Ebenezer Mining and Ceramics Industry Limited (EMCL)
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CHAPTER ONE
1.0 INTRODUCTION

Experience is the best teacher, it has been said. Although the relevance and importance of theoretical knowledge in any field of study can not be over- emphasized, the practical knowledge and experience is just as essential. It is to this end that the student industrial work experience scheme (SIWES) was instituted.
The Student Industrial Training Work Experience Scheme (SIWES) is now made compulsory exercise carried out by the entire 400level student across the country. This takes place during the 2nd semester of the 4th year in the school, to enhance and help student in building individual theoretically.
Therefore, we the present 500level student of the Federal University of Technology, Akure, academic section 2009/10 embarked on a 6month Industrial Training, in which I was attached to the Ebenezer Mining and Ceramics Industry Limited (EMCL), Owo Road, Akure. Ondo State.
1.1 AIMS OF SIWES
The Students Industrial Work Experience Scheme (SIWES) is organized annually by the Federal Government through the Industrial Fund (ITF) as an exercise designed for all university and polytechnic student in the country to:
• Acquaint the student with practice which may not be available in the institution of learning in order to adequate prepare them as fully backed professionals able to handle real life case scenarios when they leave school.
• Exposed student to new innovation ideals practical, technology and industrial aspect in their various disciplines to keep pace with new technological innovation and discoveries.
• Merge their acquired classrooms basic theoretical knowledge with industrial application and relevance.
1.2 INDUSTRIAL TRAINING PROGRAMME
I carried out the SIWES programme at Ebenezer Mining and Ceramics Industry Limited (EMCL), Owo Road, Akure between the months of April 2009 to September 2009. I was exposed to all the sections of the industry as well as the practice or real life relevance of theoretical knowledge of mining.
1.3 BACKGROUND OF INDUSTRY
Ebenezer Mining and Ceramics Industry Limited (EMCL) were formally established in May 2003. It is situated at Owo Road, beside FCC Quarry, Akure Ondo State. It is a construction company whose activities include Quarrying and Asphalt production.
The company is a small scale industry comprising of 30 members of staff with (5) Five non-professionals and (25) Twenty Five professionals, including the semi- skilled and unskilled labourers.
The Quarry sections consist of the following production departments:
Production department: this include the production process of granite stone beginning from the drilling and blasting of granite rock to haulage and crushing sections.
Administrative department: concerned with all administrative works of the quarry, which includes the sales (income and outcome exchange) in the company.
Mechanical department: this consists of the maintenance of the equipments used in all aspect of production. It also includes the workshop.
Security Section: As the name implies, the aim is to safeguard the quarry.
CHAPTER TWO
2.0 GEOLOGY OF THE AREA

The mineral exploited at the quarry is predominantly granite. Granite forms as a result of volcanic eruption of molten magma on the earth surface followed by cooling processing. The overburden is minimal and varies from trace of laterite to vegetation which is cleared using bulldozers etc. Granite is a crystalline rock comprising minerals such as quartz, feldspar, biotite and mica. It is usually fine grained and relatively light coloured. Its hardness varies according to composition and principally with the properties and types of minerals it contains and is about 7. It has considerable compressive strength with fairly low porosity and high permeability and a specific gravity of vast quantity of granite rock enough to sustain production for several years.
CHAPTER THREE
3.0 AREA OF SPECIALIZATION

The Ebenezer Mining and Ceramics Industry Limited (EMCL) specialized on the Surface mining and Production of Aggregates
3.1 SURFACE MINING
It deals with the out crust and it is known as QUARRING. Quarrying is the act of extracting useful material (as building stone) from quarries. It is basically divided into two main sections namely;
• Drilling
• Blasting.
3.2 PRODUCTION OF AGGREGATE; it is specializes in:
• Crushing operation.
• Production of Asphalt.
The breakdown of the individual area of specialization is given as follows;
A. Surface Mining
1. Quarrying:-
a. Drilling
b. Blasting
B. Aggregate Production
1. Crushing Operation.
2. Production of Asphalt.
3.3 DRILLING
3.3.1 DEFINITION:

Drilling is the process of creating or making holes in a rock mass for placement of explosive required to disintegrate the rock/ore body. Various drilling method such as thermal, mechanical etc. are used. However, the mechanical method of drilling is most widely used and will be focused upon in this report.
Mechanical drilling can be divided into;
1. percussion
2. Rotary
3. Rotary Percussive drilling.
Percussive drilling is most widely employed in quarries. It breaks rocks by a reciprocating hammering action; the percussive drilling method is further subdivided into surface mounting such as hand jack hammer and down-the-hole (DTH) such as crawler mounted air wagon drill. At (EMCL), the crawler mounted air wagon drill is used for major drilling operations while the hand jack hammer is used for minor drilling operations such as the drilling of boulders for secondary blasting. The crawler mounted air wagon drill is driven by air compressor through air hose at a very high pressure. The air compressor is powered by diesel fuel.
3.3.2 METHOD OF DRILLING
In (EMCL), the objective of drilling is to achieve maximum rate and desired degree of fragmentation as well as minimum drill bit wear. At EMCL, holes are drilled at a spacing of 1¾meter of a burden in such a way is to minimize explosive usage and obtain a good degree of fragmentation. Stripping is not needed since there is a near total absence of overburdens
The company EMCL drills in the bench height of 22m, 24m or 25m. to determine the diameter of a rock; hardness of the rock will determine the type of rock, the size and the bits want to used. Hardness of a rock is used in determine spacing and burden.
3.3.3 EQUIPMENT USED IN DRILLING
• Crawler mounted air wagon drill; it is chosen due to the rocky terrain of the quarry.
• A hand jack hammers.
• An air compressor (Indersol rand XP800).
• Drill bit; button bit studded with tungsten can bide insert rang between size of 56mm and 120mm.
• Extension (drill) rod.
• Measuring tape.
• Grease (for Lubrication).
3.3.3.1 CRAWLER MOUNTED AIR WAGON DRILL
This is a down-the-hole (DTH) type of drilling machine. It is mounted on a track and is best suited to rocky terrain and irregular topography. It comprises: a hammer which has a treaded rod-like exterior to which drill rod are attached with the aid of couplings, two set of hose; the first supplies compressed air needed to power the equipment. From the compressed air and second transfer the compressed air from the previous to different parts of the equipment, a level set comprising four (4) level which are used to move the carriage holding the hammer forward, backward, upwards or downwards as the case may be and a control level which moves the equipment from one location to another. The crawler mounted air wagon drill has an average speed rate and can drill up to fifteen drill holes per day depend in the full capacity of the machine. Its use is however fading as new drilling rigs are continuously begun invented to take the place of old ones. In spite of this obvious fact, the crawler mounted air wagon drilling is employed at EMCL largely because it’s relatively cheaper to procure and maintain over a long period.
Setting up the air wagon drill for Drilling:
An extension rod is attached to the threaded portion of the hammer exterior using coupling sleeve connects the rod with the hammer at one end while a drill bit is attached to the other end of the rod. The drilling machine must be set up in such a way to be perpendicular (at 90 º) to the rock surface. This can be ensured using a plumb line to control its straightness. When this is achieved, the wagon drill is set into motion using a plug designated for the purpose. The wagon drill is rotary percussive. It delivers a hammer blow on the rock and rotates simultaneously penetrating into the rock an bringing the dust particles generated to the surface through air flushing.
3.3.3.2 A HAND JACK HAMMER
This is a surface mounted drilling equipment type, it comprises; an handle which provides the needed drilling pressure when rested upon a body coating a key which set it into motion and a drill rod whose length and diameter are fixed. The hand jack hammer is designed for a small holes diameter. Hence it is used for drilling boulders larger than the capacity of crusher and need to be broken down as a result- like the wagon drill the hand jack hammer is pneumatic i.e. it is powered by compressed air supplied by a air compressor (Ingersol Rand XP-400)through the air hose at a very high pressure. Hand jack hammer has a slow rate and can only drill limited number of holes per day.
FIQ 1: A HAND JACK HAMMER
3.3.3.3 AIR COMPRESSOR
This is a device that supplies compressed air at very high pressure to mining equipments that are pneumatic powered. It may be built as part of the equipment or built separately. It has an inner chamber comprising an outlet for air hose and a fuel tank. The compressor runs on diesel and it comes in various shades and designs. The common types includes: three compartment and four compartment compressors. At EMCL, both three and four compartment compressors are used. The four compartments are used for the crawler mounted air wagon drill, while the three compartment air compressor is used for hand jack hammer.
FIQ 2: AIR COMPRESSOR
3.3.3.4 DRILL BIT
This is the applicator of percussive energy on the rock in order to achieve penetration. The type of drill bit used in quarrying is influenced to a large extent by the variability in rock strength and formation. Drilling bit vary in strength and design. Percussive bits are the commonly used bits and they are two types namely: the bottom studded and the insert types. These are further subdivided into different design to better adapt to all kinds of percussive drilling. They are:
i. Chisel Bits: These are inserts made of one sintered tungsten carbide inserts. They are used in hand held jack hammers for drilling holes of 37mm to 41mm in diameter.
ii. Cross-Bits: These are inserts made of four sintered tungsten carbide set at right angles and used small wagon to drill hole up to 56mm in diameter. They are also some cross bits with special rank angle designed for rotary percussive drills.
iii. X-Bits: These are inserts also made of tungsten set angle 75-105 forming an X
iv. Button Bits: These are percussive drill bits that are studded with tungsten carbide insert and they are by far the strongest and toughest of all bits and are used by wagon drill to drill holes up to 120mm in diameter.
Extension (drill) rod: these are two major variant of drill rod namely the extension drill steel and the speed rods. The former makes use of coupling sleeves for connecting the drill components together while the latter has a male thread at one end and female thread at the other. The male thread of one rod is screwed into the female thread of the other and the drill components are connected in like manner. The advantage of the speed rods over the extension rods is the male and the female thread make a perfect that minimizes energy loses at the joints and it features mechanical rod handling because of the absence of couplings. Despite this obvious advantage, extension rod is handling because of the absence of couplings. Despite this obvious advantage, extension rod is used at EMCL largely because they are less expensive.
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