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ACKNOWLEDGMENT
First of all, I would like to thank the almighty God and I would like to thank Dangote Cement
PLC since it become voluntary on my internship request. Next, I would like to thank to my
academic Advisor Mr. Biniyam and also company supervisor Mr.Yared for its consecutive
guidance and also I would like to extend my special thanks to Adama Science and Technology
University, And Department of Chemical Engineering to prepare this internship program for me
and also for my department students. Then, I would like to thank our family for giving me a lot
of financial and moral support from the beginning to the end of my internship period at Dangote
cement industry. After that, I would like to thank to all Dangote Cement CCR operator,
production manager, process engineer for their good contribution to give me important
information and sharing their knowledge and giving me valuable feedbacks and their important
work experience.

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LIST OF ACRONYMS
ASTU Adama Science and Technology University.
G.C Gregorian Calender .
BC: Belt conveyor
BE: Bucket Elevator
BFs: Bag Filters
CCR: Central Controlling Room
CEO: Chief Executive Organization
DCE: Dangote Cement Ethiopia
ESP: Electrostatic Precipitator
HGL: High Grade Limestone
LPH: Liquid Phase
OPC: Ordinary Portland cement
PPC: Portland Pozzolana cement
TPD: Ton per day
VRM: Vertical roller mill.
C3S: Tricalcium Silicate.
C2S: Dicalcium Silicate.
C4A: Tricalcium Aluminate.
C4AF: TetracalciumAluminoferritte.
PLC Private Limited Company

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EXECUTIVE SUMMERY
This report is an outcome of the exercise which was conducted during the internship period that
lasted from July till August,2022 at Dangote Cement Industry (Ethiopia) plc which is found at
Mugher project site. The purpose of this report is to show the work experience that has been
performed and the knowledge attained from performed specific tasks while working in a
professional environment. The report mainly consists introduction part which briefly describe the
background of the hosting company, Including the history, main products and services and the
overall organization. Then, the main activities and internship experience that was gained during
the practical periods was illustrated. In the second part of the report, cement production process
was described by pointing out major raw materials, their sources, and how they are transported to
the factory. Starting from raw material size reduction (crushing), preparation, grinding and
homogenization, then stored and going through rotary kiln for clinker production (pyro-
processing), then cooling clinker, finish grounding process of the cement clinker and additives to
make finished cement product, basic utilities, packaging and dispatching of the cement and
quality of the raw material was tested by quality control.
The report finally, covers the overall benefits gained from the internship like; improving
practical skills, interpersonal communication, team playing skill, leadership skill, upgrading my
theoretical knowledge and work ethics with respect to both technical and personal challenges and
conclusion and recommendation to the company.

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Table of Contents
Acknowledgment.............................................................................................................................1

Acronym..........................................................................................................................................2

Executive summary.........................................................................................................................3

CHAPTER ONE..............................................................................................................................6

INTRODUCTION...........................................................................................................................6

1.1 Background............................................................................................................................6

1.2 Mission and vision of dangote cement ….............................................................................7

1.3 Dangote cement Products ….................................................................................................8

1.4 Organizational Structure of Dangote Cement Ethiopia…………………………..........…..9

1.5 Objective of the Internship...................................................................................................10

1.6 Benefits I gained during internship.....................................................................................10

CHAPTER TWO...........................................................................................................................11

2.OVERALL INTERNSHIP EXEPERIENCE…………….……………………..11

2.1 Raw materials.......................................................................................................................12

2.1.1 Limestone (caco3 rock)..................................................................................................12

2.1.2 Corrective material (sand and clay)...............................................................................12

2.1.3 Gypsum and pumice......................................................................................................13

2.2 Manufacturing Process.........................................................................................................13

2.2.1 Crushing the raw material.............................................................................................14

2.2.2 Raw material storage.....................................................................................................14

2.2.3 Proportion of raw material............................................................................................14

2.2.4 Raw mill building..........................................................................................................14

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2.2.5 Pre heater calcinary system...........................................................................................15

2.2.6 Rotary kiln.....................................................................................................................16

2.2.7 Clinker cooler................................................................................................................18

2.2.8 Cement mill...................................................................................................................19

2.2.9 Cement storage silo.......................................................................................................19

2.2.10 Packing of cement.......................................................................................................20

CHAPTER THREE ......................................................................................................................22

3. OVERALL BENEFIT OBTAINED FROM THE
INTERNSHIP.............................................22
3.1 Improving practical skills........................................................................................................22
3.2 Upgrading my theoretical knowledge …................................................................................23
3.3 Improving interpersonal communication skill .......................................................................23
3.4 Improving team playing skill...................................................................................................23
3.5 Improving leadership skill ......................................................................................................24
3.6 Learning work ethics...............................................................................................................24
3.7 Limitations ...........................................................................................................................25
3.7.1 Challenges I have been facing while performing my work tasks .................................25
3.7.2 Measurements that I have taken to solve challenges .....................................................25
CHAPTER FOUR.........................................................................................................................26

CONCLUSIONS AND RECOMMENDATIONS........................................................................26

4.1 Conclusions..........................................................................................................................26

4.2 Recommendations................................................................................................................26

References......................................................................................................................................28

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CHAPTER ONE (1)

INTRODUCTION
1.1. BACKGROUND OF DANGOTE CEMENT INDUSTRIES PLC.
Dangote cement (Ethiopia) plc factory is one of the outstanding and technological updated
factories throughout Ethiopia. The company is located in Oromia region, west Shoa zone, Adea
Berga district around mugher town which is 85 Km far away from Addis Ababa, the capital city
of Ethiopia. The factory produces OPC, PPC and special cement for dam construction.
It established in 1994E.C. Dangote cement is fully advanced technology integrated cement
industry and has a project and operation in Nigeria and 14 other African countries. These plants
are constructed by a cost of 600 million USA dollars. Dangote Cement is the biggest listed
company in East Africa and the first Nigerian company to join the Forbes of 2000 companies.
The factory is one of the biggest cement industries in east Africa and only one line which
produce huge amount of product. This establishing factory is planned to produce 3000-5000
metric tons per day or 2.5 million tons per annually. The company began running in June 2015
G.C where lying on 15 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.

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Figure 1: Dangote Cement plc

1.2 mission and vision of dangote cement
1.2.1 Mission:
 To deliver strong returns to our shareholders by selling high quality products at
affordable prices backed by excellent customer service.
 To provide economic benefits to the local communities through permanent and
temporary employment.
 To lead the way in sustainable production, environment conservation and to set a good
example for other companies to follow.
 To guarantee our customers at most satisfaction.
 To promote national development by utilizing the state of art technologies and highly
competitive workforce in manufacturing s& marketing of cement products through
operational efficiency, excellence and sustainability.
1.2.2 Vision
 To be Africa’s respected producer of qualified cement in accordance with its services and
business organization.
 To be globally competitive cement producer.
 To be exemplary in modern systems and high standard of work culture.

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 Increase the countries and District’s revenue through vat, salary and income tax.

1.3 Main Products of the Company

This company supplying OPC and PPC cement into local and international market by
Considering the costumer need.
 Ordinary Portland cement(OPC)
 Portland- pozalana cement(PPC)
1.3.1 Ordinary Portland cement (OPC)
Portland cement is by far the most important member of the family of hydraulic cements that is,
cements that harden through chemical interaction with water.It is produced by grinding gypsum
and clinker without other additives and its percentage composition is:
 clinker = 90-95%
 Gypsum = 5%
 It is more applicable for high building in fast constriction such as bridge, dams because it
attains its strength fastly.
 It has relatively higher early strength and higher heat of hydration.
 It is the most energy consumable cement due to high percentage of clinker, high energy
consumption, and also it is high heat release cement.
1.3.2 Portland-pozzalana cement (PPC)
Portland pozzalana cements are blends of Portland cement and a pozzalana material.This type of
cement contains Pozzolana which is aluminum silicate burned by volcanic eruption in its
composition.
 The percentage composition of PPC is
 Clinker= 60-70%
 Gypsum= 3-5 %
 Pumice=20 - 30%
 It is mainly applicable for massive construction because it recesses relatively low heat.

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Types of cement Raw material Content in percent (%)

OPC Clinker 95 %
Gypsum and high grade 5%
Limestone
PPC Clinker 65%
Pumice 30%
Gypsum 5%

Table 1: Content of OPC and PPC cement type.

1.4 Organizational Structure of Dangote Cement Ethiopia

Around 1500 employers are working in DCF. The company has got workers of different levels
from top managers to Forman’s and daily labors. The factory run for 24 hours and shift is
arranged for workers. The company has also its own finance and time keeper.

General Manager

Secretary Coordinator

Office Engineer Mechanical Operator Administration

Supply& Purchase
Engineers & Finance

Chief Quality Maintenance Purchasers & Accountants

Surveyor Surveyor Foreman Store Keepers & Cashers

Diagram 1: Overall organization structure and work flow.

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1.5 Objective of the Internship

 The main objective of the Internship is:
 To understand about process of cement manufacturing comparing with what I have
learned theoretically.
 To get work experience.
 To get a better knowledge about cement plant and its process
 To have a good relationship within theindustrial workers.
 To practice being punctual on the work place.
 To Encourage students to improve both theoretical knowledge and practical skill.
 To increase the likelihood of building professional networking contacts and
mentoring relationships.
 To Maturing available and experienced job applicants when seeking employment
after graduation.

1.6 Benefits I gained during internship

During my internship period I have got work experience, to be punctual, to perform the given job
well and to finish on time while I was working especially on quality control and so on. For
example I have seen how to reduce the size of the raw material practically, which I have learned
on unit operation theoretically. Moreover, I have got how cement is produced starting from the
raw materials to packed cement and how to determine the cement strength with its constituents. I
also identified the basic raw materials and additives necessary for the production of cement. I
have also gained the knowledge to cooperate within the workers in work place.

1.6.1 Section of the company I have been experienced

Raw material preparation Crushing
Proportioning tower Raw mill
Raw mill silo Gas conditioning tower
Deducting equipment Kiln
Clinker cooler Clinker storage
Cement mill Packing plant

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CHAPTER TWO
2. OVERALL INTERNSHIP EXEPERIENCE

Reason I Select This Company:-

 First the project site is located near to our home

 The company is well organized in which I can learn a lot from the experienced engineer
and other staff members. irst the project site is located near to our home
 The company is well organized in which I can learn a lot from the experienced engineer
and other staff members.
What is Cement?
Cement refers to the commodities that are produced by burning mixtures of limestone and other
minerals or additives at high temperature in a rotary kiln, followed by cooling, finish mixing, and
grinding. Cements are used to chemically bind different materials together.
There are different types of process used to manufacturing cement in the world. Among those
there are four commonly known processes.
 Drying process, semi-drying process, wet process and semi-wet process

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The Basic Production Process and Cement

Constituents Portland cement is derived from a combination of calcium (usually in the form of
limestone), silica, alumina, iron oxide, and small amounts of other materials. These raw materials
are quarried, crushed, ground together, and then burned in rotary kiln at temperatures near
1450ºC. The resulting material (a mixture of marble- to fist-sized pellets and sand sized particles)
is called clinker. The clinker is finely ground into a grey powder and mixed with gypsum to
slow down the “setting” (i.e., hardening) of the cement when it is used in concrete.
Manufacturers use clinker and specific additives in various proportions to create cements having
different properties for specific construction applications. Typical Portland cement consists
largely of limestone, clay and/or shale, and a small amount of gypsum and other minerals, such
as iron ore, sand, or bauxite. Most of these mineral inputs into the production of cement are
quarried on site, ground and blended, then fed into a kiln system. The type of Portland cement
being produced determines the specific proportions of these raw materials. High levels of
impurities in the raw feed may cause operational problems in the kiln, and or produce inferior
cement.
Cement production have two stages.
First stage: From crusher to kiln
Second stage: From clinker yard to cement mill
That is why raw materials are divided into two stages.
First raw material:
 Lime stone
 Sand stone
 Clay
Second stage raw material:
 Clinker
 Gypsum
 Pumice
2.1 Raw Material of Cement
 The raw materials are naturally occurring minerals and basically all CaO, SiO2, Al ₂O,
and Fe₂O₃ bearing minerals can be used to manufacture cement. The main raw materials
are: -
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 Primary raw material: -limestone (CaCO₃) and lime stone containing minerals.
 Secondary raw materials (corrective materials): -red clay and sandstone.
 Tertiary raw material: gypsum, pumice, and HGL
2.1.1 Lime Stone
 Lime stone is a white or grey solid in nature that is found in sedimentary rocks.
Sedimentary rocks are formed by crystallization of sea water and other marine organisms.
Due to the existence of mainly Calcium Carbonate (CaCO₃) and the remaining is
Magnesium Carbonate (MgCO₃) in addition to total Carbonate source it also contains
Al₂O₃, Fe₂O₃, SiO₂ in the trace amount.

2.1.2 Corrective materials

 Clay is finely-grained natural rock or soil material that combines one or more clay
minerals with traces of metal oxides and organic matter. Clay deposits are mostly
composed of silicate minerals containing kinds of oxides like limestone. Al₂O₃ and
Fe₂O₃ Variable amounts of water trapped in the mineral structure and typically formed
over long periods of time by gradual chemical weathering of rocks clay found in the
mineral forms of shall and marls. Due to Silica content it has behavior like plasticity
when mixed with water in certain proportions.
 Sandstone is clastic sedimentary rock composed mainly of sand mineral particles or rock
fragments. Most sandstone is composed of quartz or feldspar because they are the most
resistant minerals to weathering processes at the earth's surface.

2.1.3 Gypsum and Pumice (Additive material).

 Gypsum is a soft sulfate mineral composed of calcium sulfate dehydrate with the
chemical formula CaSO₄.2H₂O. It is white hared in nature. It is final raw material which
is added 5 - 6% amount with clinker of cooled clinker.
 The importance’s of adding gypsum is used:
 To strength of cement and grind ability in final cement quality.
 It also used to retard setting time because it contains hydrated Calcium Sulphite
(CaSO₄.2H₂O).

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 Pumice is a very light and porous volcanic rock formed when a gas rich froth of glass
lava solidifies rapidly. It is typically light colored and another constituent material of
cement. Mainly DCE use this for medium strength cement production by the 25% to 30%
in proportion. In this it benefits economical & make profitable to increase cement
production capacity. It is come from East Shoa in Meki.

2.2 Manufacturing Process

 Mining (Quarry): Mining is the extraction of valuable mineral or other geological
material from the earth usually from an ore body or placer deposits. Quarry operations
consist of drilling, blasting, excavating, loading, crushing, stockpiling, and storing.
 Quarry is a place where raw materials are exploited by Bomb. This is raw materials
found in quarry used in cement manufacturing include: Lime stone; silica sand, clay,
gypsum and pumice but only limestone is obtaining through explosion. The raw materials
from quarry are taken to the crusher by loader.

2.2.1 Crushing the raw material

Crushing is a process which does size reduction is taken place.The quarried raw material is
transported to the plant, using mechanical conveying equipment such as rope ways or belt
conveyors. 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 for finished grinding. Generally, limestone coming out of quarry is
crushed in multiple stages in sizing plant before it is put in Lime stone stock pile.
There are two types of crushers available for this purpose compression type or impact type
crushers. There are many types of compression crushers such as Jaw crusher, gyratory crusher;
cone crushers roller crusher. Jaw crusher is basically a simple mechanism having two plates one
fixed and another moving. This is also called primary crusher.

2.2.2 Raw material storage

The raw materials comes from quarry are stored at different place in storage house. 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 are four types of storage for raw material, one for Lime stone, one for coal, one for
sand, one for clay. There is also a machine used to take a stored material and give to a belt

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conveyor which is called reclaimer. Then the belt conveyor is taking the material and transport
to the required place.

2.2.3 Proportion of raw material

All of the raw materials 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 89%,
clay 7%, and sand 4%. These proportionate are not constant. It’s determined by computer
controlling room (CCR). Before the proportionate the raw materials are stored in the bin. There
are four bins for this purpose. Two for Lime stone, one for clay, one for sand. The machine used
to proportionate this raw material is called Dismal feeder.

2.2.4 Raw mill building

After the raw materials are proportionate, they transported to the raw mill by belt conveyor for
grinding. From the earliest, two different methods of raw mix preparation were used: The
mineral components were either dry ground or to form a flour like powder, or were wet ground
with added water to produce a fine slurry and with a typical water content of 40 to 45%. Wet
grinding of hard minerals are usually much efficient than dry grinding. When the slurry is dry in
the kiln it forms a granular crumble that is ideal for subsequent heating in the kiln. In the dry
process it is very difficult to keep the fine powder raw mix in the kiln, because the fast flowing
combustion gases tend to blow it back out again.
The raw material is finish ground before being feed into the kiln for clinkering. 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 in DCE.
Function of VRM
 Reduce the size of raw material (grinding)
 Dry the material
 Classify the coarse and fine materials
 Recycle rejected material
 Transport the fine material to bin
 The main advantage of vertical roller mill
 It is higher grinding efficiency and ability to accept material with higher moisture
content.

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 Energy consumption is less compared to ball mills.

 Flexibility in operation as all forces can be controlled.
 Drying capacity is better than ball mills.
 Noise level (noise pollution) is much less than ball mills.
 Particle size distribution better than ball mills.

2.2.5 Pre heater and Calcinary system

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 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 in to the kiln.
The main advantage of calcinary system is to decompose the raw material Lime stone (CaCO 3)
to CaO and CO2 by using excess hot from the kiln and from the coal.
CaCO3 CaO + CO2
After calcium carbonate is decomposed into this they across cyclone steep by steep and reach
inlet of the rotary kiln system.

2.2.6 Rotary kiln

It is the heart of any cement plant. It is basically a long cylindrical shaped pipe, and rotates in
horizontal position. The rotary kiln consists of a tube made from steel plate, and its internal
surface is lined by refractory bricks. Raw mix is feed in at upper end, and the rotation of the kiln
causes it gradually to move down hill to another end of the kiln. 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 lower part of the kiln tube. 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.The rotary kiln is
Normally installed with a horizontal inclination of approximately 30oc towards the outlet. The
kiln capacity of Dangote cement is 5000t/d.

 The rotary kiln zones:

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 Calcination zone: In which the 5% of calcination takes place and the process
temperature.
 Transition zone (Liquid zone): In this zone the raw meal forms liquid phase due to
temperature rise about 13000C is formation of belite(C2S), aluminate (C3A), ferrite (C4AF).
 Burning zone: which is the formation of alite (C3S) reaches its critical value and
Temperature reaches 1400-1450 0C. The burning zone is the area where the raw mix is
Transformed into clinker minerals, C3A, C4AF, C2S, and C3S the length of burning zone
depends on the position of ignition point. Clinker is produced by the chemical reaction of
the dehydrated and decarbonized raw materials that occurs in the burning zone of the
rotary kiln at about 14500C.
 Cooling zone: which the clinker formed is cooled to the temperature of around 100℃.

Figure 2: rotary kiln.

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2.2.7 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 1280°C. 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 clinker coming out of the Kiln is approximately 1400ºC and above. It
is cooled in an air cooled cooler. Ambient air is blown into the cooler to exchange heat between
the hot clinker and the ambient air. After cooling the clinker temperature drops to approximately
100ºC to 90 ºC.
Functions of clinker Coolers: Clinker coolers are used to:
 Quenching of clinker
 Cool the clinker coming out of the kiln
 Heat recuperation
 Break the clinker
 Convey the clinker
Clinker storage silo
The clinker-silo is a continuous operation and storage silo for feeding and extraction of clinker
for cement production. Pan conveyor is used to transfer the clinker from the cooler in to cement
clinker silo because the clinker contain high temperature. The silo proper is built as a cylindrical
structure which is made of concrete and is provided with a plan roof for large diameter. The
material is continuously supplied to the clinker silo though an inlet located in the center of the
clinker silo top. The clinker from the clinker storage transfers by belt conveyor in to the cement
mill. clinker storage capacity 50000t/d.

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Figure 3: clinker storage silo.

The stored clinker is again out from the storage and transported to cement proportion by using
belt conveyor. On this stage there are six different bins which used to store this material like: two
for clinker, two for pumice, and two for gypsum. Whether the cement is OPC or PPC and also
they are known by the proportion of this raw material.

2.2.8 Cement mill

Clinker, along with additive is ground in cement mill. The output of the cement mill is the final
product namely cement. The finish mill system in cement manufacturing is used for reducing the
size of the clinker from as large as several centimeters in diameter to a size that is a maximum of
100 micrometers across. This process is accomplished by grinding (milling) with the use of ball
mill, roller mills, roll presses, or some combination of these processes.
There are two types of mill A and B which used to grind simultaneously at the same time to
increase the grinding efficiency. The material which is not grinding is returned to the mill by
bucket elevator and then grinded again. After they grinded the cement powder is out from the
mill by air slide and then given to the bucket and rich the cement storage.

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2.2.9 Cement storage silo

Cement after grinding will be stored in cement silo. Cement stored in silo will be sent to elevator
by air slide via silo bottom discharging device. Then discharged into inter bin by bucket elevator
through air slide Cement in the bin will be fed into opening rotary packing machine. Packing
machine feed cement to bag pack it transfer to belt conveyer then it will be loaded on car.Their
equipment cement bulk loading device at the side of cement silo. Cement is conveyed to bulk
loader via side discharging device and air slide, and then transported out of factory by truck .

Figure 4: Cement storage silo

The total material storage capacity required is determined in part by the environment where the
manufacturing facility is constructed.
2.2.10 Packing of cement And Shipping.
The powder cement is packed by using rotating packing machine. There are six rotating packing
machine used to packed cement until it weigh 50kg. This rotating packing 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.

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Figure 5:Roto Packer Haver and Rotor packer.

Roto Packer Haver is work by the application of combination of Mechanical motion, Pressure
and Electrical instruments. This machine will fill the bag and determine its weight when it’s on
his own rotation. When the required weight is attained it will discharge the bags and start other
cycles. This machine can fill 8 bags on its every revolution if there is no problem on the feeding
system or controlling system.
When the bag is filled Roto Packer Haver drives will throw the bag to the Bag Discharge Belt
conveyor. Bag Discharge Belt conveyor will take the bag from this machine and transfer the bag
to the Bag Directing Belt Conveyor. Bag Directing Belt Conveyor will direct or align the bag
and send the bag to the Check Weights or Balancing Belt Conveyor to re-check the weight of the
bag.
Then the bag will be received by Bag Reject Belt conveyor and thrown to the Receiving Belt
conveyor. On receiving belt conveyor there are bag diverting devices used to divert the direction
of the bag. Due to effect of bag diverting device the bag will transfer to the belt conveyor that
takes the bags to the Lorries. Now the bag will be discharged and arranged on the Lorries by
both the hands of mans and by machine. When the capacity of the Lorries reached the Lorries
will taken to weigh station and the amount of cement bag will be determined by the computer.
There after the shipping of the cement is done or finished.

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Figure 6: Shipping of the Cement

Diagram 2: generally manufacturing process of cement

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CHAPTER THREE (3)

3. OVERALL BENEFITS GAINED FROM INTERNSHIP

The internship program has its own aim which is intended to satisfy and qualify students in terms
of improving different skills.

3.1 In Terms of Improving Practical Skills

Theoretical knowledge is the base of knowledge but meaningless without practical skill. But,
when it is supported by practical work, theoretical knowledge will be improved and increased the
creativity of new ideas.
Practical skill is connected with real situations rather than ideas and theories. The main objective
of internship was to improve practical skills.
 It helped me to improve my practical skill in the process, quality and operating condition
of different machines.
 It enables me to improve reading skill of complicated process designs.
 Acquiring opportunity and way to change what I have in mind into practical world.

3.2 In Terms of Improving Theoretical Knowledge

Theoretical knowledge is the information, understanding and skill concerned with ideas and
principles on which a particular subject is based. The internship upgrades theoretical knowledge
through.
 Working mechanism of different machineries.
 Knowing the general safety rules of each operation.
 I have improved my theoretical knowledge by reading process manuals in Dangote cement
industry.

3.3 In Terms of Improving Interpersonal Communication Skills

Inter personal communication is my communication with the fellow workers of the company. It
can involve one on one conversation or individuals interacting with many people. It helped me to
understand how and why people behave and communicate in different ways to construct and
negotiate a social reality. The ability to communicate with other people is highly improved in my
internship period. I have widely communicated with different professionals in their offices and
also at the sites.

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Communication: is how I interact with each other. Communication whether it is verbal or

nonverbal must be clear, to the point, emphatic, and one must keep in mind that he/she must
always treat others as I would like others to treat me.
Ask questions: It’s a great way to show people that you are really interested in them. I have
been asking some questions to improving our knowledge and communication skill as well as for
more clarification. It is important and obligatory to communicate with others and solve the
problems easily.
3.4 Improving team playing skill
Team playing skill means the activity of working well together as a team to solve or share the
ideas and challenges encountered. Team playing skill is crucial skill in Chemical engineering
discipline.
Hence, in terms of improving team playing skill, I have gained the following;
 Improving interpersonal communication with each another and with workers,
 Problem solving by understanding each other
 Knowledge sharing by in terms of practical and theoretical.

3.5 Improving leadership skill

Leadership is the process of influencing individuals or groups to work towards the achievement
and accomplishment of an organizational goal or mission. Leaders are responsible for getting
work done. One of the main skills that I have acquired during the two months stay of internship
is the skill of leadership. In my context, I have met different chairman and I have seen how they
treat them depending on different issues. Generally, I got the following skills from them:
 How to organize different work divisions.
 How to treat customers in different issue
 Taking risk during any activities
3.6 Learning work ethics
Work ethics and discipline is one of the major factors for the step to professionalism. Issues that
are related to work ethics likes punctuality, honesty, loyalty, performance, and etc.
There are two commons types of ethics. These are: Personal ethics and Professional ethics
A. Personal Ethics

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These principles of personal ethics are values which are expected to be possessed by all
individual in their life, and contribute a lot for a smooth interaction among individual and
peaceful coexistence of a society.
 What I gained in the company concerning personal ethics include:
 Concern for the well being of the other
 Honesty
 Fairness
 Compliant to the law
 Doing good
 Refusing to take up unfair advantage
B. Professional Ethics
Professional ethics refers to the standards or a set of moral Principle for regulating behavior of a
certain defined profession. In order to consider that an activity to be a profession, it should be
carried out by one who has advanced education, knowledge, and skills. Thus, for developing
health working environment and increase productivity, ethical work conduct is important
medium.
 The following are some of the professional ethics I have gained during our internship period.
 Punctuality: means keeping the companies work beginning and ending time and to
complete a given task within the given period.
 Office discipline: in work place you do not have to disturb the working atmosphere for
example abstain from opening loud voice, loud music, songs and others which may disturb
others.
 Reliability: the worker should be qualified for the task he /she is supposed to perform.
He/she must have appropriate skill and knowledge for the task assigned.
 Honesty: regarding this value each worker regardless of its status should abstain from bad
behaviors such as cheating, bias, corruption etc.
 Cooperation: each worker should be interacting and cooperate with each other while
working. That is because it is through such system problems could be easily solved.
 Accountability: being responsible person & held accountable for what you do.
Tolerance with the others: respecting others ideas & beliefs.
 Transparency: workers have to held openness

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3.7 Limitations
3.7.1 Challenges I have been facing while performing my work tasks
I have faced certain problems during our two months stay in DCE Plant.
 During our internship the challenges were: -
 It was difficult to get information about the company performance, because there were no
computer and learning guidance.
 Getting data about the company and production process was very boring and exhaustive.
 Some mechanical part and process in the company was difficult to observe due to their high
movement and vibration.
3.7.2 Measurements that I have taken to solve challenges
As much as possible I have engaged with workers during work and observed the procedures they
took, asking them about the operation of the system and then involving into the task. For further
understanding and awareness, I used to read certain manual different books as well as, articles
from internet. And also:-
 I conduct the worker of the company politely and gain the information
 Search different social media and compare with the worker information
 Refer books those related to cement production
 Doing things practically rather than spending more on reading.

CHAPTER FOUR (4)

4. CONCULISION AND RECOMMENDATION
4.1 Conclusion
The Dangote cement (Ethiopia) plc is built up by modern technology. Dangote cement factory
has the best quality cement since it uses different highly efficient laboratory techniques and
skilled workers responsible for the production. Essentially, Cement is a crystalline pulverized
compound of calcium silicates and other calcium bearing compounds with impressive hydraulic
properties. The main processes of cement production include raw mix preheating and
calcinations, clinker formation and cooling to achieve a crystallographic structure that meets the
required cement specifications. After cooling, the clinker is fed into grinding or finishes mills
and is mixed with plaster and ameliorating additives.

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The strength and quality of cement produced is checked by Quality Assurance production
specifically is known as Quality Control. There are about four tasks of quality control; Sample
preparation, Physical test, Chemical test and X-ray Diffraction. Since the cement industry is
energy intensive high- temperature process attention should be given to the recovery of waste
heat from the various exhaust streams.
4.2 Recommendations
During the two months internship period at DCE, I have tried to recommend the following main
points to the company;
 In the de-dusting of raw meal, the bag-house releases dust from the stack. This problem can
cause environmental pollution and steal processed material. To solve this, it is recommended
to adjust or minimize the cleaning and purging time. Adjusting, cleaning and purging time
might affect the bag filters so adding another de-dusting is more effective solution especially
for clinker silo top bag filter.
 DCE uses highly organized technology which is also updated but most of the time
maintenance is done after the break down of the equipment. This can damage the equipment;
cause additional cost for purchasing new equipment, and reduces productivity. Therefore,
maintenance schedule of each machine must be provided before break down.

 During summer the corrective raw material obtained have high moisture content that may
affect crusher and cause blockage at raw proportion, and also it requires additional power to
dry these moistures. To reduce this moisture additional drying equipment is mandatory. The
water that is used for washing materials in the chemical laboratory is released to the
environment without being treated. Through time this accumulation of the chemical can
become hazardous for human being and also plants, so it must be treated using physical,
chemical and biological techniques.
 Cement manufacturing process releases CO₂ into the atmosphere both directly and
indirectly. The cement industry produces about 5% of global man-made CO₂ emissions, of
which 50% is from the chemical process, 40% from burning fuel 10% from transportation.
The direct release of CO₂ can solved by using alternative raw materials for clinker
production that do not contain carbonate such as waste ash from fuel consumption in thermal
power plants and blast furnace slag. Indirect emission of carbon dioxide can be reduced by

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switching to alternative fuel including Natural gas, generate lower energy specific emission
of CO₂ and biomass. Biomass is the most recommended because the coal used for
combustion comes from South Africa at high cost of transportation through Djibouti and
also, reduced by energy efficiency improvement.
 During my internship the company did not provide any safety devices “safety is the state of
being safe”. Full safety must be required such as: - helmet, eye glass, dust proof mask,
reflector, safety shoes, gloves, and safety clothes.
 Many equipment and machineries are placed in the design and installed but most are not
functional due to undefined reason. This will cause both production cost Increment (loss of
intermediate product) and/or environmental pollution. So even though it is possible to
continue production without them, this is affecting the overall potential of the Enterprise.

References
[1] AlicoDangote” Forbes.com.retrieved 8 October, 2017.
[2] “AlicoDangote profile” Forbes. Retrieved 31 July, 2015
[3] Cement Manufacturing Handbook, Kurt E. Peary, New York, 1979.Chemical Publishing Co.
Inc.
[4] Cement Manufacturing Technology Handout, White hop leman, December, 1995 in Trade
Ship Publication Ltd.
[5] “Dangote cement 2011 manual Report” (pdf) Dangote cement plc.
[6] Handbook for Designing Cement Plants, S.P. Deolalkar (Director Consultants), Second
Edition, 2009, In BS Publications.
[7] Innovation in Portland Cement Manufacturing, Javed I. Bhatty, F. MacGregor and Steven
H. Kosmat, Second Edition, January 2000, In Portland Cement Association.
[8] Lea’s Chemistry of Cement and Concrete, Peter Hewlett Publisher: Fourth Edition, January
2004, Elsevier Science &Technology Books Pub.
[9] Lecture note on Dangote cement factory.

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