Dangote final report

CHAPTER ONE
1. Introduction
1.1Objectives of internship
 To practice and apply theoretical knowledge in class to the real world and
work environment.
 To learn and understand the importance of safety and their uses in work
environment.
 To learn work ethics in work environment.
 To know and habituate smooth relationship as well as tolerance between
different staffs.
 Truly to understand and note the purpose and significance of each operation
in the mechanism of industry.
 To develop self-confidence of interns in work environment to decide their
decision from what they understand.
 To learn how to maintain, restore and increase life span of machine
component in work environment by using appropriate maintenance type.
1.2 Scope of work expected
It is expected that this internship is include all valuable and important things for
interner.
Because interns will know and practice how:
 To enhance personal and professional network
 To develop skills through encouragement and feed back
 To Access to new perspectives,borderview of the industry
 To interpret their theoretical knowledge into practice.
 How the interns share different knowledge from different staffs
and other interns that are important for their future career goal.

The output expected is almost seemed with the scope of work expected. Because what
expected is almost done.

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1.3 Background of the organization

Dangote cement Ethiopia (PLC) is located at Oromia Regional state, West Shoa zone in
Adeaberga woreda around mugher town, 85km west of Addis Ababa.
 The factory lies on 134 hectares plot of land and its construction was commenced in
March 2012. Then it was completed at the mid of 2015.
 The factory was established by foreigner privacy owner called Alico Dangote.
 This factory is the most modern industry and which is create work opportunity for
many staffs and labour worker.
 Its construction was built by Sinoma international Engineering, a giant Chinese
construction firm.
 Sinoma international is a leading cement factory construction contractor.
 The factory is the biggest and modern cement factory in east Africa region and it has
the capacity to produce 2.5 million tons of cement per day.
 The construction of this company was completed by 12 billion dollar budget and start
production on June 2015.
Dangote cement industry produce two types of cements. Those cement are namely;
1. ordinary Portland cement (OPC) and
2. Pozzolana Portland cement (PPC).

1 ordinary Portland cement (OPC):

 It is the cement type produced by this industry and its typical composition
is 85% clinker with 15% gypsum and high grade lime stone which is
added as an additive to enhance the setting time of the cement.
 OPC is in most case used in constructions like dams, bridges, strong
ground and in construction of large building.
 It differ from other types of cement by having high cost, it will be fast,
shorter setting time, and low alkality. On the other hand the use of this
cement is; for construction and flooring.
 When water is mix with ordinary Portland cement, its takes some hours to
settle and gradually hardens and increase in durability.

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2 Pozzolana Portland cement (PPC):

 Portland pozzolana cement is the second type of cement produced by

dangote which has chemical composition of 85%clinkerwith 15% gypsum
and pumice. This pumice is has no extra uses rather than increasing the
quantity of the cement produced.
 PPC is the result of adding pozzolanic or similar materials such as;
volcanic ash, silica, clay, slage, and shale. This type of cement also differ
from other cement, by its lower cost, high durability, high workability.
 It composition is 65% clinker, 30% pumice and 5% of gypsum.
 But, it gives the same result for long period of time. The advantage of this
cement is; longer setting time makes it more workable than ordinary
Portland cement (OPC).
 Portland cement is distinguished from other kinds of commercial cements
by different phases of which it is composed, and the meeting of particular
standard specifications laid down by established authorities

This industry uses raw material like lime stone from quarry that found there and also clay.

Other raw material like pumice from meky around east shoa while gypsum and sandy from
other place.

Raw material like coal which used as fuel for burning of raw in rotary kiln is imported from
Djibouti.

1.4 Mission of the organization

 Being competent in global market.
 Being an exemplary company in a country.
 To assure its existence and become a profitable company and sustainable basis
and support continuously growing for contraction industry with supply of
contractions of acceptable quality and reasonable price.
 Supporting of nearby community by providing personal needs such as light,
water, road etc.

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CHAPTER TWO

2. Management ,training and employee information

In this industry to suit for management, they manage staffs, work environment, and resources
by classifying to different department.so that, we were assigned under mechanical
department for everything we expected to do.

Under mechanical department we were given duty to practice, visit, and learn the operation,
systems, and method of working in all over the industry.

As mechanical department staffs in this department were assigned to different station

individually. So that, we oriented well and guided by staffs those assigned to their individual
station of the industry.

Department head and our company supervisor arranged to each week the order for their staffs
to train, guide, teach and share their knowledge as well as different ideas about the station
they were assigned for us.

Generally we accomplished our task during internship in accordance our advisor and
department head programmed for us to each week.

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During our internship our supervisor help us by assigning staffs who guide, train, teach us
during our job and also who share his knowledge for us.

We develop qualities like:

 How to operate different machine like: crusher, fans, mills, stackers, rotary kiln
cooler, filters and loaders etc.
 How to maintain failed component.
 How to produce new component in work shop to replace the failed component.
 The purpose and uses of each machines and their individual operation.
 Types of maintenance and how to use them.
 How to minimize loss of profit (product) due to failed component.
 Identification of component that is going to failed.
i.e. before it failed and cause for hazardous danger, how know whether the
component is on the way to fail.
 How technology is important in industries to reduce number of labor worker, staffs,
cost and also save time.
e.g. Sensors, actuators etc.
 How to control automatically operating machine only in CCR.
 Cement processing technique.
 How we can transport material from station to station or from machine to machine.

As a mechanical student I observe and understand the operation and uses of different
mechanical component.

2.1 SOME MACHINES AND MECHANICAL COMPONENTS OF THE

DANGOTE CEMENT PLANT

2.1.1 Raw mill

Raw mill is a mill that grounds raw material which is further processed in preheater to
prepare clinker.

The major Components of this raw mill are:

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 Driver (motor)
 Coupling (both input and output coupling)
 Gear box
 The six rollers that are evenly distributed around the table to grind the raw material.
 Rotating table that the rotating roller is grind the raw material on it.
 shafts

2.1.2 Fans: this machine is a machine that used to suck dust particle (material) from one
and also pump to the other direction. The main component of this machine are:

 Driver(motor)
 Coupling (both input and output coupling)
 Gear box
 Blade which can pump air or dust particle.
 Pipe or duct used to transport air and material.
2.1.3 Material transporting systems and their mechanisms: this are the
systems or combination of machines that are used to transport material from
station to station or from machine to machine. These are:
a. Belt conveyor: it is used to transport raw material and clinker where the
temperature of material is almost low. This material transporting system has the
following component:
 Belt: it is made of plastic and has closed loop.
 Idlers: is made of metal and they just simply rotates as roller
They used to reduce friction of belt and regulate smooth motion for belt.

There are four types of idler. Those are:

i. Self-adjusting idler: it used to adjust the belt not to leave (jump)
from its line while working.
ii. Shock (impact) idler: it is used to decrease vibration of belt by
consuming vibration energy when material is exit one belt and drop
on the next belt.
iii. Return rubber (self-cleaning) idler: this used to clean part the belt
that is being return at the bottom.

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iv. Normal idler: this used to reduce friction of belt because it is rotate
as the roller and regulate smooth motion for belt.
 Driver (motor): located at the head of the belt and it is connect to gear box by
shaft to drive other component.
 Couple: is a point where two shaft driver and driven shaft are coupled
(connected). It may be input and out couple.
 Gear box: is a box that has a collection of gear those has different size and
types of gear which used to change speed and direction of output shaft.
 Pulley: located at belt head connected to the driver to drive belt
 Snap pulley: located at belt tail and used to reduce friction and smooth
motion of belt.it is where the belt return back.
 Bearing: it is used as roller to decrease friction of pulley shaft when rotating.
 Sensor: is an electrical component that used to sense whether belt is leaving
its line motion .it send message to CCR when there is problem on motion of
belt for correction.
 Emergency wire: it is a wire used to lock (stop) the motion of belt when there
is a problem.

b) Bucking elevator material transporting system:

 Is one of the material transporting system which is used to transport material at

elevation or at height vertically.
 It has chain and bucks tighten on it .the bucks moving up are take material and drop it
and then return empty.
 It has driver (motor), chain and bucks.

c) Air slide material transporting system:

 Is one of the materials transporting material and it is inclined at 8o to 11o.

 The material will vibrate and slide down when the air is blown up at the bottom.
 This types of material transporting system transport dust like particle.
d) Deep pan conveyor: this transport system is to transport material that has hot
temperature coming out of cooler to store clinker in clinker silo.

2.2 Some mechanical component

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 Gear: Gears are toothed, cylindrical wheels used for transmitting motion and power
from one rotating shaft to another.
In this industries we understand that depending on their axle arrangement gear can be
classified as follows:
1. According to the position of axes of the shafts.
a. Parallel: we use this types of gear when driver and driven are shaft are parallel
each other.
1. Spur Gear
2. Helical Gear
3. Rack and Pinion

1 spur gear 2 helical gear 3 rack and pinion gear

b. Intersecting: we use this types of gear when driver and driven are shaft are
intersecting each other.
 Bevel Gear

Fig Straight and Spiral Bevel Gears

c. Non-intersecting and Non-parallel

 Worm and worm gears

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Fig .worm and worm gear.

2.3 Lubrication types and their uses

Lubrication is fluid or solid that applied to mechanical component on work to reduce
whether friction, wear and heat generation.
Depending on their state there are three types of lubrication. Those are:

1, liquid lubrication: this types of lubrication has liquid state. Many this types of lubrications
are use in gear box.

2. Semiliquid lubrication: this types are neither liquid nor solid and they used for
rotating shafts at joint and also, between meshed gear etc.
Eg. Greece
3. Solid lubrication: they are solid in state
 It is use between rotary kiln and roller support.
Eg .graphite.

CHAPTER THREE

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3.1. Specific job information during internship

During our intern ship we have a duty to visit and learn the work station that we
ordered to visit and work daily.
 Since the the company is cement producing industry, we visit and learn different
mechanisms in the industry and and also method of cement manufacturing process.
 Cement manufacturing is almost common in most cement industry.sothat we also
learn and experience the same thing in this company.

3.2 Primary Raw Materials and Cement Processing

3.2.1 Raw Materials

In cement production there are three primary raw materials; those are:

 Limestone (Caco3 rock)

 Corrective material (Clay & sand)
 Additive Material (Gypsum & pumice)

3.2.2 Limestone (Caco3)

 Limestone contain commonly calcium carbonate (Caco3)

 Used to producing cement
 It can be decompose in pre calciner in to calcium oxide and carbon dioxide

Caco3 heat CaO + CO2

3.2.3 Corrective Material (clay &sand)

 Is a material added to primary raw material (i.e limestone) , when the primary raw
material do not jointly permit achieving the desired range of module value.
 It has been a practice to recognize that a material with more than 70% silica, 40% iron
oxide, or 30% alumina can be termed as siliceous, ferruginous, or aluminous
corrective materials.
 Sand, sandstone, or quartzite acts as the source of siliceous corrective material.

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3.2.4 Additive Material (Gypsum and pumice)

 Both are added to a clinker by percent to produce two types of cement; Namely
pozzolana port land cement (PPC) and ordinary port land (OPC) cement.
 To produce pozzolana port land cement these two raw materials (i.e gypsum and
pumice) are added to clinker, But to produce ordinary Portland cement (OPC) only
gypsum is added to clinker.

3.3 Cement producing process

The process that is very important in cement processing is dry process. Dry process is the
grinding and mixing of raw material in their dry state. In dry process the material are
separately crushed and ground in suitable machine and dried. These are then mixed in proper
proportion, pulverized in ball mill and finally homogenized, that means dried. On the other
hand the fuel consumption is low, cost of producing cement is comparatively less, but it can
only be used when the raw material are quite hard. The raw materials are crushed and fed in
the correct proportions into a grinding mill, where they are dried and reduced in size to a fine
powder.

3.2.1 The main step in cement processing

 Step-1: in this step the raw material, i.e limestone is dig out from its natural
place by using exploding material such as ‘’FENJ’’. The quarried limestone
is normally in the form of big boulders, ranging from a few inches to meters in
size. This varying size of Limestone needs to be crushed to a size of about
10mm in order to be prepared. So it can be transported to hammer crusher
machine by using manual cars to be crushed. Limestone coming out of quarry
is crushed in multiple stages in sizing plant before it is put in Lime stone stock
pile.

 Step-2: After the coming out limestone is prepared in proper size, it can be
transported to the raw material store through belt conveyor. By the way as our
guide told us: there are about four storage for the raw material. Those are :
Limestone (caco3) storage
Corrective material (clay & sand) storage

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Additive material (Gypsum & Pumice)

storage
Coal storage
 All raw materials can be stored according to their identified storage.
 The machines used to store these raw materials are called stacker. It contains
its own belt called stacker belt. This belt is used to move from place to place as
the material is not stored at one place.
 There is also a machine used to take a stored material and give to a belt
conveyor which is called declaimer. Then the belt conveyor is taking the
material and transport to the required place.

 Step-3: Proportion of Raw Material: All of the raw materials are must be
proportionate to produce cement. From This material Lime stone is required in large
amount. The proportions of raw materials are as follows: Lime stone 80%, clay 11%,
and sand 9%. These proportionate are not constant It determined by computer
controlling room(CCR).Before the proportionate the raw materials are stored in the
hopper. There are four hoppers: two for limestone, one for clay and one for sand. Each
hopper has its own capacity to store the raw material; 600 tone for each lime stone
hopper and 200 tone for clay and sand hoppers.

NB The machine used to proportionate this raw material is called dosimal feeder.

During the filling of raw material to hoppers in proportion station, both sandy and
clay are transported by theme belt from storage. But, at separated time after one is
filled, the other is filled one after another.

After all raw material proportionate it’s transported by belt to raw mill to ground it to the
required grain size.

During material transporting from proportion station to raw mill, there are the place where
unwanted like metals, should be extracted from raw material. This metals are ferrous metals
and non-ferrous metals.

I.e. ferrous metals are taken away from the belt by strong magnet and non-ferrous metal are
sensed by non-ferrous metals sensor and taken away from the belt again. Passing this the
material leave the belt and enter to raw mill station.

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 As we seen that even if the material again impurity like a metal before, it is
sensed by the sensor and this material taken away from the right way that this
material should be cleaned by magnetic separator and non-ferrous by closing
the plate valve to this way automatically by actuator using massage from the
sensor.
 This material is re cleaned and returned by bucking elevator to the material
which is cleaned of metal impurity and have been transported by another belt
to the raw mill and enter to the raw mill together with each other.
 Everywhere around the material flow, the place where the material leave one
belt to another, there is a pipe or a duct that suck a dust material to a filtering
system.
 To perform the sucking system there is the fans that adjusted to the required
position and direction for the operation.

 Step-4: After the raw material is properly proportionate it directly go to raw mill by
belt conveyor for grinding.
 Before starting grinding in raw mill the raw material must dry by using hot air
that come from the burning coal in pre heater through pipe or duct. After the
raw material is dry the grinding process start in raw mill.
 This grinding is done using either ball mill or vertical roller mill (VRM). The
raw material is simultaneously dried. Vertical roller mill uses the compression
principle to grind the raw material.

After the raw material is grind in raw mill, the grounded material stored in the storage called
raw mill silo. This raw mill silo can be described as follows:

No Designation Data and type

1 Capacity 20,000 tone

2 Inner diameter 22.5m

3 Height 42m

4 Permitted moisture of raw meal (%) 0.5%, max 1%

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5 Total aeration area for silo 133m3

Fig 2. Raw mill silo

Raw meal from the elevator is fed into raw meal distributor on the top of the silo, then it is
Conveyed into the silo via 8 air slides. The aero boxes are fully arranged on the silo bedplate.
According to the requirements, they form some aeration areas on silo bottom. There is a
conical central chamber at the middle of silo. Out of the chamber is outer annular area. Raw
meal is feed into the central chamber from the outer annular area, then is discharged into the
silo bottom discharging device. The raw meal quantity fed to the weighbin is adjusted and
controlled by pneumatic switch valve and motorized flow valve. In total process, at first, raw
meal is laid in the silo as even layers. When raw meal is fed into the central chamber, aero
boxes of outer annular area aerate at only one area, so it results in gravity mixing and cutting
and loosing material beds above it. Then the raw meal is fed into central chamber, raw meal
is intensively mixed by aerated flow in central chamber. There is a sufficient pneumatic
mixing for raw meal after the gravity mixing, at last realize the homogenizing purpose.

 The raw meal homogenizing silo is mainly composed of raw meal distributor, silo
inner aero boxes, silo bottom discharging device, inner and outer aeration system of
the silo and measuring device to control raw meal quantity and so on.

NB This silo can measure the production line of clinker.

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 After all above mentioned process accomplished and the raw material stored in raw
mill silo, the material is transported to pre-heater or pre-calciner by using bucking
elevator for further process.

 Step-5: Pre- calcination: Preheater and Calciner complete the preheat of the raw
material and the decomposition of the calcium carbonate.

 The decomposition rate of the raw material before entering kiln can amount to 90%
above.

 The kiln can mainly complete burning (calcination) function, so the size of the kiln
can be smaller. Positive as it does, Preheater and Calciner is key equipment of the
clink calcination. It relates to the stabilization of the burning schedule and increase of
the quality and quantity directly.

 The most important activity in cement manufacturing is clinkering (burning of raw

material) clinkering takes place in the cline and pre heater system.

 Pre heater system offer heat transfer from the hot cline gases. Preheater Cyclonepre
heater enable the raw material of cement production to be preheated before entry into
the kiln. This increases the energy efficiency of the kiln as the material is 20-40%
calcined at the point of entry into the kiln. .

 In the pre heater tower the raw materials are heated rapidly to temperature about 340
degree Celsius. The main advantage of calcinary system is to decompose the raw
material Lime stone (CaCO3) to CaO and Co2 by using excess hot from the kiln and
from the coal. The target of preheater modification:-increase production capacity,
reduction of specific heat consumption, improve kiln operation efficiency.

 The capacity of preheater to decompose limestone is 6000 tons per day

CaCO3 heat CaO + CO2

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 Step-6: Clinkerization: clinkerization can be occur in rotary kiln.

 Kiln;-is designed to maximize the efficiency of heat transfer from the fuel burning to
the raw material, where the lime stone forms burnt lime. In rotatory kiln, temperature
reaches up to 1400 degree Celsius.

 To increase the temperature of the kiln, coal must be burned at the starting part of the
kiln.

 At starting part of the kiln the temperature is 340 degree Celsius. At this high
temperature, mineral fused together to form predominantly silica crystals-cement
clinker. It is the heart of any cement plant.

 Mixed raw material is feed in at upper end, and the rotation of the kiln causes it
gradually to move downhill to another end of the kiln.

 The kiln was adjusted at 4 degree inclination. At the other end fuel, in the form of the
gas, oil, or pulverized solid fuel, is blown in through the burner pipe, producing a
large concentric flame in the end part of the kiln tube.

 At the end of the kiln the temperature can reach 1400 degree Celsius but it’s not
constant at mentioned temperature.

 As the material moves under the flame it reaches its peak temperature, before
dropping out of the kiln tube into the cooler.

 Air is drawn first through the cooler and then through the kiln for combustion of the
fuel. In the cooler the air is heated by the cooling clinker, so that it may be 400 to 800
degree Celsius. Before enter the kiln, thus causing intense and rapid combustion of
the fuel.

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 After the raw material clinkerized in kiln it must be cooled in clinker cooling system

Fig: 3. kiln

 Step-7: Clinker cooler

In cement manufacturing, formation of clinker nodules occurs at the entrance
to the hottest part of the kiln with material temperature of around 1400°C.
The clinker is preferably in the form of 10-mm to 25-mm size nodules that exit
from the front end of the kiln into the cooler.
It is critical that cooling of the clinker is rapid to secure a phase composition
that imparts adequate cementations properties.
It is equally important that the heat exchange between clinker and air is
efficient to ensure proper cooling, and at the same time maximize the recovery
of heat to secondary air, tertiary air, and the related process requirement.
The modern cooler must accomplish all of these tasks efficiently and
simultaneously.
The clinker coming out of the kiln is hot .it is cooled in a set up called cooler.
In the cooler, cold air is blown to effect heat exchange between hot clinker and
cold air.
Early system used rotary cooler, which were rotating cylinder similar to the
kiln, into which the hot clinker dropped. Cooler the molten cement clinker is
then cooled as rapidly as possible. The ambient air used to cool the clinker is

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then fed into the kiln as combustion air –ensuring high utilization of heat
produced.
The use of clinker cooler are: -
 To facilitate clinker handling and storage,
 To maintain a minimum velocity in order to
avoid unfavourable mineralogical clinker phases
and crystal size.

After the clinker cooled, it transported to clinker store by using deep pan conveyor or chain
conveyor. This store has a capacity to store 50,000 tone.

 Step-8: Material proportion :

In this step the raw material (Clinker, Gypsum& pumice)
must be proportionate to produce two types of cement .Namely OPC &PPC.
From those raw materials Clinker is required in large amount.
The proportion of those raw material (Clinker, Gypsum& pumice) are
different for both OPC &PPC.

For OPC:
 Clinker 85% & Gypsum 15% , no pumice involved

For PPC:

 Clinker 85% , Gypsum and pumice 15%

 After those raw material proportionate properly they transported to cement mill
through belt conveyor.

 Step-9: production of final product by cement mill

 Clinker, along with additive, is ground in cement mill.
 There are two cement mill which is called mill ‘’A’’ and mill ‘’B’’.
 Either of those mill can produce OPC or PPC.
 The output of the cement mill is the final product namely cement.

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 In cement mill, there are cylindrical shells lying horizontally which contain metallic
balls and as it rotates the crushing actions of the balls help in grinding the clinker to
fine powder.
 The term bag house is applied to large filters containing a number of tubular bags
mounted in a usually rectangular casing.
 The bag house is used to remove dusty particle from discharge of different equipment
such as cement mill, coal mill and raw mill.

The finished product. i.e cement is stored in cement storage silo .then the cement is out from
the silo by air slide and transported by bucket elevator. There are two cement storage silo,
one for OPC & one for PPC, each have a capacity to store 10,000 tone.

 Step-10: Packing Cement:

 Although a significantly large portion of cement is handled in bulk,
introduction of large sacks holding 1 to 12 tons of cement provide a new
alternative to cement handling.
 The large sacks or totes are of advantage when the requirements of a job may
require cement to be transported below ground, as in mining operations.
 Cement is routinely bagged for convenience at the construction site and for
small jobs.
 Bag sizes for use on construction sites vary significantly.
 The powder cement is packed by using rotating packing machine. There are
six rotating packer machine used to packed cement until it weigh 50kg.
 Each rotating packer machine has eight arms. When the cement is weighed
50kg this machine is out from its arm and gives to belt conveyor. The belt
conveyor is transported to loading machine.

Fig:4. Packing process

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Finally we can describe the cement manufacturing process by block diagram as follows:

Fig. 1 Block diagram of cement manufacturing

3.3 Technical knowledge and skill from our course those beneficial
for our assignment

 As we explained before, during this apparent what we applied and practiced is

almost what we know and also understand from our class course.

i.e. there are many course that are help us for our assignment. Those are:

a) Strength course: this course is essential in designing of different beams, structures,

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b) Dynamics course: this course is important for in adjusting, designing of speed and feed
rates of material transporting system and for knowing motion of different mechanism.

c) Mechanism course: this course is used in designing and creating all mechanism in overall
industry as well as adjusting speed, acceleration for these mechanisms.

d) Welding, Principle of metal cutting, Machining process and work shop courses: This
courses are essential and used them in welding, machining and producing mechanical
component this company work shop.

e) Maintenance course: This is important course that help as in our work how to maintain
failed component and the type and technique of maintenance used in this industry.

f) Vibration course: this course is help us how to design vibration of ground for different
machine and also how limit transmission of vibration from ground to the other ground.

g) Machine element course: this course helps us well in how to design machine component
as all, welding design and rivet joints in beams etc.

h) Heat transfer and thermodynamics courses: these courses are also help full for us how
cooling, heat flow operation is proceed and also how machines like compressors, fans are
work.

3.4 Relevant research project that we identify

As we tried to describe above this origination is new, modern and too technological. But we
identified one problem and also we tried to solve this problem as much as possible.

Problem identification

During Our internship period we have been visiting different work station of this (Dangote
cement industry) industry. This industry is the most modern industry from the industry we
have visited before and also this industry has minor problems. This means it is possible to say
it has no major problem .rather it has some minor problem.

The following are some problem that we tried to identify from our observation during the
visit in Dangote cement factory. Those problems are:

1. Some work station of this industry is very noisy . For Example raw mill
station and cement mill station.

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This problem is Unavoidable due to it is from the machine itself.

2. Some areas of the industry are covered by water : (it is only during
summer). Especially roads (ways) and areas around work station are covered by water
and as a result it difficult to move and work during rainy season. We think tha this
problem is due to the water dishes are closed by some waste that eroded by water and
added into them.
Even though this problem is eliminated by either cleaning water dishes timely or
preparing some filtration mechanism (that filter solid material from the water and
remove them from the water channel) in order not to close that those dishes, it is not
our major areas of study and so we leave (passed) this problem as a minor only by
telling them to correct the problem.
3. Some work station of the industry is full of dust and that may cause health
problem (especially breathing organs and may be eye) i.e. lack of ergonomics.
 This dust is emerged from(the source of this problem) :
1) Feeding mechanism itself (packer machine itself)
2) The way of dropping (removing bag after feeding to the bag) the cement bag
from the feeder (packer).
3) The way of packing the bag i.e. the cement bag doesn’t fixed and it drop dust
starting from feeder to loading point. Sometimes this will decrease the amount of
cement that is added to the bag up to 47kg which is the least.
 In addition it we asked some of workers that the industry pays 80,000 birr to clean
this dust (packing station) monthly.
But after we decide the component and rough design of the component and its
mechanism and as well as rough estimation of its cost ,this problem cause high cost
and need precise design as well as complex that will be gained after the problem is
solved. This means it need high cost to design manufacture the component that solve
problem itself than the advantage that obtained from the problem after it is solved.
Therefore we leave it to search solution for this problem.
4. Finally the last problem we have observed is, in loading station. there is problem
with roller table of one of the loading machine when load the cement bag on car. When
the cement comes through positioning belt to the roller table the cement bag cannot be
rolled on this table in correct direction and it cannot be placed in its proper position. This
problem is happening only in summer season when the temperature of the environment

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is cold and also some times during night. As we have observed this problem is due to
cooling of the temperature of the environment. When the environment temperature is
cool, the rolling table temperature also decrease from its room temperature and have
moisture that will restrict the bag from slide simply on the roller table rather stick to the
roller table itself. So this problem will stop the machine automatically from the work
and also need man power to remove the bag from the machine.
That means Most of the time due to this problem when the cement bag rolling on this
table it stopped without reaching its destination due to contact between the table and the
cement bag. This problem also disturbs the direction of arrangement of the cement bag.
Due to this problem this packing machine stop working at the summer time and when
the environmental temperature is decreased (cooled).
In addition we seen by our eyes that the life of one operator is passed away by this
loading machine this summer (the machine stacked by cement bag and stopped
automatically.to remove the stacked by the operation enter into the machine. But while
he remove the bag the machine start to work and simultaneously the machine killed the
operator immediately.

From those problems listed above we are going to solve the last problem which we have got
at packing station. Because due to this problem most of the time from 8 packing machine one
of the machine is totally stop working and to minimize the down time of this packing
machine and to increase the profitability of the company the problem of this machine must
get the solution.

How this problem can be solved?

Observing this packing machine we think the mechanism that will solve this problem by
blowing hot air to the roller table to adjust (increase) the temperature of the table to adjust
rolling of the cement bag on the this table and to make proper arrangements of the cement
bags on it. The mechanism blows hot air to all around the roller table to adjust (increase) the
temperature of the table to simply and correctly roll the cement bag without stack due to
cooling of the roller table and minimize the disarrangement of the cement bag on the roller
table.

N.B The temperature of the roller table must be kept to room temperature to body
temperature (25-37 degree Celsius), because when temperature of the table is too high it can
damage the cement bag.

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What are needed for installation of this mechanism to the machine?

The basic equipment’s needed for the mechanisms that adjust the temperature of the roller
table of the loading machine are:-

 Compressed (pressurized) hot air that blew to the roller table to adjust its
temperature. This hot air is obtained from cement mill station that will dry the
clinker and gypsum mixture before grinding the cement.
The temperature of this hot air is about 400 degree Celsius.
The length of the transporting is about 80 meter.
This transporting pipe is made of metal and has no insulation on its outer surface to
dissipate the heat to the atmosphere and the temperature is reduced to about 40
degree Celsius. Through the second flexible plastic pipe the temperature of the air is
reduced to about 35 degree Celsius.
Finally the air of 35 degree Celsius reaches the roller table surface.
 Air pipe or tube, which will transport the hot air to the roller table (used to blow the
hot air to the roller table). Two type of pipe will be needed. One is that made of
metal and the other is that made of plastic that is flexible in order not to restrict the
pipe from movement. This plastic pipe must be flexible and thick pipe.
N.B this plastic pipe should not be the pipe that may be damaged by the temperature
of the air that flow through it. On the other hand the pipe (tube) which is made of
thin sheet metal must be made in such a way that it can blow the hot air to all around
the body of roller table. To make this simple it should have “T” shape and slide
along the table.to to blow the air to entire the body of the roller table. Also this tube
(pipe) should have a series of small hole on its body for the outlet of the air.
 Mini motor. This motor is used to rotate the link that slide back and forth the “T”
shaped metal tube along the roller table.

How to install it?

The pressure vessel (pressurized hot air) will be fastened to one side of the support beam of
the packing machine. And the thin sheet metal “+” shaped pipe should be fastened under the

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roller table. Also the small capacity electric motor should be fastened under the roller table.
The plastic pipe should be installed in such a way that it can connect the pressurized hot air
container to the thin sheet metal “+” shaped tube.

How the mechanism is working?

As the valve of the hot air vessel will be opened the hot air flow through thick plastic pipe to
the thin “T” shaped sheet metal tube. The thin sheet metal tube is rotated around its
intersection point by the mini motor to blow the air to all around the body of the roller table.

Therefore by installing this simple mechanism to the machine, the problem with this machine
can be easily solved, and the machine will work well. The installation of the mechanism
needs less cost. It needs only initial cost of the equipment as it doesn’t need any other cost
like maintenance cost and other costs. Then installations of this mechanism to the machine
will solve the problem of the machine and minimize the down time of the machine, then
increase the profit of the company by eliminating the loss of income due to stoppage of the
machine by this problem. The components are the below one

1. Mini motor (purchase component)

2. Transporting pipe (metal) (purchase component)

3. Flexible plastic pipe (purchase component)

4. Temperature distributing pipe (metal) (purchase component)

5. Valves (purchase component)

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6 links (two in number and made of metal. And also manufactured through the required
design.(designed component)

7. Slider (designed component)

8. Bolts (purchase component)

9. Guide way (designed component)

The 3D model and relative simulation of the idea is prepared by CATIA V5 for clear
understanding of the working mechanism of the system.

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3.5 Reflection and conclusion

 As we are mechanical student, this internship fit our career goal and the
experience which expected from mechanical staffs at working area. This is
because the company that we were placed is seems with our department as all
and our future career goal.
 This internship changes our career goal since all activities and mechanisms are
too computerized and automatic.
i.e before this internship we think that our career goal is just limited to some
manually working factory. But now we changed our career goal to those
modernized and computerized.
 In addition to this, this internship has many significance in that it:
Improve our experience in working environment.
Improve our relation with other interns and staffs.
Is clear that learning practically is clearer and save time than learning
theoretically.
Is known that we learn and know different systems, mechanisms and
machines before we learn about them theoretically.Sothat it is clear for
us when we learn them in the coming courses.
 During our internship there is some challenge that face us. This is we were
unable to solve the problem of automatic loader machine.
i.e this machine is preprogramed loader machine and so we can’t write its
working program due to that we were not learned the corresponding course
like mechatronics.
 During this we have some strength and improvement in solving some problem
that is occurred in packing station.

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We commenced the idea and systematic mechanism how to control the dust
that has health problem in this station.

3.6 Recommendations

 Being as intern, this internship is good during summer because any intern can
be placed to the company they want due to only some university send their
student for intern during summer.
 Being as company staffs interns are not properly solve the company problem
due to they were not learned all courses those important for solving the
corresponding problem.

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Reference
In addition to what I see and learn we use Dangote manual reference to prepare this final
report

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