NEW Overall - Report - of - Dangote - Jit Hope

INTERNSHIP REPORT FROM DANGOTE CEMENT FACTORY 2019
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__________________________
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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.
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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.
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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
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3 THE OVERALL BENEFITS GAINED FROM INTERSHIPS ............................................................................... 25

3.1 In Terms of Improving Practical Skills ............................................................................................... 25
3.2 In Terms of upgrading Theoretical Knowledge ................................................................................. 25
3.3.In Terms of Improving Inter Personal CommunicationSkills............................................................. 25
3.4.In Terms of Improving Team Playing Skills ....................................................................................... 26
3.5. In Terms of Improving Leadership Skills .......................................................................................... 26
3.6 In Terms of Understanding about Work Ethics Relate Issues ........................................................... 27
3.7 In Terms of Entrepreneurship Skills .................................................................................................. 28
CHAPTER FOUR ........................................................................................................................................... 29
4. DESINGING AND MODELING OF CDE MACHINE ..................................................................................... 29
4.1. BREIF DETAILS ABOUT THE STUDY ................................................................................................... 29
4.1.1. INTRODUCTION ......................................................................................................................... 29
4.1.2. LITERATURE REVIEW ................................................................................................................. 30
4.1.3. LIST OF PROBLEM IDENTIFIED IN COMPANY .......................................................................... 31
4.1.4. SCOPE OF THE STUDY................................................................................................................ 33
4.1.5. SALIENT FEATURES .................................................................................................................... 33
4.1.6.OBJECTIVES ................................................................................................................................ 34
4.1.7. METHODOLOGY ........................................................................................................................ 34
4.1.8.SIGNIFICANCE OF THE STUDY .................................................................................................... 35
4.1.9.APPLICATION .............................................................................................................................. 35
4.1.10. Advantages.............................................................................................................................. 36
4.1.11. Limits ....................................................................................................................................... 36
4.2. COMPONENTS OF DEVICE AND MATERIAL SELECTION ................................................................... 36
4.2.1. Components Of Dust Collecting Machine ................................................................................. 36
4.2.2. FUNCTION OF MAIN PARTS ...................................................................................................... 36
4.3.DESIGN ANALYSIS FOR COMPONENTS OF DEVICE............................................................................ 37
4.3.1. Design of Blower Fan ................................................................................................................ 37
4.3.2.Design Of Belt And Pulley Of Rotor And Rotory Feeder ............................................................ 38
4.3.3. Shaft Design .............................................................................................................................. 43
4.3.4. Bearing Selection...................................................................................................................... 47
4.3.5.Wheel Selection ......................................................................................................................... 48
4.3.6. Design of Container................................................................................................................... 49
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4.3.7. Design Of Bolt ........................................................................................................................... 50

4.3.8.Design of Nut ............................................................................................................................. 50
4.3.9.Design Of Hopper ....................................................................................................................... 51
4.3.10. Design of Handel ..................................................................................................................... 52
4.4. Working principle of cement dust collecter machine ...................................................................... 53
4.5. PROCESSES INVOLVED IN FABRICATION .............................................................................................. 53
4.5.1. Pipe bending ............................................................................................................................. 53
4.5.2. Gas cutting (Oxy-Fuel cutting)................................................................................................... 54
4.5.3. Welding ..................................................................................................................................... 54
4.5.3.1. Arc welding ............................................................................................................................ 55
4.5.4.Other Fastener ........................................................................................................................... 55
4.6. MANITENANCE OF MACHINE .......................................................................................................... 56
4.7.COST ESTIMATION OF DEVICE .......................................................................................................... 57
4.8 RESULT AND DISCUSSION ................................................................................................................. 58
4.8.1 RESULT ....................................................................................................................................... 58
4.8.2. DISCUSSION............................................................................................................................... 59
CHAPTER FIVE ............................................................................................................................................. 60
CONCLUSION AND RECOMMENDATION .................................................................................................... 60
5.1. CONCLUSION .................................................................................................................................... 60
5.2. Recommendation............................................................................................................................. 61
Reference .................................................................................................................................................... 62
Appendix 1 .................................................................................................................................................. 63
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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
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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].
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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.
Figure 1.1 Dangote Cement Factory overall view
1.2 Dangote cement Strategy

Dangote Cement is well on the way to becoming one of the world’s leading cement companies
and certainly the largest in Sub-Saharan Africa, which we believe will be the next big growth
market for cement.
Our business is organized into two strategic regions: Nigeria and the Rest of Africa. Each region
pursues its business plan in line with the overall corporate strategy set out by the Group’s Board
and Executive Management, but mindful of the prevailing conditions in each market.
1.3 Vision, Mission and Value of Dangote Cement

1.3.1 Vision
To be a global leader in cement production, respected for the quality of our products and services
and for the way we conduct our business.

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.
1.4 Dangote cement PLC Products

Dangote Cement is of the highest quality and comparable to any quality cement brand in the world.
Cement from Dangote’s modern factories is sold in 50 Kg bags, 1.5 tons jumbo bags and in bulk
tankers. Stringent quality assurance processes are put in place so that customers can be assured of
receiving a high-quality product that meets all the required technical standards.
Dangote cement is a cement factory which produces two types of cement. Those cements are
different by their raw material composition.
The major products of Dangote cement is.
 Ordinary Portland cement(OPC)
 Portland-pozzalana cement(PPC)

1.4.1 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. The manufacture of Portland cement
is, in principle, a simple process that relies on the use of inexpensive and abundant raw materials.
1.4.2 Portland pozzalana cement (PPC)

Portland pozzalana cements are blends of Portland cement and a pozzalana material. The role of
the pozzalana is to react slowly with the calcium hydroxide that is liberated during cement
hydration.
Types of cement Raw material Content in percent(%)
Clinker 95%
OPC Gypsum 5%
Clinker 67%
PPC Pumice 28%
Gypsum 5%
Figure 1.2 products of Dangote Cement Factory

The main techniques and process takes place for producing the product are as follows
1. Blasting
 The raw materials that are used to manufacture cement (mainly limestone and clay) are
blasted from the quarry.
2. crushing and transportation
 The raw materials blasted from quarry is feed into the crusher in order to get the required
size and transported to the plant by belt conveyer.
3. Transport
 The raw material that comes from far place is transported by lorry and crushed in small
crusher that exists in the plant.

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.

1.5 Company’s Customers

 Neham international business
 Adinas Cement Mehari Tesfaye cement whole seller
 Mikir Trading PLC
 Buzualem Kids G/Trading PLC
 KibreabMinuyel PLC
1.6 Company’s Stake Holder

 Ethiopian Investment commission
 Agencies
 Land use and environmental protection
 Minister of mines
1.7 Organizational Structure of the Company

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. There is also other work
division in the company. Each has its own department coordinate according to section.
Figure 1.3 overall organizational structures of the company

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.
2.2 Procedure Used While Performing Our Work Tasks

When we come to this company for Internship we visiting; and working in the company section
according to the following procedure: -
 Getting safety and company supervisor.

 Visiting and observing the plant.
 Study and analysis the plant and system.
 Sharing ideas with the regarded staff workers.
 Take part in maintenance activity when and where necessary
 participating inspection and returning evaluation with each technicians
 Writing the daily and weekly report as the company supervisor order and accepting
consecutive feedback.
 Acting as normal workers as much as possible for all entire duration of internship

2.3 The Section of the Company we have been working

In Dangote Cement enterprise there have three sections for production process on plant such as
Back section (curser, quarry, Storage and Raw material Proportion Area), Middle section
(Preheater, Kiln,raw mill, cyclone, dedusting, condition tower, homogenization silos, ESP,ID Fan
and Cooler Area) and End section(Cement Proportion and Cement mill Area including packing
and loading and cement silos).
There are five section for controlling the factory such as:
 Mechanical and Electrical part maintenance
 Central Control Room (CCR)
 Water treatment station
 Electrical Power Station and
 Laboratory section.
Therefore, we have been working here all around with my technician and consecutive colleagues.
However, our project highly concentrates on the End section of the factory.
2.3.1 Back section

Back section is the section where raw material is transported from Quarry to stored in the storage
and makes to proportionate in the proportion area. There are different processes and machines are
there in this section those are.
2.3.1.1 The quarry
Quarry is a place where raw materials are exploited by Bomb, scavetor and tracker. These raw
materials (limestone, clay, red sand, and gypsum) found in different Quarry are used in cement
manufacturing.
Figure 2.1 Quarry

2.3.1.2. Hummer Crusher

Hummer crusher is a rotating machine which has a very large weight to producing high force that
breaks up the raw material delivered from the quarry and provides the raw mill with the feed size
range it requires. Therefore, Crushing is the first step where reduction of raw materials takes place.
The hummer crusher reducing the size of raw material 25mm to 75mm. limestone raw materials
from quarry are transported to the storage room inclined and horizontal by belt conveyor.
Parts of crushing plant:
 hopper
 Apron feeder
 V- Belt
 Belt weigh feeder
 Jet pulse bag filter
Figure 2.2 Hummer Crusher

2.3.1.3 Raw Material Transportation and Raw Materials Storages
All raw materials are transported from crusher to their respective storage by Belt conveyor, trucks
and different types car. All raw materials have their own storage at the plant site.
2. 3.1.4 Stacker
It is used to pile bulk materials like limestone, coal, additive, and corrective on to stock pile.
Normally it travels on a rail between stockpiles in the stockyard. A stacker can usually move in at
least two directions: horizontally along the rail and vertically by luffing (raising and lowering) its
boom. Luffing of the boom minimizes dust by reducing the distance that material needs to fall to
the top of the stockpile.
The boom is luffed upwards as the height of the stockpile increases.

Figure 2.3 Stacker

2.3.1.5 Reclaimer
A Reclaimer is a machine used in bulk material handling applications. Its function is to recover
bulk material such as ores and cereals from a stockpile. Reclaimers are volumetric machines and
are rated in /h (cubic meters per hour) for capacity, which is often converted to t/h (one ton per
hour) based on the average bulk density of the material being reclaimed. It is normally travel on a
rail between stockpiles in the stockyard. Generally, it is electrically powered by means of a trailing
cable. Reclaimer capacity to feed materials on the belt is 1250tons/hr.
Figure 2.4 Reclaimer

2.3.1.6 Raw Material Proportioning
Limestone, sand stone and red clay are transported from their respective storage to the
proportioning or raw material feeding systems bin or hopper with the help of Reclaimer, Scraper
and belt conveyor.
There are four bins on the building of raw material feeding system.

These bins or hopper are;

I, Two Lime stone bin
II, Sand stone bin
III, red clay bin and
S.No Types of material Percent of raw material required Storing capacity of the bin
1 Lime stone 75% 600t each

2 Corrective material 200t each
3 Red clay 10% 200t
4 Stand stone 15% 200t
Under each bins hopper there are small apron feeder which are operated at different speed to feed
the material as required ratio to the bottom belt conveyor. At this stage the proportioning of raw
material is done and transported to VRM.
2.3.2 Middle section
In this; section where raw material is transported from storage to clinker production. In this there
are different mechanisms and system process to changing the property of the raw material to
clinker production. Those are:
2.3.2.1 Vertical roller mill (VRM)
VRM is a machine used in that company to mill a material.
Working principle
The material to be ground is crushed between the rotating grinding table and the individually
guided grinding rollers. Grinding is carried out primarily through the application of compressive
force. A small amount of shear force supports the displacement of crystalline layers in the raw
material. A higher specific grinding pressure is applied compared to coal grinding and a lower
specific grinding pressure is applied compared to the fine grinding of clinker and granulated blast
furnace slag. Hot gases are added in the dry grinding process to evaporate material moisture. Use
is predominantly made of the exhaust gases from the rotary kilns, the heat exchanger or the cement
clinker cooler. If none of these sources are available or the heat content of these gases is
insufficient, Loesche’s own hot gas generators are deployed but in dangote cement plant these hot
gas generator is taken off because, there is sufficient hot gas from rotary kiln and clinker cooler.

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.
Figure 2.5 Vertical Roller Mill (VRM)

2.3.2.2 Heat Conditioning Tower
Heat conditioning tower is used to reduce the temperature of hot gas by receiving hot dust from
preheater. The inlet temperatures of hot dust are from 316-600 oc and the out let temperature of
hot gas is only 250 oc. This tower is reducing the temperatures of hot dust by spraying the water
to hot dust. Then the dust will be separated from the air and the hot gas with temperatures of 250
oc will be send to the VRM. Under this tower the screw conveyor is exist to transfer the dust
materials to the drag chain conveyor which finally transport the materials to homogenization silo.
Figure 2.6 Heat Conditioning Tower

2.3.2.3 Bag House

Bag filter is a new type of dedusting equipment which has many proprietary technologies such as
side gas inlet, the length of bags is able to reach 6 – 8 meters, and it is the long bag fabric filter in
real sense. LJP fabric filter (bag house) consists of support structure(optional), bottom girder,
hopper, bag chamber, inlet and outlet ducting(optional), outlet damper, bags, cages, clean gas
chamber, gas piping system, penthouse, top hoist, thermal insulation (optional), dust conveyor and
air lock devices (optional), ladders, platforms, control system and so on.
Working principle
Gas with dust comes from gas inlet into gas passage, and enters each bag chamber from side via
inlet valve separately. Gas distributes evenly and diffuses toward-up in bag chamber and enters
filtration area from top. Dust is stopped on outside surface of filter bags after gas is filtered by
bags and goes into atmosphere through clean chamber and outlet shutter valve, the gas-purge
process is over. Equipment operation pressure difference will increase when the accumulated dust
thickness outside surface of filtration bag reaches certain thickness. When pressure difference
reaches the given value, ash-purge programmer starts working. On the off-line ashpurge condition,
firstly close outer shutter valve (off-line) in one clean chamber, and then pulse valves in this
chamber will start jet to clean the filtration bags step by step; open outlet shutter valve(in-line)
again after ash-purge process has finished. Removed dust will all fall down into hopper and
exhausted by air-locking device and conveyor. Bag Filter operation is controlled by one ash-purge
controlling device which can purge dust automatically by timing or given differential pressure.
Figure 2.7 Bag Filter

2.3.2.4 Homogenization Silo

Homogenization silo is used to store the raw materials and homogenized the raw materials. Under
this silo there are three root blowers which are used to prepare the compressed air used in this silo
to homogenize the raw materials.
Figure 2.8 Homogenization Silo

The materials are transported to this silo by air slide conveyor from the cyclone and by the drag
chain conveyor from the air bag. Then on the ground the materials from both sides are transported
to the one hopper and from this hopper the materials will be transported to the top of silo by bucket
elevator conveyor. Then on the top of this silo there are eight, 8 different Air slides which are used
to receive materials from bucket elevator conveyor discharge and storing in the silo.
2.3.2.5 Gas Conditioning Tower System
The conditioning tower in the cement plant is used to lower the specific resistivity of the dust and
temperature of the exhaust gas from the preheater to improve operating environment of the
electrostatic precipitator and to increase the dust collecting efficiency. It is used to deal with the
exhaust gas from the preheater in the clinker production line or the similar exhaust gas.

Structure and working principle
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.

2.3.2.6 Air Slides

Air slide is pneumatic and conveying equipment that is widely used to convey dry and powder
material. It is used to convey cement and raw material powder in cement industry. Air slide is
characterized by easy maintenance, good sealing, no noise, safe operation, low consumption,
convenient to divert, It is widely used to charge and discharge at multi-point etc. because of no
driving part.
The main part of air slide is ventilated layer. The series product is applied PET5～6( terylene )
compound fibre textile, which is a new type ventilated layer. It is characterized by high temperature
resistant (to centigrade 150), anti-corrosive, anti-abrasion, low moisture absorption, light weight,
level surface and long life... etc advantages.
Working principle
Air slide is used rivet joint; connect groove body of steel thin steel plate and other appendix with
bolt. The upper and bottom shell of groove body has ventilated layer. The air slide is inclined with
the level in some angle. The material chamber is on the top of ventilated layer, Gas chamber is
under it. Pressure gas is blown to gas chamber through ventilated layer that can make material
flow. Material is flowed like fluid in groove body with the gravity. Wind source is fan usually.
The remainder air is discharged by dust filter from air outlet.
2.3.2.7 Preheater
The most common designed Preheater in Dangote Cement has five cyclones. These are used to
preheat materials before entering to the kiln. Secondary air from clinker cooler and primary air
Preheater and Calciner complete the Preheater 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 (calcinations) function, so the size of the kiln
can be smaller. Positive as it does, Preheater and Calciner is key equipment of the clink
calcinations. It relates to the stabilization of the burning schedule and increase of the quality and
quantity directly. Preheater, kiln and cooler are three sets of main equipment of cement plants.
This Preheater system is composed of a double-string Preheater and on-line Calciner. Fuel and
preheated raw material entered the Calciner are taken by high-speed current of air, suspend inside
in the stove, go upside in spiral flow and fire and resolve at the same time. The combustion of the
fuel gives out heat and the raw material absorbs heat to decomposition. These two processes

happen very quickly at the same time in suspended situation. The CaCO3 decomposition of raw
material has already completed before going into the kiln.
Figure 2.9 preheater

2.3.2.8 The Rotary Kiln
A kiln is horizontal cylindrical tubes which have a length of 74m and diameter of 5.2m and
supported by double freely rotate rollers at three positions. A kiln has a temperature of around
1400 Cº and arranged to an angle of 4 degree to the cooler. In rotary kiln, material is fed through
kiln inlet, because kiln tube erection is at inclination, when the kiln rotates, material continuously
moves from kiln inlet to kiln outlet, therefore cement kiln is also the transmission equipment. The
raw meal is fed at the upper or cold end of the rotary kiln, and the slope and rotation cause the
meal to move toward the lower or hot end. The kiln is fired at the hot end, usually with coal as the
primary fuel. As the meal moves through the kiln and is heated, it undergoes drying and pro
processing reactions to form the clinker, which consists of lumps of fused, incombustible material.
There are Three Common Techniques for Burning Clinker in a Rotary Kiln
 Maintain a constant kiln speed, and vary the fuel rate to counteract the temperature
changes in the burning zone
 Maintain a constant fuel rate, and vary the kiln speed to hold the burning zone temperature
at the desired label
 Vary the kiln speed, the fuel rate or both to maintain the desired burning zone temperature
These techniques have one error in common. They show concern only for the burning zone
temperature.

Figure 2.10 rotary kiln

2.3.2.9 Clinker Cooler
The clinker Cooler serves to cool clinker from the 1200ºCat which it leaves the kiln to less than
100oC by exchange of heat with ambient air before preheated and entering the kiln (or pre
Calciner) as combustion air. 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 90ºC to 65 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
2.3.2.10 Hot clinker conveyer
These conveyors are used to transport hot clinker from the great cooler exit to the clinker store.
Their designs are various types of bucket conveyor with two strand of chain. The chains tend to
be long pitch and have outboard rollers mounted on one side of the chain. A typical layout consists
of two chains, each 1200kN breaking load, 250mm pitch with stay bar bearing pins at two pitch
spacing and outboard rollers on the stay bar ends. Overlapping buckets are bolted between the
chains at every two pitches.

Figure 2.11 hot clinker conveyers
2.3.2.11 Electrostatic Precipitator Air Filtering Method

An Electrostatic precipitator (ESP) is a device that removes dust particles from a flowing gas using
the force of an induced electrostatic attraction i.e, like charges repel; unlike charges attract.
Components of ESP
 Control box
 Boosting transformer (6)
 Rectifier
 Knocking hammer
 Collecting electrode
 Rotary locker
 Exhaust fan, etc
2.3.2.12 Air Compressor
It is a mechanical device which converts mechanical energy into fluid energy. The compressor
increases the air pressure by reducing its volume which also increases the temperature of the
compressed air. The compressor is selected based on the pressure it needs to operate and the
delivery volume. The compressor can be classified into two main types
a. Positive displacement compressors and
b. Dynamic displacement compressor

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.
Figure 2.12 Clinker Storage

2.3.3 End Section:
This section is the section where clinker is mixed with Gypsum or pumice for grinding in cement
mill and produce cement which is final product of the factory. Therefore it is the final section of
the plant.
2.3.3.1 Cement Mill Proportioning
Cement mill is station where the milling of cement is started. There are three lines. All lines have
their own proportioning station. On every cement mill proportioning there are three independent
bins. These bins are used to store Clinker, Pumice and Gypsum. This material will be proportioned
by required ratio and finally grinded in ball milling.

S.No Name of raw material at cement mill proportioning Capacity of bins

1 Clinker 600 tones
2 Pumice 200 tones
3 Gypsum 200 tones
The process of quality of cement is end at these stations. There are two types of cements produced
in dangote Cement. They are OPC and PPC. The difference between these cement is based on their
strength. The strength of OPC is 42.5 and the strength of PPC is 32.5. This strength is based on
the type of composition of the clinker, Gypsum and Pumice.
2.3.3.2 Cement mill
The LOESCHE roller grinding mill for grinding clinker/slag consists primarily of the feed material
gate;
– the mill
– the classifier
– the mill gearbox with clutch and drive motor
– hydraulic control and lubrication cabinets for the rollers.
from there directed via a reject hopper to the The individual machines are assembled into a "roller
grinding mill" functional unit or interconnected by pipes. The grinding material is dumped through
an air gate into the feeding chute on the classifier. Gravity forces it centrally onto the table, which
is set into rotator motion by an electric motor and the mill gearbox. The centrifugal force acting
on the table delivers the grinding material to the rollers. The grinding material is crushed between
the respective master roller and the grinding route by pressure and friction under the influence of
the hydropneumatic roller spring assembly system. A support roller for preparing the grinding bed
is located upstream of the master roller in each case. Crushed grinding material is discarded via
the tableedge into the area of the Louvre ring. There it is intercepted by the air flow which is drawn
in through the mill and the classifier to carry and classify the grinding material.
Material already crushed to final fineness exits the LOESCHE cement mill together with the air
flow via an outlet fitting on the classifier. Oversized material is rejected by the classifier and
redirected via a directing cone to the table to be crushed again. Grit which is neither intercepted
by the rollers for crushing nor routed by the air flow to the classifier falls through the Louvre ring
into the ring duct surrounding the table and external reject handling system.

Figure 2,13 Cement mill

Flow of grinding material through mill, pictorial representation
Key
1 Grinding material inlet via air lock 6 Rollers grind material
2 Material is intercepted by hot gas flow 7 Material rejected by classifier
3 Grinding material drops through chute onto centre of table 8 Classification of material in
classifier
4 Hot gas flows through louvre ring 9 Finished material outlet
5 Hot gas inlet
2.3.3.3 Cement Silos
The cement will be stored in these silos after pass the phase of cement mill ball milling. The
powder of the cement will be transported from ball milling station, to underground of silos by Air
slide conveyor and then after transported by elevated bucket conveyor to the top of silos. Under
these silos there are root blowers used to remix the powder in this silo. There are three silos in this
factory. Two silos are used to store the PPC and the rest one is used to store OPC. Based on the
interest of the customers, the customers who want the powder cement without bag they can take

from these silos by special Lorries designed for this interest. Otherwise the powder will be
transported to the packing stations.
Figure 2.14 Cement Silos

2.3.3.4 Packing and Loading
Once the production of Portland cement is complete, the finished product is transferred using
bucket elevators and conveyors to large, storage silos. Most of the Portland cement is transported
in bulk by truck or in 50 kg multi walled paper bags. Bags are used primarily to package masonry
cement.
Figure 2.15 Packing and Loading
2.4 Our Performance at the Company

Strength
 We have a great inspiration to work with company’s community.
 Best relation with other student that comes for internship from other university.
 Respect the rule and regulation of the company full in full
 Punctuality and willingness to learn and accept constructive criticism and change
 Capacity of developing and proposing technical ideas and implementing system
 Initiative and responsible trainees

 Teamwork skill and interpersonal communication

Our weakness
 Lack of memorizing and relating some theoretical knowledge with practical.
 Weak work speed or productivity
2.5 Challenges We Faced While Performing Our Work Tasks

There are few challenges that encountered during our stay in the company.
 Get use to the working environment
 Getting the trust of workers to execute a specific job alone
 Following rules and regulation
 Taking health and security measures
 Understanding executed working procedure
 It was difficult to get information about the company performance, because there were no
computer and learning guidance.
 Lack of manuals and even we get manuals it’s difficult to understand because the
manuals are contains grammatical disorder and difficult language.
2.6 Measures taken for the Challenges we faced

 Getting familiarized with the workers
 Prepare do and not do lists and follow them
 Try to complete the job given on time and with good quality
 Ask for help if find difficulty in executing assigned job.
 we were contact the IT office to fill the password to us and we were able to find some
books with soft copy from internet.
 we took a time for discussion on the introduction new technology and system with our
colleagues and gather required data by repeating many days without boring.

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.
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 in the following ways;
 how the certain machines are operates
 how the certain machines are handled
 how the theoretical knowledge and real world are integrated
 how to reason out the problem of equipment and come with solution
 acquiring opportunity and way to change what we have in mind into practical world as
much as possible
3.2 In Terms of upgrading Theoretical Knowledge

The additional skills and knowledge gained during an internship can often be directly applied to
the studies and applied correctly can lead to better grades.
The theoretical knowledge can be upgrade by:
 Seeing practically and get more information through observation.
 Ask the maintenance operators and other responsible person to the different machines in
different department.
 By relate with theories, calculations, machine type differences, working principles,
efficiencies, and property of the machines.
 And by using manuals and other materials from the company
3.3. In Terms of Improving Inter Personal Communication Skills

The ability to communicate with other persons is highly improved in our internship duration. We
have wisely communicated with different professionals getting into their offices and also at the
sites. In work place there are many workers, laborers and we must be easily communicated with
these persons. Because to upgrade our theoretical knowledge with practical work, even we must

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.
3.4 In Terms of Improving Team Playing Skills

Team building is a process where a group of people analyze their group strengths and weakness,
capacity and potential in order to achieve and improve effectiveness. It can also be defined as a
skill of a person to work with other people co-operatively. During our internship we observed that
how many different workers, foremen, site engineers and supervisors are coop erative for one
common goal to achieve it.
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
3.5. In Terms of Improving Leadership Skills

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.
In our context, we have met different chairman and we have seen how they treat us in different
issues. We also got different skills from them, starting from the Forman to the mangers.
Generally we got the following skills from them:
 How to organize different work divisions

 How to treat customers in different issues.

 Taking risk during any activities
Generally, during our internship period we have improved and obtained different professional
ethics and the right way to behave at work place. These include:
 Responsibility
 Punctuality
 Following order
 Initiation
 Productivity
 courtesy (a polite speech)
3.6 In Terms of Understanding about Work Ethics Relate Issues

While working in Dangote Cement Industry was obliged to know the work ethics issues such as
punctuality, motivation and commitment, respecting others work, preceding countries benefit
instead of once benefit, etc. This is important for our in the future because we will not be new to
this rules, and by now we know that respecting and trying to implement the rules is beneficial for
once and countries development. From this perspective, we have gained a valuable lesson that
transparency and carefulness are two very important work ethics one needs to abide and live by:-
Punctuality: - means keeping the companies work beginning and ending time and to complete a
given task within the given period.
Office disciplines: - in work place we don’t have to disturb the working atmosphere. For example
abstain from opening loud voice, loud music, songs and things which disturb others workers
working mood.
Reliability: - The worker should be qualified for the part he is supposed to be performing.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 interact 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.

3.7 In Terms of Entrepreneurship Skills

What is entrepreneurship and what makes a successful entrepreneur? If you look at the pure
definition of entrepreneurship it is described as” the capacity and willingness to develop, organize,
and manage a business venture along with any of its risks in order to achieve profit”. We believe
that what distinguishes a mediocre entrepreneur from a great entrepreneur depends on the
following 10 skills.
 The ability to execute (hugely important!)
 Great interpersonal skills and Endurance

 Willingness to take risk
 Must have a vision
 Eagerness to create a fundamental change in an existing market or new market
 Confident in own abilities
 Can-do-approach to work
 The ability to identify consumer’s “pain points”
 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.

4.1.2. LITERATURE REVIEW

Prathmesh Joshi , p., at al [10]
This paper is based on “Manual driven platform cleaning machine” which provides the basic need
of cleaning very large floor areas such as railway platforms, hospitals, malls and many investments
have been made for the same. In recent times Indian Railways has purchased platform rider
scrubbers and platform cleaning machines from various companies to ensure hygiene. Due to
absence of electricity at bus stand, railway platforms and other commercial places, the automatic
cleaning machine isn’t suitable in every condition. The author fabricated a four wheeler cart with
the help of accessories such as belt, pedal axle, scrubber brush, U-clamp cleaning process is
executed.
This paper deals with design and fabrication of tricycle operated street cleaning machine
suggesting that we have few foreign automated machines that are used in our country according to
the road conditions. The objective of the author is to propose semi- automatic machine for rural
and urban areas in order to reduce human efforts and time.
A suggested solution over the current state of art is being explained through this article. The
technique of this unique machine runs with the power of ten humans.
Pedal operated floor mopping machine is operated at low speed with the help of mechanical power
using foot pedals. This mechanism is somewhere close to the spinning mop also known as “magic
mop”. For speed multiplication with right gear specification bevel gear has been used. And for
better ergonomics the machine move on three wheels which is driven using pedals with the help
of mechanical drive train. Attempts have been made to make the turning radius of the machines as
small as possible so as to get efficient and effective cleaning without missing any spots. An
additional mechanism is provided to remove dirty water by which the mop can be cleaned and
fresh water is supplied to offer continuous floor cleaning.
This paper elaborates manually used floor cleaning machine which differs from conventional floor
cleaning machine which is dependent on electricity for the usage. Modeling and analysis of this
machine is done by using available software called ANSYS, the stress level in the machine were
found to be within safe limits after finite element analysis. This cleaning machine is uniquely
designed to clean the floor which are smooth and plane such as tiles, mosaic and smooth surfaces.

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.
4.1.3. LIST OF PROBLEM IDENTIFIED IN COMPANY

 Extra cement and powder dropped from different parts makes pollution. Those powders
are deposited at different area like that of; limestone storage, packing and loading area etc.
this makes extravagance of raw material without their usage. Even if this dust is found
there is no machine which used to clean. The worker clean by using spade, shovel and
squash on the loader outside machine room because loader cannot inter to room due to
space occupation so that it needs high man power as well as time.
 Energy auditing and waste heat recovery system design for cement rotary kiln. This waste
energy is released from rotary kiln in to the environment during the rotation of the kiln and
high formation of heat when the raw materials are burning. Therefore; this energy should
have to be control and used for another work.
 There is no simple and moderate machine to transport medium load from one place to the
other even exist the existed hand truck has make injuries on the health of worker.

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.

Figure 4.1 Problem We Saw
4.1.4. SCOPE OF THE STUDY

 Design and fabrication of dust extractor machine
 Selection and Implementation of major components
 Motor
 Rotor
 Blower fan
 Integration of all other engineering details
4.1.5. SALIENT FEATURES

 Dust collector machine is provided with stainless steel 304/316contacts parts
 In this Dust Collector Machine, Blower Fan is dynamically balanced and the unit is with
castor wheels.
 Overcome dust hazards as well as cross contamination at packing plant
 Machine in fitted with the castor wheels for easy mobility

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

 Checking availability and manufacturability of those components

 Selecting materials for each component
 Analyzing each component strength wise
 Choosing method of joining for components
 Assembling orderly
4.1.8 SIGNIFICANCE OF THE STUDY

In our main concern of the study the designed machine can facilitating the following significant;
 Manual effort is reduced.
 Operating time is less.
 Operating cost is less
 Design is very simple.
 Easy fabrication.
 It occupies less floor area.
 Initial cost is less.
 Net weight is less.
 Maintenance cost is less.
 It can be used in various places.
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
4.2. COMPONENTS OF DEVICE AND MATERIAL SELECTION

4.2.1. Components of Dust Collecting Machine
 Dust collector hopper
 Filtration Bag
 Rotor and Motor
 Blower Fan
 Caster wheel
 Pulley
 Container
 Bolt and Nut
 Shaft
4.2.2. FUNCTION OF MAIN PARTS

 Dust collector hopper
Dust collector hopper is used to collect the dust which is sucking by the blower fan also collect
the small dust which is stappered by stapper through the Filtration bag
 Rotor and 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.
4.3.DESIGN ANALYSIS FOR COMPONENTS OF DEVICE

Technical Specification
We divided the design part into to the machine element part and turbo machinery part.
4.3.1. Design of Blower Fan.
Motor power 5Hp
Motor speed 3600
Inlet diameter of rotor(D1) 120mm (0.12m)
Outlet diameter o the rotor(D2) 200mm (0.20m)
Vane angle () 20 degree
Width of the vane 60mm
 SECTION 1.1 VELOCITY OF THE VANE(U1)

𝜋D1N
Velocity of the vane (u1)= Where : D1=inlet diameter of fan
60

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)
4.3.2.Design Of Belt And Pulley Of Rotor And Rotory Feeder
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
 angular speed of driven pulley(ωp2) for D=40mm

𝑉 1.4
ωp2= 𝑅𝑝2 = = 70rad/s
20×10−3
2𝜋𝑁𝑝2 ωp2×60 70×60
But ωp2 = Np2 = = = 668rpm. So speed of driven pulley:
60 2×𝜋 2𝜋
 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:

𝑅𝑝𝑚 𝑓𝑎𝑠𝑡𝑒𝑟 𝑝𝑢𝑙𝑙𝑒𝑦 1338

SR = 𝑅𝑝𝑚 𝑠𝑙𝑜𝑤𝑒𝑟 𝑝𝑢𝑙𝑙𝑒𝑦 = =2
668
3.Minimum Diameter of Pulley:

The Dimensions of driver pulley is selected from dimension of standard V-belts according to IS:
2494 –1974 based on design power. Since the design power is minimum here belt for minimum
design power application is chosen.
 Type of belt A.
 Driver pulley diameter (Dp1) =75mm.
 Top width =13mm(belt)
 Thickness= 8mm
4.Velocity of Belt:
𝜋𝐷𝑝1𝑁𝑝1 𝜋𝐷𝑝1𝑁𝑝1 𝜋×0.075×1338
Vb = = = = 5.25m/s.
60 60 60
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.

Graph 4.2 variation of power added to rated power. hp Vs speed ratio

For speed ratio of 2 the power added to rated power (RP) is 1492W.
Total power = Rated power + Power added to rated power
 TP = 1492 + 2611 = 4103W
7.Estimation Of Center Distance:
Based on design book the approximation of the center distance for the belt is
D1 <Cest<3(D1 + D2 ) →20<Cest<3(20+ 75 ) → 20 <Cest<285
The estimated center distance of the belt must lie between range of 60mm and 285m.
So the estimation done is Cest = 200mm.
8.Non Actual Belt Length:
2 (𝐷
2− 1𝐷 )2
Non actual belt length is given by: Lna = 2Cest +𝜋 (𝐷1 + 𝐷2 ) + 4×𝐶𝑒𝑠𝑡
2 (75−20)2
Lna = 2×200+𝜋 (20 + 75) + 4×200 =464mm
9.Finding Standard Length:
From Standard pitch lengths of V-belts according to IS: 2494 – 1974. The selected belt is the
one nearest to the non- actual belt length which is 645mm.
 Lst = 645mm.
10.Actual Center Distance:
Actual center distance ( Cact) is given by:
B+√𝐵2 −32(D2−D1)
 Cact= …………..Eqn [3.7]
16
 B =4Lst-2π(D2 – D1)= 4×645- 2π(75 -20) = 2235mm

2235+√22352 −32(75−20)
So Cact= = 279mm.
16
11.Wrap angle Of Smaller Pulley:

𝐷2−𝐷1 75−20
θd = 1800 - 2sin−1 [ 2𝐶𝑎𝑐𝑡 ] = 1800 -2sin−1 [2×279]= 1690
12.Correction Factor (CΘ):

Correction factor is obtained from standard table using wrap angle of smaller pulley. For wrap
angle of pulley 1690 the correction factor is 0.95.
Cθ = 0.95
Graph 4.3 variation of angle of wrap correction factor Vs angle of wrap, degrees
13.Corrected Power (CP):

 CP =1.2×Cθ×TP
 CP=1.2×0.95×4103 = 4677W
14.Number of Belt Needed:
Design Power 1400
 The number of belt needed is = = = 0.3 ≈1
Corrected power 4677
 So the required number of the belt needed for cleaner is 1

figure 4.2 v-belt pulley and rotary feeder

4.3.3. Shaft Design
Assuming that the shaft is made up of C45 steel from this σy=380N/𝑚𝑚2
Factor of safety, n=2 𝜏y =σy/2=380/2=190N/𝑚𝑚2
Assumption that we take to design shaft.
 The machine supported in bearing having their center 500mm apart.
Power transmitted P=5hp=3730W.
 Speed N=3600rpm.
 Diameter of gear Dg=60mm.
 Diameter of pulley Dp=75mm.
 Pressure angle , =200
 Wrap angle =1690
 Weight of pulley Wp=200N
 FOS=2
𝑇1
 Belt tension, 𝑇2=3
2𝑁𝑀𝑡
Power P= 60
2𝑥3600𝑥𝑀𝑡
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
 Normal load acting on the gear

𝐹𝑡𝑔 333
WB= 𝐶𝑜𝑠 = 𝐶𝑜𝑠20=355N
 Resolving the normal load vertically and horizontally

Vertical component at B
WBV=WBCos=355Cos20 =333N
 Horizontal component at B
WBH=WBSin=355Sin20 =122N
 Pulley is carrying total load T1+T2 that acts horizontally
Horizontal load at P
WDH=T1+T2=400+133=533N
 Self-weight of pulley acts down wards vertical load at D
WDV=Wp=200N
Where ; L1=250mm,L2=250mm,L3=250mm
 CONSIDER VERTICAL LOAD ONLY
Let RCV and RAV reaction forces at A and C

Taking moment at about @A

RCVx500=333x250+750x200
RCV=466.5N
For equilibrium condition
RCV+RAH=333+200
RAH=66.5N
 BM at A=0
 BM at B, MBV=RAVx250=66.5x250
 BM at B= 1.6625x104 Nmm
 BM at C MCV=200x250=5x104 Nmm
 CONSIDER HORIZONTAL LOAD ONLY

Let RAH and RCH are reaction at A and C respectively
Taking moment about @A

RCHx500=750x533+122x250

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
 RESULTANT BENDING MOMENTS

Resultant BM at A and D =0
Resultant BM at B Mb@c=√(𝑀bv)2 + (𝑀𝑏ℎ)2
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
Resultant Bending Moment Diagram

Equivalent torsional moment

Mte=√(𝑀b)2 + (𝑀𝑡)2 =√(1𝑥104 )2 + (1.423𝑥105 )2

Mte =1.43𝑥105 Nmm
Assuming that the shaft is made up of C45 steel from this σy=380N/𝑚𝑚2
According to maximum shear stress theory
𝜏y =σy/2=380/2=190N/𝑚𝑚2
Factor of safety, n=2
Allowable shear stress
𝜏= 𝜏y/2= 190/2=95N/𝑚𝑚2
We know that

Mte=16x𝜏x𝑑3

1.43x105 =16x𝑑3 x95 𝑑3 = 7651
D=19.7mm
The nearest standard diameter of shaft is
D=20mm
So the result d=20mm
Figure 4.3 Shaft
4.3.4. Bearing Selection

A ball bearing is a type of rolling-element bearing that uses balls to maintain the separation
between the bearing races. The purpose of a ball bearing is to reduce rotational friction and support
radial and axial loads. It achieves this by using at least two races to contain the balls and transmit
the loads through the balls. In most applications, one race is stationary and the other is attached to
the rotating assembly. As one of the bearing races rotates it causes the balls to rotate as well.
Because the balls are rolling they have a much lower coefficient of friction than if two flat surfaces
were sliding against each other.

Selecting a ball bearing with

 minimum inner diameter of 10mm,
minimum load carrying capacity of 50kg radially, and
 Speed greater than 100 r.p.m.
 Bearing selected - SKF6006 open deep groove ball bearing 15x30x13mm
 Inside diameter: 10 mm
 Outside diameter: 20 mm
 Width: 13 mm
Figure 4.4 Bearing

4.3.5 Wheel Selection
Here we have used 4 wheels in pair on 2 each with one shaft mounted on both side of the frame
with bearing inside the bore of wheel to get friction free movement of wheels.
 Specification of wheels i) Material: - filled rubber wheels
ii) Diameter: -120mm
iii) Thickness: -30mm
Table 4.2 material and their coefficient of friction
S.no Material Coefficient of friction
1 Rubber/concrete 0.85
2 Polyurethane/Concrete 0.5
3 Steel/Concrete 0.45
Rolling resistance of wheel

Coefficient of rolling resistance [Crr] = (0.0048) (18/D)1/2(100/W)1/4

Where, D = Diameter of the rolling wheel in inches
W = Load acting normal to the wheel on the frame in lbs
Rolling Resistance [F] = (W.Crr)/R
The diameter of the wheel = 12 cm=4.72in
The maximum load acting normal to the Base plate = 100 kg=220.46lbs
 Now coefficient of rolling resistance
Crr= (0.0048) (18/D)1/2 (100/W)1/4
Crr= (0.0048) (18/4.72)1/2 (100/220.46)1/4
Crr= 0.007688
 Rolling resistance
F = (220.46*0.00768)/2.95
F = 0.696 lbs
F = 0.574kg
∴F = 5.74 N Rolling resistance determines the stability of rolling wheel
Figure 4.5 Wheel
4.3.6. Design of Container

The container is made of a sheet metal which is used to collect and temporarily storage for
material to be transported. It is designed in such a way that it fits with the frame by using bolt
and nut and also it has a covering plate in order to avoid material jumping from inside of
container
Its dimension is selected as follow.
 Sheet metal of 5 mm in thickness was used for the fabrication of the container.
 Width x Length x Height of container =900mm x 900mm x 1200mm

Figure 4.6 Container

4.3.7. Design of Bolt
Assumption and material selection
We select mild steel having structural property (ASTM-A36):𝜎𝑢𝑡 = 400Mpa, 𝜎𝑦 = 250Mpa,
𝜏𝑦 = 145Mpa and mass of motor Mm=10kg. Then applied force on bolt F=mg=10×10=100N
𝐹 100𝑁
We use four bolts, Then the applied force on each bolt Fb=4= 4 =25N, F.s=2
Design analysis
𝜎𝑦 250
𝜎𝑎𝑙𝑙 = = = 125𝑀𝑝𝑎
𝑓. 𝑠 2
𝐹 4𝐹
𝜎𝑎𝑙𝑙 = =
𝐴 𝜋𝑑𝑏2
25000
𝑑𝑏 = √(4 ∗ ) = 15.96𝑚𝑚 ≅ 16𝑚𝑚
(𝜋 ∗ 125 ∗ 106 )
Take diameter of bolt =16mm
Figure 4.7 Bolt

4.3.8 Design of Nut
When a bolt and a nut is made of mild steel then the effective height of nut is made equal to the
nominal diameter of the bolt. If the nut is made of weaker material than the bolt, then the height
of nut should be larger. Such as 1.5d for gun metal, 2d for cast iron and 2.5d for aluminum alloy
(where, d is the nominal diameter of the bolt).

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
Figure 4.8 Nut
4.3.9 Design of Hopper

The material We select for hopper is a sheet metal with 3mm thickness
Figure 4.9 Hopper

 Area of upper part
A=width x length =(wxl)
A=220mmx220mm=48400mm2=448cm2
Volume =width x length x height=(wxlxh)

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
4.3.10. Design of Handel

The handle is made of plastic tube. The handle is designed in such a way that to fit to the body
and based on considering the average height of a man.
Based on this consideration we fix the dimension of the handle as follows
Plastic tube of 5 mm in inside diameter was used as handle. Plastic tube is used for safety
of hand and to make friction between hands.
Outer Diameter of handle tube = 20mm
Maximum height of handle =100mm

Figure 4.10 Handel
4.4. Working principle of cement dust collecter machine

Cement dust extractor machine is extremely useful in controlling the dust generated during the
packing of the cement and transferring to the loading. These equipments are used to remove excess
powder and loosed powder from the floor and the material around the packing plant. These Dust
Extractor Machine is not only ensure a dust free end product for use but also health and safety of
people coming in contact with packing of cement and loading process. Extracting hazardous dust
at the point of origination and conveying them to the correctly designed filtration system is
necessary to protect both personnel as well as the plant.
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.
4.5. PROCESSES INVOLVED IN FABRICATION

4.5.1. Pipe bending
Tube bending as a process starts with loading a tube into a pipe bender and clamping it into place
between two dies, the clamping block and the forming die. The tube is also loosely held by two
other dies, the wiper die and the pressure die. The process of tube bending involves using
mechanical force to push stock material pipe or tubing against a die, forcing the pipe or tube to
conform to the shape of the die. Often, stock tubing is held firmly in place while the end is rotated
and rolled around the die. For some tube bending processing, a mandrel is placed inside the tube
to prevent collapsing. Much of the tooling is made of hardened steel or tooled steel to maintain
and prolong the tools life. However wherever there is a concern of scratching or gouging the work

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
Fig 4.11 Tube bending for CDE machine
4.5.2. Gas cutting (Oxy-Fuel cutting)

Oxy-fuel cutting is a very effective method for cutting a sheet metal and welding of the strong
metal. It can be used to easily cut rusty and scaled plates and only requires moderate skill to
produce successful results. The oxy-fuel gas cutting process creates a chemical reaction of oxygen
with the base metal at elevated temperatures to sever the metal.
We selected the gas cutting to cut the side part of the container used to store the dust and the side
part of the hopper .
Fig 4.12 Gas cutting for CDE machine
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.
4.5.3.1 Arc welding

These processes use a welding power supply to create and maintain an electric arc between an
electrode and the base material to melt metals at the welding point. They can use either direct (DC)
or alternating (AC) current, and consumable or non-consumable electrodes. The welding region is
sometimes protected by some type of inert or semi-inert gas, known as a shielding gas, and filler
material is sometimes used as well.
We choose arc welding to join and weld the side part of the hopper and the container and also to
weld the motor with its holder.
Fig 4.13 Arc welding for CDE machine
4.5.4 Other Fastener

There are two types of fastener
 Permanent
 Temporary

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
Fig 4.14 Type of fastener used for CDE machine
4.6. MANITENANCE OF MACHINE

For effective and efficient performance of the machine proper maintenance activity
must be carried out regularly or daily as per requirement. The maintenance technique
can be preventive maintenance or proactive maintenance. The operator or the user of
the machine has to follow the proper instruction of operation of the machine during
installation and during the operation of the machine. When the maintenance activity is
carried out proper maintenance procedures has to be followed to avoid maintenance
induced failure.
Routine maintenance such as cleaning, lubricating, adjusting the loosened nuts
and bolts is very necessary as it avoids the occurrence or rate of failure and
sudden stoppage of the machine.
 Checking the lubricant oil level of bearing reduces the failure of the bearing as
well as loss of power due to high friction developed due to lack of oil.
 For effective splitting action the condition of the splitting blade should be

checked and reconditioned by the correct procedure.

 The machine has to be cleaned after use.
Proper maintenance activity carried out for the wood splitting machine reduces:
 Sudden stoppage of the machine.
 Reduce time of regular maintenance made to restore failed component.
 Cost of replacement of some components like bearing, cutting blade etc.
So proper maintenance activity must be carried out for effective and efficient
performance of the machine daily or regularly as per required.
Table 4.3 COST ESTIMATION OF DEVICE

Item Material used Dimension (mm) Quantity Price
Dust collector hopper Sheet metal W1=220 L1=220 L2=60 1 200

W2=300 W3=60 L3=60
Filtration Bag D= 100 L=350 300
Rotor and Motor Blower V angle ()20 degree 1 4000

Fan Width of vane 60m
Ball Bearing Deep groove, OD=30,ID=15, 2 280

SKF6006)
W=13
Caster wheel Filled Rubber OD=150 4 800

Pulley Rubber Dp =75 2 300
Bolt and Nut Mild steel M12, Lb=30 8 320
Container Sheet metal 900 x900x 1200 1 1300
Pipe Bending and plate - - - 190

cutting costs
Material for - - - 270

lubrication
Welding and Finishing - - - 1120

costs
Shaft Mild steel D=15,L=750 3 750
Total cost in Ethiopian Birr(ETB) 9830
4.8 RESULT AND DISCUSSION

4.8.1 RESULT
According to our study we are try to solve some problem specially around packing area. Depend
on this we design and fabricate cement dust extractor machine which is used the 5hp motor and
other machine elements parts to fabricate and also it works automatically without use of human
power. But, it usea less of human power incase of moving the machine to deserve place. This
machine is design for extracting the cement powder around packing area and also used to clean
the machine available around that. When we design the parts of this machine we use some analysis
and material selection and also other softwaresinorder to check whether the design is safe and
unsafe.so we got almost our design safe by checking in the use of the above methodology.
Generally, we got our machine is used for the following
 To remove dust powder from the packing area

 It can collect other solid trashes

 To store the dust
 To transport the material
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

 Develop our self-confidence and professionalism

 The designed project has a full capacity to save the existing problem as it has many
advantage and multi-use.
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
[2] http://www.dangote cement.com/about –us/history/

[3] G. M. Maitra, Handbook of Gear Design, New Delhi: McGraw Hill Publishing, 2001.
[4] Erik Oberg, Franklin D. Jones, Holbrook L. Horton, and Henery H. Ryfel, Machinery's
Handbook, New York: Industrial Press Inc., 2004.
[5] R. C. Hibbeler, Mechanics of Materials, Boston: Pearson Prentice Hall, 2011.
[6] R.S. Khurmi and J.K. Gupta, A text book of machine design, New Delhi: Eurasia Publishing
House, 2005.
[7] Design of Machine Elements by V. B. Bhandari
[8] [Rama_S.R._Gorla,_Aijaz_A._Khan]_Turbomachinery_D()
[9] www.wikipedia.com. [Online]
[10] Joshi,P, et al (2013). Manual driven platform cleaner.International Journal of emerging
techonolgy and advanced engineering

Appendix 1
Detailed Drawing of Parts and Assemblies











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INTERNSHIP REPORT FROM DANGOTE CEMENT FACTORY 2019

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3 THE OVERALL BENEFITS GAINED FROM INTERSHIPS ............................................................................... 25

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4.3.7. Design Of Bolt ........................................................................................................................... 50

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Figure 1.1 Dangote Cement Factory overall view

1.2 Dangote cement Strategy

1.3 Vision, Mission and Value of Dangote Cement

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1.4 Dangote cement PLC Products

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1.4.1 Ordinary Portland cement (OPC)

1.4.2 Portland pozzalana cement (PPC)

Figure 1.2 products of Dangote Cement Factory

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1.5 Company’s Customers

1.6 Company’s Stake Holder

1.7 Organizational Structure of the Company

Figure 1.3 overall organizational structures of the company

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2.2 Procedure Used While Performing Our Work Tasks

 Getting safety and company supervisor.

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2.3 The Section of the Company we have been working

2.3.1 Back section

Figure 2.1 Quarry

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2.3.1.2. Hummer Crusher

Figure 2.2 Hummer Crusher

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Figure 2.3 Stacker

Figure 2.4 Reclaimer

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These bins or hopper are;

1 Lime stone 75% 600t each

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Figure 2.5 Vertical Roller Mill (VRM)

Figure 2.6 Heat Conditioning Tower

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2.3.2.3 Bag House

Figure 2.7 Bag Filter

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2.3.2.4 Homogenization Silo

Figure 2.8 Homogenization Silo

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Structure and working principle

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2.3.2.6 Air Slides

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Figure 2.9 preheater

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Figure 2.10 rotary kiln

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Figure 2.11 hot clinker conveyers

2.3.2.11 Electrostatic Precipitator Air Filtering Method

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