GEP & GMP
•Available in Single skin/Double skin & MS/SS construction.
4.1.11. Limits
Can’t be use in heavy Duty application.
Noise produced due to the rotor & motor
Rotor is the heart part of automatic cement dust collector, by rotating rotor at high speed the air is
sucked ,the rotor is provided with 12 number of blade each having angle of 20 degree .the inner
and outer diameter of rotor are 120mm and 200mm respectively .motor is used having power of
5hp and 3600 RPM.
Blower Fan
Blower is used for the suction purpose. The main function of the blower is to suck the dust
powder from the floor through intake manifold. Blower is designed according to required suction
capacity.
Filtration Bag
Filtration bag is used to filter the big dust particles of the powder. Some of the small dust
particles is stick with the filtration bag and there after with the help of stapper all the particles
which is sticked to the filtration bag is collecting at the dust collecting hopper.
Castor wheel
Castor wheel is provided at the bottom of the machine to make the machine movable. with help
of caster wheel machine is easily transport by pushing the above handle.
N=speed of rotor
𝜋D1N 3.14𝑥0.12𝑥3600
(U1)= =
60 60
(U1)=22.619m/s
SECTION 1.2: VELOCITY OF AIR =V(M/S)
Velocity of air (V)=U1tanɵ where: ɵ=vane angle, U1=velocity of vane
(V)=22.619xtan20
(V)=8.233m/s
SECTION 1.3 : SUCTION CAPACITY (Q)
Suction capacity(Q)=πxVxD1xB Where : V=velocity of air
D1=inlet diameter
B=width of the vane
(Q)=πxVxD1xV
(Q)=3.14x8.233x0.12x0.06
Suction capacity(Q) = 670.068m3/hr (11.167m3/min)
Belt is a component which is used to connect the rotor feeder and motor.
The parameters for the belt design are:
Permissible force 1000N
The average speed 1.4m/s.
Diameter of the pulley on rotor feeder is 20mm
Input power required from belt to rotate the rotor feeder
Pin = FV
1000×1.4 = 1400W
Let diameter of rotor feeder, 𝐷𝑅𝐹 =20mm
𝑉 1.4
Angular velocity of the rotor feeder = ωRF = =10𝑥10−3 =140rad/s
𝑅𝑅𝐹
Angular velocity of the rotor feeder ωRF is equal to angular velocity of driver pulley on it (ωp1)
ωp1 =ωw = 1 40rad/s
2𝜋𝑁
But ωp1 = ;
60
ωp1×60 140×60
Np1 = = = 1338rpm (Rpm of driver pulley)
2×𝜋 2×3.14
Np2 =668rpm
1.Design Power:
DP = SF×Pin
SF is service factor. Since the design power is minimum for fan than given by standard table.
The service factor chosen the minimum from service factor table SF =1.
DP = 1×1400 = 1400 W
2.Select belt type
Table 4.1 dimensions of standard V-belts according to IS:2494-1974
2.Speed Ratio:
5.Rated Power:
From standard table using pitch diameter the rated power is 2611watt (since pitch diameter is
small rated power is selected)
Rated power (RP) = 2611W
Graph 4.1 Variation of rated power per belt. hp Vs smalt sheave pitch diameter.in
6.Total Power (TP):
First let’s find power added to rated power using speed ratio from standard table.
2235+√22352 −32(75−20)
So Cact= = 279mm.
16
Graph 4.3 variation of angle of wrap correction factor Vs angle of wrap, degrees
2𝑁𝑀𝑡
Power P= 60
2𝑥3600𝑥𝑀𝑡
3730= 60
Mt=10Nm=1x104 Nmm
Since both shaft and pulley are mounted on the same shaft torque is the same.
Total torque on shaft.
𝑇1
Mt=(T1-T2)RD=T1(1-𝑇2)RD
1
10000=T1(1-3)x37.5
𝑇1
T1=400N since =3
𝑇2
T2=133N
Tangential force acting on the gear.
2𝑀𝑡 2𝑥10000
Ftg= 𝐷𝑔 = =333N
60
Where ; L1=250mm,L2=250mm,L3=250mm
CONSIDER VERTICAL LOAD ONLY
Let RCV and RAV reaction forces at A and C
RCH=860.5N
For equilibrium condition
RAH+ RCH=122+533
RAH= -205.5N
BM at (A and D) =0
BM at B M@BH=RAHx250=-205.5x250
MBH= -5.14x104 Nmm
BM at C M@CH=250x533
MCH=1.3325x105 Nmm
Mb@c=√(1.66𝑥104 )2 + (−5.14𝑥104 )2
Mb@c=5.4x104 Nmm
Resultant BM at C
Mb@c=√(𝑀cv)2 + (𝑀𝑐ℎ)2
Mb@c=√(5𝑥104 )2 + (1.33𝑥105 )2
Mb@c=1.423x105 Nmm
D=19.7mm
The nearest standard diameter of shaft is
D=20mm
So the result d=20mm
1 Rubber/concrete 0.85
2 Polyurethane/Concrete 0.5
3 Steel/Concrete 0.45
Assumption
Nut may experience tensile stress
Material selection
We select the same material as the bolt.
𝜎𝑦 250
𝜎𝑎𝑙𝑙 = = = 125𝑀𝑝𝑎
𝑓. 𝑠 2
𝐹 4𝐹
𝜎𝑎𝑙𝑙 = = 2 2
𝐴 𝜋(𝑑𝑛 − 𝑑𝑏)
𝐹 25000
𝑑𝑛 = √4 ∗ + 𝑑𝑏 = √4 × + 16𝑚𝑚
𝜋 ∗ 𝜎𝑎𝑙𝑙 𝜋 × 125 × 106
= 31.96mm ≅ 32𝑚𝑚
V=220mmx220mmx400mm=19360000mm3=19360cm3
Area of lower part
we can find the area of this part by dividing into three define shapes those
are 2 triangle and one rectangular defined shapes.
Area for triangle shapes =1/2xBasexHeight(1/2xbxh)
A=1/2 x80x300=12000mm2=120cm2
we have two rectangular shape so we multiple our result by two
A=2x120cm2=240cm2
Area for rectangular shapes
Area=basexheight(bxh)
A=60x300=18000mm2=180cm2
Area of shutter
-Area of shutter is rectangular area
A=wxl=60x60=3600mm2=36cm2
-Volume of the shutter
V=wxlxh=60x60x100=360000mm3=360cm3
These Dust Extractor Machine successfully capture dust with the air stream and convey it to the
dust collector. when the rotor is start rotating the blade mount on the shaft of the rotor is also start
rotating with the rotary shaft. Then the rotation of this blade makes the pressure difference between
the inlet of casing and the atmosphere. We know that any things flows from low pressure to high
pressure. So in case of the pressure difference between inlate of the casing and atmosphere the air
and the dust start sucking to the tube (inlet of the casing). There is bag filter at the inlet of the blade
it is used to felt the air and dust. So the dust and air is stay on the bag filter before interring into
the blade. After this the bag filter passes the air through it and protect dust. There is a rotary feeder
devices at the bottom of the hopper and at the inlet of the container.this device is used to lock air
and transfer dust to the container . the protected dust by the bag filter is pass by the rotary feeder
into the container.
piece, a softer material such as aluminum or bronze is utilized. Pipe bending machines are typically
human powered, pneumatic powered, hydraulic assisted, hydraulic driven or electric servomotor.
We have employed pneumatic system bending tube with the diameter of 20mm
4.5.3. Welding
Welding is a fabrication process that joins materials, usually metals or thermoplastics, by causing
coalescence. This is often done by melting the work pieces and adding a filler material to form a
pool of molten material (the weld pool) that cools to become a strong joint, with pressure
sometimes used in conjunction with heat, or by itself, to produce the weld. This is in contrast with
soldering and brazing, which involve melting a lower melting-point material between the work
pieces to form a bond between them, without melting the work pieces.
Many different energy sources can be used for welding, including a gas flame, an electric arc, a
laser, an electron beam, friction, and ultrasound.
While often an industrial process, welding may be performed in many different environments,
including open air, under water and in outer space. Welding is a potentially hazardous undertaking
and precautions are required to avoid burns, electric shock, vision damage, inhalation of poisonous
gases and fumes, and exposure to radiation. The main Types of welding used in industry and by
home engineers are commonly referred to as MIG welding, Arc welding, Gas welding and TIG
welding.
Permanent fastener is a type of fastener that used for a long time and doesn’t reused. we talk
about a permanent fastener in the above those are welding and other.
Temporary fastener is a type of fastener that can be reused and it’s movable. This type of
fastener is bolt, screw, nut.
We choose temporary fastener to
Fastening motor with container
Fastening blade with the rotor shaft
To fastening the two part of casing
4.8.2. DISCUSSION
Our machine is designed to replace the manual dust collecter machine wich is very harmful for
human and material. Dust extractor vary widely in design operation, effectiveness, space
requirements, construction, and capital, operating and maintenance costs. Each type has
advantages and disadvantage. Dust collection technology is taken lightly by the production or
maintenance engineers of a manufacturing plant and they try to fabricate a simplistic collector,
which, unfortunately, never works. It is not uncommon for us to deal with such customers who
have either tried their own hands or have taken the services of a back –yard fabricator for this
purpose and have burnt their fingers. A purely designed/manufactured dust collector might cost
less to begin with, but it might cost a lot over a short/medium term and may achieve absolutely
nothing.
CHAPTER FIVE
CONCLUSION AND RECOMMENDATION
5.1. Conclusion
In general, Various types of orientation programs, tasks, and trainings that we have been under
taking during those past four months on site and in the office boosted our knowledge in many
areas. This session of intern ship has not been only about theoretical knowledge but also about
learning how to interact with the people that work around us. We have learned how to handle those
different problems that may arise around us. During this internship, even outside the compound of
the company, we have been gaining knowledge on how to live by ourselves. Almost all of us have
gone far away from our hometowns to do this internship. Due to this we have been able to see
what the world look like for a worker living by his own in cities. We have learnt how to manage
our money, differentiate between our needs and wants. Learning how to work together with
different kinds of people and sharing information is also a part of this internship. The company is
composed of so many departments that we had to be dispersed one student at a point in order to be
able to get as much knowledge as we can. Even then we were not able to see everything
conclusively, even with four month to spare. Therefore we needed to work at different parts of the
company and convey the information that we got each day. Through this we have acquired the
ability to express what we have seen and done to each other. Theoretically we have been able to
upgrade the knowledge that we have been able to acquire during our stay in university learning
something while seeing it practically is easier than learning in theory only. In company like
Dangote cement industries one can get so many varieties of ideas, even on a practical field. On
one machine, one can see an action done by some mechanism and on another machine the same
action might be done by some different mechanism. Therefore in accompany like this one can
perceive different ways suitable to the condition needed.
Internship program provide us many knowledge and experiences in many ways like: -
The spirit of working together and cooperativeness
Communication & interaction with colleague
Gave us the chance to change theoretical knowledge to practical or real knowledge
The ability of making decisions and taking responsibility
The skill of giving a solution for specific Problems
5.2. Recommendation
As internship program gave an opportunity to change the student to change theoretical knowledge
into practical or real world and exposes the student to exercise the real world life, we strongly
recommended to be continue in a manner that it achieves its goal.
Furthermore we recommended dangote cement plcs the following points .
Dangote cement plc should;
In order to increase accuracy and durability of maintained components, the company
should implement the use of CAD software’s like Solid works and Catia.
In order to decrease time consumption on collecting dust and to protect labors health at
the company the company should implement the dust collecting machine.
Using older machines does not make competent, so the company has to use latest machines
such as CNC machines to become successful company regardless of time management
and upgrading its production capacity.
Finally, our design of a dust collector has to be implemented to solve problem that the
company facing and increase productivity by reducing labor.
Jimma University should;
Follow our internship projects whether they are manufactured or not if they are
mandatory to manufacture.
Communicate with workshop and maintenance office of company to help the students
to expand their capacity by designing new machine, modifying the existing machine
and also implementing designed machine for the company to reduce the extravagance
of costs on maintenance to overcome related problem identified in company.
Give workshop course for students to increase effectiveness and advise them during
construction.
Support the company’s on constructing designed star climbing hand trolley machine
and other easy way of material transportation.
Fulfil the materials required for the construction of machine
Reference
[1] Training for Dangote Ethiopia cement project,2015, introduction of cement manufacturing
Appendix 1