Department of Mechanical Engineering

Internship Project

On

Special Bucket elevator design

By

Abreham mehari
And
Zemikael yemane

Mentor: Hassen

Date: from February 29 to Jun 29 ,2012

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Acknowledgment
First we would like to express our heartfelt gratitude to Engineer Hymanot Taddese for his
support by giving continuous suggestions and ideas during the project. We also would like to
express our sincere appreciation to Manyazewal Aklilu (Eng), Lemma Bulcha (Eng) and Nahom
Tesfaye (Eng) for supporting us throughout the internship program, they were our practical
teachers and also friends in the company and it would be too difficult for us to stay in the
company without the help of these three Engineers.
Last but not least we are greatly thankful for our mentor Mr. Hassen for his advice which enables
us to come up with a great design idea.

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Contents
Chapter one.....................................................................................................................................6
Company background.................................................................................................................6
Company profile..........................................................................................................................7
Chapter two.....................................................................................................................................9
Introduction................................................................................................................................9
Activities......................................................................................................................................9
Process Flow.............................................................................................................................10
1.Raw materials.....................................................................................................................10
2.Raw material preparation..................................................................................................11
3.Storage and pre-blending:-................................................................................................11
4.Material proportioning......................................................................................................11
5.Raw material grinding and waste gas treatment..............................................................12
6.Raw material homogenization and kiln feeding...............................................................12
7.Pre-heater and calciner.....................................................................................................12
8.Clinker burning and transportation..................................................................................13
9.Clinker storage...................................................................................................................13
10.Cement grinding..............................................................................................................13
11.Cement storage.................................................................................................................14
12.Cement packing................................................................................................................14
Chapter three.................................................................................................................................15
3.Literature review..................................................................................................................15
3.1 Bucket elevator................................................................................................................15
3.2 Three phase induction motor.........................................................................................16
3.3 Rotary air lock.................................................................................................................17
3.4 Gear Reduction Ratio.....................................................................................................18
Chapter four..................................................................................................................................20
4.1 Problem description...........................................................................................................20
4.2 Objective.............................................................................................................................20
4.3 Methodology.......................................................................................................................20
Chapter five...................................................................................................................................21
5.1 Design specifications..........................................................................................................21
5.2 Material selection...............................................................................................................21

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 5.3 Component design.............................................................................................................21
I. Bucket design.................................................................................................................22
I. Bin design.......................................................................................................................25
II. Supporting Frame design.............................................................................................29
III. Rail design......................................................................................................................31
Calculating bucket speed…................................................................................................33
Selection of motor and finding Gear box ratio.................................................................35
Mechatronic design of the system........................................................................................36
Chapter six....................................................................................................................................38
6.1 Cost analysis....................................................................................................................38
Chapter seven................................................................................................................................40
7.1 Conclusion..........................................................................................................................40
7.2 Recommendation...............................................................................................................40
Reference..................................................................................................................................41

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 List of figures

Figure 1.1 National cement………………………………... 7

Figure 3.1 Typical induction motor rotors………………… 17
Figure 3.2 Rotary air lock…………………………………. 18
Figure 5.1 Bucket geometry………………………………. 22
Figure 5.2 Bucket………………………………………….. 24
Figure 5.3 Lower bin………………………………………. 25
Figure 5.4 Upper bin………………………………………. 26
Figure 5.5 Force analysis of blocking arm ………………... 27
Figure 5.6 Blocking arm…………………………………… 29
Figure 5.7 Supporting frame………………………………. 31
Figure 5.8 Rail…………………………………………….. 32
Figure 5.9 Rail support……………………………………. 32
Figure 5.10 Pulley…………………………………………… 34
Figure 5.11 Schematic diagram…………………………… 37

Figure.. Design assembly drawing 38

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Chapter one

Introduction
Company background
The cement plant was first erected by Italians in Dire Dawa in 1938.Now acquired by National
Cement, the nation’s first plant has also gone through unprecedented change with its new
owners, including the upgrading of the old plant, which has a daily output of 500tn of clinker.
National Cement has come to be yet another large cement plant in the country, owned by private
investors.

Dire Dawa Cement & Lime Factory was acquired from the Privatization and Public Enterprises
Supervising Agency (PPESA) in 1995, after East Africa Group Plc paid 80pc of the 48 million
Br recapitalized company.

Since then, the company has gone through some major share restructuring after the PPESA sold
its remaining stakes, leaving five shareholders in control of National Cement, today: Jatish
Manila Patel, a Kenyan businessman with 250,000 Br in shares; Mekonnen Legesse, with
303,000 Br; and East Africa Group Plc, with 72,000 Br. But, the two largest shareholders are
East Africa Mining Corporation at 23.6 million Br in shares and SGI Ethiopia Cement Ltd a
subsidiary company of the British Virgin Island-registered Schulze Global Investments, which
has 24.2 million Br in shares.

The architect of all of this maneuvering is Bizuayehu Tadelle, an established businessman with
dominant ownership in East Africa Holdings and all its subsidiaries, including the East African
Mining Corporation. Having a background in commodities trading back in the military period
and during the first decade of the current administration, Bizuayehu proved to stand out from
many of his peers by transforming himself into an industrialist.

Indeed, his decision to acquire Dire Dawa Cement plant was seen by many as a mistake, for the
company had been on the auction bloc for over a decade with hardly any interest from buyers. It
was also a period when the state-owned Mugher and Messebo, owned by the EFFORT, were in
cutthroat competition, unable to sell their products for lack of demand in the market.

That had changed soon after East African acquired Dire Dawa Cement. A sudden surge in
demand, fuelled by state-driven public infrastructure projects escalated prices of cement in the
country from under 100 Br a quintal in 2005 to close to 500 Br in 2010

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Company profile
Located three kilometers north of the existing plant in Dire Dawa, the new plant that National
Cement is erecting on 40ht of land, including the quarry, in Ija Aneni Kebele, off the highway
towards Dire Dawa, will have the capacity to produce 4,500tn of cement a day. It is planned to
be commissioned in October 2012, after consuming a projected cost of 1.9 billion Br, largely
financed by loans from the Development Bank of Ethiopia (DBE).

Figure 1.1 National cement

Back in November 2011, the plant was through with its civil works of building the mills;
storages for clinker, limestone, and clay; as well as silos for clinker and cement. There were
close to 200 Chinese expatriates hired by the company, supported by 314 local professionals,
semi-professionals, and labourers, preparing to install the mammoth machinery that a cement
plant of its size requires. The kiln, a rounded shape and rotary chimney vent that determines
everything in the cement plant has been installed, also the electromechanical part is almost
finished.

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“To produce cement is to produce clinker,” said Basso Assefa (Eng), an old hand in the cement
industry who had served as general manager of Mugher, and now chief executive officer of
National Cement S.C.

And clinker comes after the kiln burns limestone and clay with a heat that reaches 1,500 degree
centigrade, using coal generated power, while grinding the raw materials inside it.

Whether in the old plant of Mugar or the recent Messebo and the newly built Derba and
National, most cement plants process limestone and clay to produce clinker, according to
specialists in the field. Cement is thus manufactured after grinding and mixing the clinker with a
small quantity of gypsum, designed to control hydration of the product.

All of these deposits are readily available within kilometer from where the new plant of National
Cement is erected. Senior managers at National Cement project said that the limestone lying in
their backyard will be sufficient for 70 years.

The project would create 1000 jobs when starts operation and the factory would use state of the
art technology which is environment-friendly.

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Chapter two

2. Internship experience

Introduction
In this internship program we had a great practical experience and knowledge. We saw practical
application and working principle of almost all machines in the company, which helped us to
develop our theoretical knowledge that we get in Mekelle University.
On the other hand, on the first month of the program, we also faced some beaurocratic and social
challenges. But gradually all the problems are solved so that we were able to finish the rest of
our internship program smoothly and nicely.

Activities
In the 1st month of our internship program we mostly spent our time by touring in different
sections of the factory with a constant guidance of local Engineers. Since the factory is too large
and complex, it is not possible to understand the process flow and working principle of each
mechanical equipments in one or two weeks. So our company adviser arranged us a four week
tour for the four sections of the factory and we spent one week at each sections.
During the tour at each section we were given a detail explanation about each process and
machines by the assigned mechanical/industrial engineers.
The factory is divided in to the following four sections and each section has their own sub
process which will be explained on the next sub topic.

Section 1
- Raw material preparation
- Storage and pre-blending
- Raw material proportioning

Section 2
- Raw material grinding and waste gas treatment

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Section 3
- Raw material homogenization
- Pre-heater and calciner
- Clinker burning and transportation
- Clinker storage

Section 4
- Cement grinding
- Cement storage
- Cement packing

Starting from the 2nd month we luckily got a chance to attend a maintenance training which was
given to a group of mechanics from the working factory (old national cement). The training was
given for one month almost three hours a day and we tried to attend the whole training without
affecting our main objective that we had in the company. By the end of the 2 nd month we were
able to identify some problems of the company and we decided to work on the most crucial
problem which is about the coal VRM (Vertical Roller Mill).
On the 3rd month we start our internship design project with our full effort. While doing our
project we got continuous supports from our company advisor and university mentor.

Process Flow
1. Raw materials
The main raw materials used in the factory are limestone, Pumice, Clay and Gypsum. The main
materials Limestone and Gypsum are mined in nearby quarry while the other minor materials are
come from another place.

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 2. Raw material preparation
Mining of limestone requires the use of drilling and blasting techniques. The blasting techniques
use the latest technology to insure vibration, dust and noise emissions are kept at a minimum.
Blasting produces materials in a wide range of sizes from approximately 1.5 meters in diameter
to small particles less than a few millimeters in diameter. The material is loaded in to trucks for
transportation to the crushing plant.

At the crushing site there are 3 hammer crushers for limestone, coal, and gypsum. Since clay and
pumice doesn’t need crusher there are two hoppers without crusher for them because they are
soft and already crushed on quarries.

3. Storage and pre-blending:-

What is pre-blending? -since a given material come from different parts of a quarry it will
not have the same quality so it should have to be mixed with itself (eg limestone with limestone)
to make the quality of the material uniform.

In this site there are two types of storages, open storage (for Limestone, High quality limestone
and Clay) & closed storage (for Coal, Gypsum and pumice). Bothe storages have a 42 meter
width and 192 meter length.

For the open storage there is a side type stacker which stacks and pre-blends Limestone, High
quality limestone and clay individually (one at a time). Also they use bridge type reclaimer for
collecting Limestone & High quality limestone and side type reclaimer for collecting clay.

In the closed storage (shade) two car type stackers are used for stacking and pre-blending the
materials which stacks by moving along the roof of the shade (one for coal and one for gypsum
& pumice). But for collecting they use two side type reclaimers.

4. Material proportioning
In this department three intermediates silos are built for Limestone (550 ton), Clay (180 ton) and
High quality limestone(180 ton). Beneath each silos there are weigh feeders which adjust their

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speed according to the signal given from CCR (central controlling room) and delivers to a
common belt conveyor that takes the material to the VRM (vertical roller mill).

5. Raw material grinding and waste gas treatment

There are two Vertical roller mills (VRM) for raw mill and coal grinding with the capacity of
260 ton/hr and 26 ton/hr respectively. The waste gas which is sucked from the kiln through the
pre-heater by the suction of ID fan (induced draft fan) is supplied to the two VRM’s as a hot gas
source to dry the material in the VRMs.

6. Raw material homogenization and kiln feeding

Kiln feeding system is mainly comprised of Homogenizing silo of 62m height & 18m diameter
with 11000 ton capacity and LOW (loss of weight) system, homogenizing silo is for raw mill
storage and homogenizing. Kiln feed measuring is mainly accomplished by LOW system. There
are 6 extraction holes at the bottom of the silo. And the blowers controlled by the programmable
logic control, will alternatively aerate 2 segments (place at 2 different extraction holes), and
simultaneously material is extracted from these out let holes. Three load cells are provided at the
bottom of LOW hopper, which are used to measure materials weight in the hopper.
Kiln feed control is fulfilled by measuring the reduced material quantity in the hopper within
certain period of time (during emptying period).
The adjustable motorized gate is controlled by signal from the programmable control unit, the
load cells in the tank, and set values for the feed rate from the operator at CCR.
Metered kiln feed is conveyed to the top of the preheater by bucket elevator.

7. Pre-heater and calciner

There is a single five stage pre-heater with inline calciner. The raw mill is pre-heated in the pre-
heater from cyclone 1 to 5 (from top to bottom) and calcinated to CaCO3 in the calciner. Up to
95% of the raw mill is calcinated in the calciner and the rest 5% of the calcinations &
clinkerization process will be taking place in the kiln.

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8. Clinker burning and transportation
The kiln burning system is composed of a 4.3m diameter and 62m length kiln and a single burner
which is blowed by two air blowers in which one is working and the other is standby.
A grate cooler is applied to the clinker just at the outlet of the kiln which cools the clinker by
using cooler fans. The clinker getting out of the cooler is crushed by the built in hammer crusher
and then carried to clinker storage by means of bucket conveyor. The exit gas from the cooler
partly goes to kiln as a primary air and partly to calciner as tertiary air supply. The surplus air is
emitted to the atmosphere after cleaned by ESP (Electrostatic prisptator).

9. Clinker storage
A clinker silo of 27m height and 45m diameter with a capacity of 65000ton is built for storing
clinker. Under the silo there are 3 rows of discharging gates, each rows have 8 motorized
discharging gate. The clinker discharged by the equipment is fed to different belt conveyor
correspondingly, then carried to the clinker bin in cement grinding plant by means of belt
conveyor.

10. Cement grinding

Grinding is the last process of cement production and also is the most current consuming
working procedure, it takes 8mw power only to drive the two grinding mills (4mw each). The
main equipment consists of a 4.2m diameter and 14.5m length double compartment Horizontal
ball mill and two O-sepa high efficiency separators. The clinker, additive (limestone and
pumice) and gypsum are fed by the corresponding weigh feeder to a common belt conveyor
which feeds the material to the Horizontal ball mills.
At this stage the mill produces two types of cement namely Ordinary Portland Cement (OPC)
and Pozzolana Portland Cement (PPC).
OPC is made from 90% clinker, 5% additive (limestone) and 5% gypsum. PPC contains 70%
clinker, 25% pumice (pozzolana) and 5% gypsum.

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The grinded material is carried to the o-sepa high efficiency separator via bucket elevator and air
slide conveyors. The separator will classify the material in to two parts, the Corse and fine. Then
the Corse material is fed back to the mill via air slides.

11. Cement storage

Four 15m diameter and 48.4m height are built as a cement storage facilities, each of them has a
storage capacity of 8000ton. Air ducts are erected on the bottom of the cement for fluidization.
The air is supplied to these ducts by root blowers. On the bottom of each silo a discharging unit
of manual gate and a pneumatic flow control gate is installed. The discharge from these gates is
transported to the cement packing system via air slides and bucket elevator. Connecting with
discharging unit, there is a bulk loader for the two silos installed for loading the bulk cement to
the lorries.

12. Cement packing

The flow of material rises from the bucket elevator to reach the vibrating screen, where is
screened, to be settled in the storage hopper. The former is equipped with control systems (called
sensors) placed inside the hopper. These sensors control the extraction system and keep the level
as the steady as possible.
Then the flow of materials passes through the rotary vane feeder equipped with alternate gear to
adjust the level of materials in the packet hopper. The sensor, by which the bag packer is
equipped, serves the purpose of the checking the rotary vane feeder in order to keep the level as
steady as possible. The flow of materials is in then directed to the spouts; most part of it is
packed in the bag, whereas a very small of scraps, in the form of dust, over flows.
The dust is sucked up and collected, by means of a sucking chute, in the lower hopper. The reject
is then separated: the dust is gathered by screw conveyors and led back into the conveying cycle.
The packing bag cement is sent out and guided to the bag cleaner and bag cutter (for those less
than 50kg) by means of belt conveyor. The cleaned bags are carried by a roller conveyor and a
belt conveyor to truck loaders conveyors.

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Chapter three
3.Literature review
Bucket elevator

A bucket elevator, also called a grain leg, is a mechanism for hauling flowable bulk materials
vertically. As a means of vertical mechanical transport, bucket elevators have become
indispensable links in the production sequences in many branches of industry. Based on traction
elements bucket elevators divided in two, chain conveyors or belt conveyors.

It consists of:

1. Buckets to contain the material;

2. A belt/chain to carry the buckets and transmit the pull;
3. Means to drive the belt;
4. Accessories for loading the buckets or picking up the material, for receiving the
discharged material, for maintaining the belt tension and for enclosing and protecting the
elevator.

A bucket elevator can elevate a variety of bulk materials from light to heavy and from fine to
large lumps.

A centrifugal discharge elevator may be vertical or inclined. Vertical elevators depend entirely
on the action of centrifugal force to get the material into the discharge chute and must be run at
speeds relatively high. Inclined elevators with buckets spaced apart or set close together may
have the discharge chute set partly under the head pulley. Since they don't depend entirely on the
centrifugal force to put the material into the chute, the speed may be relatively lower.

Nearly all centrifugal discharge elevators have spaced buckets with rounded bottoms. They pick
up their load from a boot, a pit, or a pile of material at the foot pulley.

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The buckets can be also triangular in cross section and set close to on the belt with little or no
clearance between them. This is a continuous bucket elevator. Its main use is to carry difficult
materials at slow speed.

Early bucket elevators used a flat chain with small, steel buckets attached every few inches.
Current construction uses a rubber belt with plastic buckets. Pulleys several feet in diameter are
used at the top and bottom. The top pulley is driven by an electric motor.

The bucket elevator is the enabling technology that permitted the construction of grain elevators.
A diverter at the top of the elevator allows the grain to be sent to the chosen bin.

A similar device with flat steps is occasionally used as an elevator for humans, e.g., for
employees in parking garages. (This sort of elevator is generally considered too dangerous to
allow use by the public.)

Three phase induction motor

The induction motor is the most rugged and widely used machine in industry. The AC induction
motor is well suited to applications requiring constant speed operation.

In general, the induction motor is cheaper and easier to maintain compared to other alternatives.
The induction machine can operate both as a motor and as a generator. However, it is
seldom used as a generator. The performance characteristics as a generator are not satisfactory
for most applications.
The three-phase induction motor is used in various sizes. Large motors are used in
pumps, fans, compressors, and paper mills
The induction motor is made up of the stator, or stationary windings, and the rotor. The
stator consists of a series of wire windings of very low resistance permanently attached
to the motor frame. As a voltage and a current is applied to the stator winding terminals,
a magnetic field is developed in the windings. By the way the stator windings are
arranged, the magnetic field appears to synchronously rotate electrically around the
inside of the motor housing.

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The rotor is comprised of a number of thin bars, usually aluminum, mounted in a
laminated cylinder. The bars are arranged horizontally and almost parallel to the rotor
shaft. At the ends of the rotor, the bars are connected together with a “shorting ring.”
The rotor and stator are separated by an air gap which allows free rotation of the rotor.

Figure 3.1 Typical Induction Motor Rotors

The magnetic field generated in the stator induces an EMF in the rotor bars. In turn, a
current is produced in the rotor bars and shorting ring and another magnetic field is
induced in the rotor with an opposite polarity of that in the stator. The magnetic field,
revolving in the stator, will then produces the torque which will “pull” on the field in the
rotor and establish rotor rotation.

Rotary air lock

Rotary airlocks are referred to by many different names. Some are appropriate, and some are not.
There are three appropriate names which are universally accepted when referring to this product.
Technically, they all refer to a similar device in terms of design and appearance. These are:
1. Rotary Feeder.
2. Rotary Valve.
3. Rotary Airlock

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r lock

The word ‘rotary’ refers to the fact that during operation of a rotary airlock, the vanes turn or
rotate. As they turn, the pockets, which are formed between the vanes, become rotating pockets.
The material being handled enters the pockets at the top, through the Inlet port, travels around in
a rotating motion, and exits at the bottom, or through the Outlet port. As the vanes and pockets
continue to turn, material continues to be moved from top to bottom, or from Inlet port to Outlet
port, in a rotating motion.

Gear Reduction Ratio

The term “gear reduction” applies to speed. A 2:1 reduction means that the speed will be
reduced by a factor of two, or in other words, to 50%. Obviously, if the gear reduction reduces
speed by 50%, the resulting torque will be doubled.
To select the suitable type of reduction gear for the type of application it is necessary to know the
torque T and the output speed n2 (min-1), where the latter, based on the input speed n1 (min-1
2a) shall define the ratio of transmission i with the following relation:
n1
i=
n2

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Otherwise, if the installed power p (kw) and the input revs n1, is known, the torque T is
calculated using the following relation

955 × P
T=
n2
In which for simplification we do not consider the efficiency of the reduction gear.

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Chapter four

4.Internship project

4.1 Problem description

According to the original design of the factory the coal which is not grinded will be discharged
through discharge shut of the vertical roller mill (VRM) and the discharged coal will be
transported to the coal storage which is more than 150m far from the VRM. And it will be
transported by labor forces or trucks which is labor intensive and costly.

4.2 Objective
The main objective of our project is to return the discharged coal to the belt conveyor which is
found at the inlet of the VRM by keeping continuous and controlled flow of material.

4.3 Methodology
For doing our design we use different methods. The main methodologies are discussed below.
1. Data collection
 We take different measurement data from the layout design of the coal VRM
like the height and width of the building which carries the belt conveyor on the
inlet of the VRM.
2. Direct measurement
 Some measurements were difficult to know from the layout design so we
directly measure by using metering device.
3. Internet sources
 Our main source of information in our project was the internet. Beside using as a
source of literature we used internet to get detail information about some
component that we used in our design.

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Chapter five

5. Design analysis

5.1 Design specifications

- It should lift a height of 17.3meter.
- Have a capacity of lifting 58kg of coal
- Uses electric power source.

5.2 Material selection

We use metals which are commonly used in the workshop of the older national cement
factory. For making buckets and bins we used a standard mild steel which is practically
used in the older company for making buckets. And for the supporting frame and other
parts we used steel 37.

Steel 37……….maximum tensile stress (σ) = 360MPa

……….maximum shear stress (τ) = σ × 0.82 = 295.2MPa
Where 0.82 is a constant used to change tensile strength in to shear strength for
wrought steel

5.3 Component design

In this portion we designed the main parts of the elevator mechanism
- Bucket
- Bin’s (the Lower bin and the Upper bin)
- Supporting frame (which carries the bucket)
- Rail

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 I. Bucket design

According to the design the discharge of the vertical roller mill (VRM) is 2.6 ton/hr
(2600kg per hour). Changing to kilogram per minute.
2600kg = 60min
X = 1min
X=2600/60
X =43.33kg/min
Some information that we need
 The bulk density of coal……..860kg/m3
Density(ρ) = mass(m)/volume(v)
ρ = m/v……..eq
 Filling factor of a bucket is 75%
- ie the coal fills 75% of the total volume of the bucket.
 Parameters of the bucket.
- L length
- w width
- h height

L x x

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 Figure 5.1 bucket geometry
where w = 2x

To get an optimum size of bucket we made an iteration displayed below…

Number of try L (mm) H (mm) W (mm) V1 (mm3) V2 (mm3) m (kg) t (sec)

1 500 600 300 67,183,457 50,387,593 43.33 60

2 500 600 700 157,500,000 118,125,000 101.1 140
3 400 400 600 72,000,000 54,000,000 46 64
4 400 500 600 90,000,000 67,500,000 58 80

Table 5.1 bucket iteration

Where..
- M mass of coal
- V1 volume of bucket
- V2 volume of coal
- t time

 We chose the 4th row which gives us an optimum size of bucket and mass of
coal.
The final size of the bucket will be the following
L = 400 mm
H = 500 mm
W = 600 mm
 For the bucket to roll in to the blocking arm there is a roller with a diameter of
30 mm, and the center of the roller is 30 mm from the tip of the bucket. There is
a 1 mm clearance between the bucket body and the roller to prevent friction.
 To maintain a relative motion between the bucket and supporting frame we used
a pin joint.

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 d- diameter of the pin
p- load on a single pin joint (there are 2 pin joints)
Wt- total weight of the bucket applied on the pin joint.
n- factor of safety … take n=3
A- Cross-sectional area of the pin
τu- maximum shear stress of the material
Wt= weight of bucket + weight of coal in the bucket
= (47kg + 58kg)× 9.81
= 1030N

wt
P= ¿ 1030/2 = 515N
2

( p ×n)
τu = 2A
double shear

=(515×3)/(2×A)

772.5
295.2=
A
A= 2.617mm2
d= 2mm
For manufacturability and other factors we make the diameter of the pin 5mm.
d= 5mm

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 Roller

Figure 5.2 bucket

I. Bin design
a. Lower bin
This bin should not be bigger than the bucket itself because it will release
all it carries at each cycle to the bucket. But for safety reason we left a little
volume allowance, it also helps to fit the bin with the discharging valve.

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 Motorized gate

Figure 5.3 Lower bin

For simplicity let’s make a cubic bin

Let L = w = h = 450 mm
Bin volume=V = 450× 450 ×450
V = 91,125,000 mm3

 At the bottom of the bin a motorized discharging gate is mounted with

opening size of 20cm by 20cm. The motorized gate will be set to open in every
80sec (each cycle)

b. Upper bin
For continuous and controlled discharge through the rotary valve we make
the bin three times bigger than the bucket
Volume of bucket = 90,000,000 mm3
Volume of bin = 3× volume of bucket
= 3× 90,000,000 = 270,000,000mm3

Let’s set estimated parameters and check the volume.

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 L =600mm
h =600mm
w = 800mm
volume of bin =600×600×800
= 288000000mm3

Blocking arm

Upper bin

Rotary air lock

Figure 5.4 Upper bin

Blocking arm

First we have to find the load which the roller apply on the arm
Where
w = 1030 N …. The total weight of the bucket and the coal

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 p = reaction force on the roller( on the arm)
R p= reaction force act by the pin joint.
L1 = 25mm….the length of center of weight of the bucket from the pin
L2 = 270mm….the length of the roller from the pin

L2

L1
Rp

Figure 5.5 force analysis of blocking arm

By taking moment at the pin joint

W×25 = P’×270
P’ = 95.4 N
 maximum binding stress occurs on the curvature of the arm, so we’ll calculate the
thickness at that point which is 313mm from the tip of the blocking arm
since the load p on the arm is too small we gave a reasonable size and check it for
bending.
P ’ 95.4
- P= = = 47.7N……..load on each arm
2 2
- This load is acted on the tip of the arm
L= 313mm ………. From the edge of the arm

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 - M ….maximum bending moment
M = P×0.313m = 47.7×0.313= 14.93NM
- σ…… maximum tensile strength.
- I ……..area moment inertia
1 3
I= ×b × h
12

- Y………the distance between the neutral axis to the point of interest

h
Y=
2
Let h= 10mm and b= 10mm
h 10
Y= = = 5mm
2 2

1 3
I= ×b × h
12
1 3
I= ×0.01 ×0.01
12
I = 0.0000000008333m4

M ×Y
σ=
I

14.93 × 0.005
σ=
I
σ= 89583583.34N/m2
σ= 89.58N/mm2

since σ << σ u (ultimate stress of the material) which is 360N/mm2

our design is safe
but there is some impact load on the arm by the roller because at the time of contact the bucket is
in motion, therefore we doubled the height(h) to resist more bending.
b= 10mm h= 20mm

Page | 29
 Figure 5.6 Blocking arm

 The arm is placed at the corner of the bin (on the building side), the gap between the
two arm is 406mm.
 Under the bin a Rotary valve is mounted with an opening size of 20 cm by 20 cm. the
flow rate of material through the rotary valve can be controlled by adjusting the rotating
speed of the valve.

II. Supporting Frame design

 The total width of the frame should be equal to the length of the bucket (ie 400mm)

 Maximum stress will be created on the lower arm of the frame so we calculate the
bending moment on that position.
 To determine the thickness of the lower arm we’ll calculate the maximum bending
moment created on the arm.
- Maximum load acted on the arm is the total weight of the bucket
W =1030 N
- This load is acted on the pin joint
L= 295 mm ………. From the edge of the arm

Page | 30
 W
- P= ……. Load on each arm
2
- M ….maximum bending moment
M = p×0.295m = 515×0.295= 152NM
- σ…… maximum tensile strength.
- I ……..area moment inertia
1
I=( )×b×h3
12
- Y………the distance between the neutral axis to the point of interest
h
Y=
2
b

Cross-sectional area of the beam.

h for the value of b(thickness) we used a standard value of b 10mm and
h 40mm. let’s check whether it can hold the maximum bending
moment created on the beam or fail.

M ×Y
σ=
I

1
I =( )×0.01×0.043
12

= 0.000000053m4

Y= h/2= 0.04m/2 =0.02m

152× 0.02
σ=
0.000000053

=57358490.57N/M2

Page | 31
 =57.56N/mm2

This value is much less than the maximum tensile stress of the material (360N/mm 2).
57.56nN/mm2 << 360N/mm2 therefore our design is safe.

Roller

Figure 5.7 Supporting frame

III. Rail design

 To make the vertical rail we used a standard U channel beam from Indian standard
table. We used a total of two U channel beams with a length of 17.35m.

Page | 32
 Figure 5.8 Rail

 The rail will be attached to the building at four specific positions along its height.
 For connecting the rail and the building we used four standard I-section beams with a
length of 1m each.

Figure 5.9 Rail support

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Calculating bucket speed…
From bucket design
- mcoal = ρcoal × v coal
= 860Kg/m3×0.0675m3
= 58kg
Since the coal VRM has a discharge of 43.3kg per minute (60sec).
- 60sec = 43.33kg
Xsec = 58kg
X= 80sec
 Then the bucket should complete its cycle at a maximum time of 80 seconds.

Reversing time of the bucket= 2 sec

To complete one cycle the bucket moves a total length of
17.1m (upward)+17.1m (downward)=34.2m

 Time taken … 80sec -2sec = 78sec

length
Speed(v) =
time
34.2m
V=
78 sec

V = 0.44m/sec
 The bucket should move at a minimum speed of 0.44m/sec but it is more safe if we move
it faster.
Let’s make the velocity of the bucket will be 0.5m/s and calculate the total time.
s 34.2
t= = = 68.4sec+(reversing time)
v 0.5
t= 70sec
NB:-This is the total time for the bucket to reach at the top and return back to the
bottom position.

Page | 34
The recommended diameter of the pulley which is attached to the gearbox is 50mm.

Keyway

Figure 5.10 Pulley

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Selection of motor and finding Gear box ratio...

We select a medium duty induction motor which is widely used in the company for making
screw conveyors and different fans.
Type of motor…………….three phase induction motor
Speed…………………….1400rpm
Mass………………………25kg
Power…………………….3 kw
The diameter of the pulley is 50mm
Radius(r)= 25mm
Circumference(c)= 2 π r
C= 157mm

The mean velocity (v) of the bucket is designed to be 0.5m/s

The maximum height (h) that the bucket move is 17.1m
Time taken by the bucket to reach the top position
h 17.1 m
T= = = 34.2sec
v 0.5 m/s

Number of rotation of the pulley to bring the bucket to the top position
h 17100 mm
Rotation = = = 109 revolutions
c 157 mm

109 rev
Speed of pulley = = 3.187rev/sec
34.2

Speed of pulley = 3.187×60

= 190.22rev/min
Gear box reduction ratio (R)

Page | 36
 speed of motor
R= =1400rpm/190.22rpm =7.36
speed of pulley

Mechatronic design of the system

 Initially the bucket is at the bottom position.

 The main driving motor is triggered by a built in timer switch at each cycle
 The timer switch will start the driving motor on a time interval of 80 sec.
 At the height of 17.1m on the rail there is a reversing switch.

 When the supporting frame which carries the bucket touches the reversing
switch the motor will change the direction of rotation. Then the frame will
start moving downward after a delay of 1-2 seconds.
 At the bottom of the rail there is a plastic rubber which stops the supporting
frame.
 At 50cm from the bottom of the rail there is a switch which stops the motor.
 After the motor is switched off the frame will slowdown until it touches
the plastic (rubber) stopper.
Schematic diagram is presented on the next page.

Page | 37
 Schematic Diagram

Reverse switch Power

source

Electric motor

Timer switch

Stop switch

Page | 38
Chapter six

6.1 Cost analysis

The main aim of this cost analysis is to show that how much capital can be saved with this
project instead of using the former process. As a student it is difficult to know the exact price of
all equipments and materials that we used in our project, as a result we take an estimated price of
the materials from the people which concerns (salesman and Engineers). To be more reliable we
take an exaggerated price value of the equipments that we used in this project.

Cost of metallic materials

NB:- some of the metals are found in the workshop of the operating company.

No Material Size/ amount price

1 U-channel beam 35m 12000 birr

2 I-section beam 4m 3000 birr
3 Sheet metal 3000kg 27000 birr
Summation 42000 birr

Table 6.1 cost of material

Cost of equipments

No Equipment Quantity of the material price

/
Amount
1 3-phase induction motor 1 5000 birr
2 Rotary valve 1 15000 birr
3 Gearbox 1 10000 birr
4 Motorized gate 1 12000 birr
5 Wire rope 18m 5000 birr
6 Roller 6 3000 birr
Summation 50000 birr

Table 6.2 cost of equipments

Page | 39
Finally the maximum estimated manufacturing cost of our design…20000 birr
Therefore the total cost of the project will be 42000+50000+20000 = 112000 birr

Now let’s see the cost in the former method……

- In this process the minimum number of labor force will be four.

With a salary of 900 birr (not including the cost of health service, insurance,
overtime payment, food…etc)
- A loader with a rent of 700 birr per hour.
The loader will work three times a day for 30 minute each.
- A truck with the same price with the loader.

No Item Payment/ salary Payment/ salary

Per day Per month

1 Labor force 30 birr × 4 = 120 birr 3600 birr

2 Loader 1050 birr 31500 birr
3 Truck 1050 birr 31500 birr
Total cost 66600 birr

Table 6.3 cost of former method

The total cost per month of the former method is 66600 birr which is much costly than
our project.
As we can see the expense of the company in two months will be 133200 birr. This is
much greater than what we need for our project (112000 birr).

Page | 40
Chapter seven

7.1 Conclusion

During our stay in NCSC We have gained an understanding how to interpret and apply our
theoretical knowledge in practical situations. We also understand that it is difficult to directly
apply our theoretical knowledge into practical problems in industries or projects like this one
because it needs some experience to apply a theoretical knowledge on practical problems, and
from the intern program we can tell that we got some of these experiences. Working in this plant
project allowed us to observe the installation of machineries and helped us to understand the
process cement production more simply. We are sure that we’ll have more confidence working
as an employee in factories after graduation.

7.2 Recommendation

- In our design most parts can be manufactured in the workshop of the company this
highly will reduce the cost of the project. Some of the parts that can be
manufactured in the workshop are rollers, bucket, bins and supporting frames for
the bucket and bins.
- For a longer life of the rail a liner can be placed between the rail and roller, in this
case we intentionally left the liner just to reduce the cost of the project.
- For transporting the coal from the discharge to the lower bin of our design many
conveying mechanism can be used like drag chain, special type belt conveyor, a
screw conveyor etc. but we highly recommend a screw conveyor because of its
transporting capacity at high angle and its capacity of transporting abrasive
material.

Page | 41
Reference
- Hand book for designing cement plants, SP Deolalkar.
- Marks’ calculation for machine design, Thomas H. Brown, Jr.
- Internet
-

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