CHAPTER ONE

1.0 INTRODUCTION

The Student Industrial Work Experience Scheme (SIWES) is a Skills Training Program

designed to expose and prepare students of Nigerian tertiary institutions for the industrial

work situation they are likely to meet after graduation. The participation in SIWES has

become a necessary pre-condition for award of diploma and degree certificate in specific

disciplines in higher institutions in Nigeria, in accordance with the education policy of the

Government. An Industrial Attachment is a structured, credit-bearing work experience in a

professional work setting during which the student acquires and applies knowledge and skills.

It involves the application of learned skills in an organization related to the student’s course

of study. The Student Industrial Work Experience Scheme exposes students to then much-

needed industry-based skills which will help them to be useful in the industries, in addition to

the knowledge obtained from the classroom. Students get to experience a working

environment first-hand and familiarize themselves with various activities which take place in

the industries and work-place, and also learning efficient machinery and equipment handling.

Opportunities of doing these may not be made available in educational institutions for various

reasons, hence this experience aids in a smooth transition from the classroom to the world of

work after graduation.

As part of the pre-requisites for the award of B.Sc. Geology in Federal University Lokoja, the

content of this report contain the activities and judicious time spent at Dangote Cement Plc.

Obajana plant KM 22 Kabba/Lokoja road Obajana (Oyo-Iwa mines) Kogi State during my

six months SIWES program. Thus, the training provided an avenue for me to acquire skills

and has afforded me practical experience in Geology and other Mining fields. It has also

helped me to bridge a gap between theory and practical knowledge

1
 CHAPTER TWO

2.0 HISTORY AND ORIGIN OF SIWES

The Students Industrial Work Experience Scheme (SIWES) was established in 1973 by

Industrial Training Fund (ITF). It is a Skills Training Program designed to expose and

prepare Universities, Polytechnics, Colleges of Technology, Colleges of Agriculture and

Colleges of Education students for the Industrial Work situation they are likely to meet after

graduation. The scheme also affords students the opportunity of familiarizing and exposing

themselves to the needed experience in handling equipment and machinery that are usually

not available in their Institutions.

Before the establishment of the scheme, there was a growing concern among our Industries

that graduates of Institutions of Higher learning lacked adequate practical background studies

preparatory for employment in Industries. Thus, the employers were of the opinion that the

theoretical education going on in higher institutions was not responsive to the needs of the

employers of labor. It is against this background that the rationale for initiating and designing

the scheme by the Fund during its formative years 1973/74 was introduced to acquaint

students with the skills of handling employers’ equipment and machinery. ITF has one of its

key functions; to work as cooperative entity with industry and commerce where students in

institutions of higher learning can undertake mid-career work experience attachment in

industries which are compatible with student’s area of study. ITF solely funded the scheme

during its formative years.

But as the financial involvement became unbearable to the Fund, it withdrew from the

Scheme in 1978. The Federal Government handed over the scheme in 1979 to both the

National Universities Commission (NUC) and the National Board for Technical Education

(NBTE). Later the Federal Government in November 1984 reverted the management and

2
implementation of the SIWES Program to ITF and it was effectively taken over by the

Industrial Training Fund in July 1985 with the funding being solely borne by the Federal

Government.

2.1 OBJECTIVES OF SIWES

As stated in Information and Guidelines for Students Industrial Work Experience Scheme

(2002), the objectives of the Students Industrial Work Experience Scheme (SIWES) are as

follows:

a) Providing an avenue for students in institutions of higher learning to acquire industrial

skills and experience in their course of study.

b) Preparing students for the industrial work situation they are to meet after graduation.

c) Exposing students to work methods and techniques in handling equipment and

machinery that may not be available in their institutions.

d) Make the transition from school to the world of work easier, and enhance students

contacts for later job placement.

e) Provide students with an opportunity to apply their knowledge in real work situation

thereby bridging the gap between theory and practice.

f) Enlisting and strengthening employer's involvement in the entire educational process

and preparing students for employment in Industry and Commerce.

2.2 BRIEF HISTORY OF DANGOTE OBAJANA CEMENT PLANT (OCP)

Dangote Cement Plc. (DCP) Obajana Plant is located at km 22 Kabba/Lokoja Road, Obajana

Kogi State. Obajana Plant is a branch of Dangote Cement Plc. which has its headquarters

3
located at Alfred Rewane Road Union Marble House, Ikoyi, Lagos State with branch

factories located within the Country.

The organization ventured into setting up a cement plant in Obajana village, Lokoja LGA,

Kogi state, Nigeria with the discovery of large marble deposit. The large marble deposit is

located in Oyo-Iwa Village which is approximately 9 kilometers North East of Obajana

village. Obajana is located about 25 kilometers from the old Kabba road junction, off the

Lokoja-Okene high way. An exclusive prospecting license to an extent of 8.00 sq. Km was

obtained from federal ministry of solid minerals vide order No. MSM/KG/EPL 17807/19.

Subsequent to this, a mining lease was granted in favour of Obajana Cement Company

Limited Lokoja, over an extent of 527.045 hectares at Oyo-Iwa village, Lokoja LGA of Kogi

State. The proposed mining lease is located by grid reference longitudes 07° 59.816’ N and

latitudes 06° 26.511’ E. The deposit can be accessed via Obajana Jakura road. The plant is

proposed at Obajana village while the mines situated at Oyo-Iwa village respectively. Market

survey indicated that cement requirement would be around 6 million tonnes per annum to

meet both local and international demand. To achieve this, a plant capable of producing

14,000 tonnes of clinker per day is required hence; limestone major raw material requirement

would be around 21,000 tonnes per day. It was based on these the company was started and it

has witnessed rapid growth ever since. The Cement Plant was incorporated by the Kogi State

Government in 1992. It was acquired by Dangote group of companies in 2002 and

commenced the construction of the first cement production plant in 2004. Production of the

product commenced in 2007 and in January 2008, the production got into the Nigerian

market. Since then more production plants has been created and now there are four

production lines in Dangote cement Obajana with a view of developing another line in years

to come.

4
2.3 OBJECTIVES AND VISION OF DANGOTE CEMENT PLC

The main objectives of the Dangote Cement Company, Obajana Plant is to produce good and

quality cement that will be able to meet the standard in any part of the world and to supply

Nigerians with as much Portland cement as they need. Also the vision the company is to

become Africa’s leading cement producer and a global force in cement

2.4 MISSION AND VALUES OF DANGOTE CEMENT PLC

2.4.1 MISSION OF DANGOTE CEMENT PLC

The following are Dangote Cement Company, Obajana Plant’s Mission:

 To provide economic benefits to local communities by way of direct and indirect

employment opportunities in Nigeria.

 To build a position as a global force in cement production, delivering high-quality

products that generates substantial value for shareholders.

2.4.2 VALUES OF DANGOTE CEMENT PLC

The following are Dangote Cement Company, Obajana plant’s values;

 Customer service

 Entrepreneurship

 Excellence

 Leadership

5
 PLANT DIRECTOR

CGM

GM HUMAN GM GM GM GM GM GM GM GM
RESOURCE TRANSPORT PRODUCTION FINANCE STORE SALES MEHANICAL MINES SECURITY
ADMIN

AGM
AGM AGM
AGM
SUPERVISORS
MANAGER MANAGER
AUDITORS AGM

AGM MANAGER JUNIOR SUPERVISORS

SUPERVISORS
STAFFS
SUPERVISORS JUNIOR
ESTATE
MANAGER SUPERVISORS STAFFS SECURITY

HOD MANAGER AGM MINES

SUPERVISORS JUNIOR SALES PROCUREMENT
STAFFS

AGM PRODUCTION MANAGER

JUNIOR SUPERVISORS
STAFFS
SUPERVISORS

MANAGER JUNIOR MANAGER

AGM SUPERVISORS
STAFFS PACKING PLANT
QUALITY
ASSURANCE JUNIOR
STAFFS
DOUBLE
JUNIOR
SUPERVISORS SARA
STAFFS

MANAGER
SUPERVISORS
JUNIOR SUPERVISORS
STAFFS

JUNIOR SUPERVISORS
STAFFS JUNIOR
STAFFS

JUNIOR
STAFFS

Fig.2.0 Organogram of Dangote Cement plant , Obajana

6
 CHAPTER THREE

3.0 ACTIVITIES DURING SIWES

This involves the activities undertaken at Obajana Cement Plant owned by Dangote Cement

plc. which run a mines at Oyo-Iwa that deals with surface mining of marble deposit for local

cement product.

Each activity carried out by me during my six month SIWES program is incorporated into

various units/section which includes the following;

a. Geology Section

b. Mines Survey Unit

c. Mining/ Quarrying Section which involves Drilling, Blasting and Crushing process

d. Quality Assurance/ Laboratory

3.1 GEOLOGY SECTION

This section practically deals with geological works in the mines which includes the studying

the local geology and stratigraphy of the mine/area, lithological study of rock found in the

area and mineralogical study of minerals such as calcite, mica minerals (muscovite and

biotite), pyrite crystal and haematites found within the mine area. Also in this section samples

from the mines are collected, package and are sent to the laboratory for geochemical analysis.

In the mines, the mine geologists is responsible for the affairs of this section and the perform

the following roles;

i. The mines geologist gives advises on the geological aspects of development and

production process in mines, quarries and pits

ii. They study the relationship between geology and ore formation and locate new

mineral resources

7
 iii. They are responsible for accessing and analyzing geological data in order to advise on

short term and long term mine production plans

iv. Conducting survey and interpreting geological in order to inform drilling and

production procedures

v. Drill core logging, identification of different strata of rock and estimate how big the

ore body is

vi. Liaising with a range of expert including engineer, metallurgy expert and mine

workers

vii. Also keeping up to date with current geological research and producing written

reports.

3.1.1 LOCAL GEOLOGY OF THE AREA

Obajana lies within Longitude 60 24’E to 60 27’E and Latitude 70 54’N to 70 57’N. The area

falls within the Basement Complex of the south western part of Nigeria. Rocks in this area lie

within the Lokoja-Jakura schist belt of the Nigeria Basement Complex. The Basement

Complex rocks of Nigeria are composed predominantly of migmatite gneiss complex;

slightly migmatised to unmigmatised paraschist, meta-sedimentary and meta-igneous rock;

charnockitic; order granite suites and unmetamorphosed dolerite dyke (Rahman, 1976). The

rock type in this area includes schist, pegmatite, quartzite, marble, granite and granulites. The

schist outcropped extensively along the access road to the mines. The regional strike of the

rocks in this area is 0200 NE and dips 450 towards the east. Marble bodies are widely

distributed within the Precambrian Basement Complex of Nigeria and are commonly

associated with the Schist Belts which may be regarded as folded belts (perhaps initially

protobasins) into the multiple deformed and variable metamorphosed migmatite-gneiss-

quartzite complex. Data available reveals that the area contains significant amount of marble

deposit within the Basement Complex geology of the area (Hockey,et al 1986 and Efu-

efeotor.,1989).

8
Marble, a metamorphosed limestone occurs within the migmatite gneiss- schist-quartzite

complex as relicts of sedimentary carbonate rocks. The marble have roughly NE-SW trend

and thinning out in the South-Western direction. The marble is grey-pure white in colour,

medium to coarse grained (mosaic texture with increase in depth) in nature with few mica

specks. In some places, mica schist and granulite intrude the marble. The marble is overlain

by an average thickness of 6.83 meters of overburden, which appears to be red sandy clay and

marl clay. The stratigraphic succession of the area consists of magmatic intrusion of older

granite series, folded meta-sediments of Igarra-Kabba-Jakura formation and gneissic

complex.

3.1.2 MINERALOGICAL STUDY

This is the study of naturally occurring crystalline substance called minerals, which form

rock. Mineral is a naturally occurring homogeneous solid inorganically formed, with a

definite chemical composition and crystalline structure.

At Dangote cement mine, marble deposit is the major resource mined for cement production

which is a carbonate metamorphic rock. It is mostly composed of calcite mineral and other

carbonate minerals. Sulphide minerals (especially pyrite) are also found to be associated with

carbonate rocks. Minerals found within the mines and it’s environ includes;

 Calcite: it is the main constituent of limestone and marble with a composition of

CaCO3, it is hexagonal mineral with a wide range of form. It has a perfect

rhombohedra cleavage with a hardness of 3 on Mohs scale, it is usually white but

many colour varieties may occur. In Dangote cement mines Oyo-iwa, calcite crystals

are usually found abundantly in the pit where extraction of marble deposit takes

place.

9
 Plate 3.1 Calcite crystal

 Pyrite (FeS2): it is the most wide spread sulphide mineral which occurs as an

accessory mineral in many rock type. It has a cubic crystal system, it is pale brassy

yellow in colour with a black streak and has a metallic lustre. It is most times refer to

as a fool’s gold. It occurs in traces in rocks in the pit where extraction of marble

deposit takes place at Dangote cement mines.

Plate 3.2 Pyrite from

 Muscovite KAl2[AlSi3O10][OH]2: are phyllosilicates, they appear in sheet. It is a

colourless mineral and soft with a hardness of approximately 2. It is common in

metamorphic rock called mica schist. Large flakes of muscovite are usually found

within the mines area.

Other minerals such as graphite and haematite are found in traces within the pit at OCP.

10
 Plate 3.3 Mica flakes from
Obajana mine

3.2 MINE SURVEYING

Mine surveying is the practice of determining the relative position of point on or beneath the

earth by direct or indirect measurement of distance, direction and elevation. It is the branch of

mining science and engineering that uses measurements made in the field and also

subsequent geometric constructions, as a basis for the study of the structure of a deposit, the

shape and dimension of mineral bodies in the interior, the spatial arrangement of mine

workings and the earth’s surface in connection with mining works. It also reflects the

dynamics of the production process of a mining organization.

Mine surveying is a composite science that is closely related to many scientific disciplines

such as mathematics, engineering, physics, astronomical geodesy, geology and mineralogy,

geological exploration, the technology of exploitation of deposit and construction. Mine

surveying work is done by means of mine survey instruments. Data from mine surveying are

synthesized in mine documentation which is a set of diagram produced by geometric

projection.

3.2.1 ROLES OF MINE SURVEYOR

Mine surveying is an inseparable part of all stages of mining operation. The work is done by

a mine surveyor that is within the mining organization in charge of the exploring the deposit.

For detailed exploration of deposit, the tasks of a mine surveyor include the followings;

11
  A mine surveyor is responsible for the creation of maps and plans for the mines

which include the construction of a reference grid

 Mine surveyor takes part in planning, surveying work and also planning the

boundaries of the mining organization

 They work with geologists to use survey data to compile diagrams for mining

documentation; the diagrams reflect the volume of the exploratory work that has

been done and the conditions of the earth’s surface

 They also take part in the estimation of geological reserves and also they measure

the area and volume of rock/mineral deposit blasted

 They also carry out initial survey and risk assessments and environmental impact

assessments on potential site to access the viability of a potential mine site.

3.2.2 MINE SURVEY EQUIPMENT

Surveyor depends on their equipment for acquiring accurate measurements quickly and

easily. This equipment helps the surveyor measure various parameters on land area.

Equipment such as chains, compass, solar compass, transit, theodolite and tapes are ancient

equipment used by surveyors. Modern equipment such as Level, GPS, Electronic distance

measurement (EDM), Total Station and survey software are often used by surveyors due to

their high degree of accuracy.

At Dangote cement mines Obajana Oyo-iwa the following survey equipment are majorly

used in the mines:

1. Tripod: this is a portable three legged frame usually used as platform for supporting

the weight and maintaining the stability of surveying instruments such as theodolite,

total station, levels, and transit.

2. Reflector and detailing pole : A reflector is an optical survey instrument used to

reflect receiving rays from the emitting total station

3. Tape: it is a measuring device used in distance measurement

12
 4. GPS: global positioning system is a device that is capable of receiving information

from GPS satellites and then to calculate the device's geographical position.

5. Total station : is the are the primary survey instrument used in mining surveying.

3.2.3 TOTAL STATION FUNCTIONS AND USES

Total station is a survey equipment combination of EDM instrument and electronic

theodolite. It is also integrated with microprocessor, electronic data collector and storage

system. The instrument can be used to measure horizontal and vertical angle as well as

sloping distance of the object to the instrument.

The microprocessor unit in total station process the data collected to compute. Hence the total

station is capable of computing the following: Average of multiple angles measured, Average

of multiple distances measured, horizontal distance, Distance between any two points,

elevation of objects and the three coordinates of the observed points.

The total station instrument is mounted on a tripod and is levelled by operating levelling

screws. Within a small range instrument is capable of adjusting itself to the level position.

Then vertical and horizontal reference directions are indexed using onboard keys. It is

possible to set required units for distance, temperature and pressure. Surveyor can select

measurement mode like fine, coarse, single or repeated.

When target is sighted, horizontal and vertical angles as well as sloping distances are

measured and by pressing appropriate keys they are recorded along with point number.

Heights of instrument and targets can be keyed in after measuring them with tapes. The

processor computes various information about the point and displays on screen. This

information is also stored in the electronic notebook. At the end of the day or whenever

electronic note book is full, the information stored is downloaded to computers.

The point data downloaded to the computer can be used for further processing. There is

software like auto civil and auto plotter clubbed with AutoCAD which can be used for

13
plotting contours at any specified interval and for plotting cross-section along any specified

line.

3.2.4 FUNCTIONS OF THE TOTAL STATION

There are four major functions of the total station there are as follows:

a. Distance measurement: this function is done by the EDM instrument part of the total

station. It is used to measure distance range that varies from 2.8km to 4km. Distance

is determined by emitting and receiving multiple frequencies. The accuracy of

measurement varies from 5mm to 10mm per km measurement.

b. Angle measurement: the electronic theodolite component of the total station performs

this function which helps in measuring vertical and horizontal angle. The accuracy of

angle measurement varies from 2 to 6 seconds.

c. Data processing: the total station has an inbuilt microprocessor which averages

multiple observations. It computes the horizontal distance and X, Y and Z coordinates

when height axis of instrument and target are supplied.

d. Coordinate measurement: coordinates of an unknown point relative to a known

coordinate can be determined using the total station as long as a direct line of sight

can be established between the two points.

3.2.5 ADVANTAGES OF USING TOTAL STATIONS

The following are some of the major advantages of using total station over the conventional

surveying instruments:

 Field work is carried out very fast and accuracy of measurement is high.

 Manual errors involved in reading and recording are eliminated.

 Calculation of coordinates is very fast and accurate. Even corrections for temperature

and pressure are automatically made.

 Computers can be employed for map making and plotting contour and cross-sections.

Contour intervals and scales can be changed in no time.

14
3.2.6 AIMS AND OBJECTIVES OF SURVRYOR AT DANGOTE CEMENT PLC

The aims and objective of surveyor at Dangote cement plc in the mines are;

 Determination of bench heights using the total station in the pit

 They also determine drilling depth for explosives

 They plan and design the pit and also give monthly mines parameters update

 They determine the volume/tonnage of material excavated and also they calculate the

amount of reserve using AutoCAD software to compute data from the total station.

 Topography survey

3.2.7 OPERATIONAL PROCEDURES FOR SURVEYING AT THE MINES

In determination of drilling depth and also determining the height of benches the following

procedures is followed:

 The tripod stand is mounted on an established or known control point marked and the

total station is mounted on the tripod stand ensuring that it’s well plumbed and

levelled.

 Measure the height of the total station with the tripod stand, and then input the values

obtained into the total station and coordinates of a known points (control stations)

relative to the station where the total station must be reference to check for accuracy.

 When all this measurement have been taken and stored in the total station someone

will hold the reflector with the detailing pole at the point interest and will be moving

at the top of the bench (crest) at an interval of 10m, 15m, or 17m depending on what

you are working on at each interval measurement are recorded in the total station and

also repeat same process at the bottom (toe).

 The height of bench is obtained by subtracting the value gotten from the crest (top)

from the value gotten from the toe (bottom). Bench height = crest – toe.

15
  The height of drilling points is obtained by subtracting the value measured from each

bore hole at the top (crest) of the bench and the average value measured from the

bottom (toe).

To determine tonnage/volume of marble stockpiled at particular area, the following process

must be taken into consideration;

i. Use a G.P.S to take co-ordinate readings of each points of interest and also a

meter tape to measure the heights.

ii. Plot the co-ordinates manually (graph sheet) or automatically (computer

system using software called AutoCAD) to calculate the area covered.

iii. Calculate for the average value of the measured heights

iv. Multiply the area covered by the average heights which is equal to volume

Area* height = volume.

v. Multiply the volume by the density of marble which is equal to tonnage

Volume*density of marble = tonnage.

NO EASTING NORTHING HEIGHT

1 884722 218207 2.4m

2 884691 218205 2.1m

3 884684 218229 2.3m

4 88493 218252 1.8m

5 884718 218275 2.0m

6 884725 218247 1.6m

7 884725 218229 1.4m

Table 3.0 Stock pile data obtain from the field

Area= 2020m2

Average height=1.94m

Volume=area* average height= 2020*1.94

16
=3924.860m3

Density of marble= 1.68

Tonnage= volume*density= 3940.860*1.68

=6593.765tons

Plate 3.4 Surveyor operating the total station

Plate 3.5 Total station mounted on a tripod

3.3. MINING OPERATION

Mining is the extraction of valuable minerals or other geological materials from the earth

usually from an ore body, lode, vein, seam, and reef or placer deposits. These deposits form a

mineralized package that is of economic interest to the miner. The act of mining required

different methods of extraction depending on the mineralogy, geology, and location of the

resources. Characteristics such as mineral hardness, the mineral stratification, and access to

that mineral will determine the method of extraction. Generally, mining is either done from

the surface or underground. Mining can also occur with both surface and underground

operations taking place on the same reserve. Mining activity varies as to what method is

employed to remove the mineral.

At Dangote cement plc Obajana Plant, the most common raw materials used for cement

production are marble, clay and laterite. The major raw material which is the marble is

17
usually extracted from the mine. The mine operated by Obajana Plant is an open pit which is

a form of surface mining.

Open pit is a surface mining technique of extracting rocks or minerals from the earth by the

removal from an open pit or barrow. It requires digging into the earth. Open pit mines are dug

on benches, which portray vertical levels of the hole. Walls of the pit are normally dug on an

angle less than vertical, to avert and lessen damage and hazard from rock falls. The walls are

stepped, the incline part of the wall is called the batter and the flat part of the step is known as

the bench.

After prospecting and exploration has been done by geologists, the processes involved in the

extraction of marble from the mine includes drilling, blasting, hoisting, hauling and crushing.

3.3.1 DRILLING OPERATION

In rock extraction, drilling operation involves the process of creating or making holes in a

rock mass for the placement of explosives required to disintegrate the rock ore body. It is the

technique whereby a hole is drilled in the rock surface up to certain depth and then explosive

are loaded to induce failure to the rock mass which results to the fragmentation of the rock

body.

Plate 3.6 Blast

hole

3.3.2 DRILLING METHODS

This refers to the mechanics used in drilling process, it requires a bit to penetrate the rock and

cause it to fail. It can be classified into two broad categories as follows;

18
 a. Percussive drilling method: in this method, the rock is caused to fail by impacting

a sharp blow onto the bit and using a rotation device to merely turn the bit a

sufficient amount to keep it indexed to cut a circular path. This method is

subdivide into;

 Top hammer drill

 Down the hole (DTH) method

b. Rotary drilling method: this method differs entirely from the percussive drilling.

In this method, no blow is struck and the rock is made to fail by a combination of

down pressure and rotation speed.

At Dangote cement plc Obajana Plant the drilling method used is the DTH drilling method. In

DTH drilling, the percussion mechanism commonly called the hammer is located directly

behind the drill bit. The drill pipes transmit the necessary feed force and rotation to the

hammer and bit plus compressed air or fluid for the hammer and flushing of the cutting. The

drill pipes are added to the drill string successively behind the hammer as the hole get deeper.

The DTH drilling rig used in Dangote cement mine is CM 785 manufactured by Atlas Copco.

Some important parts of the DTH CM785 drilling rig and it’s are as follows;

 Drill bit: it is the cutting used in the rig to bore hole. The drilling bit used has a

diameter of 152mm (6 inches)

 Drilling rods: these are rod used for drilling which are two types: Starter rod which is

the first rod use in drilling to attacks the rock surface. The drilling bit and the hammer

is attached to the starter rod and it is 4.5m long and the Standard rod, it is used after

the starter rod; it is also used to increase the drilling depth and it is about 5m long.

 Hammer: it is used to impact blow energy to the drill bit.

 Rotary head: it provide the rotation drive to the bit

 Hose: it provides hydraulic oil and fluid to bit and rig in general.

19
 Plate 3.7 DTH drilling rig used

in Dangote marble mines Obajana

3.3.3 DRILLING PATTERN

Drilling pattern can also be refer to as blast hole pattern. It is the manner of which spacing

and burden is arranged. Holes are drilled in special pattern so that blasting can produce the

type of fragmentation desired for the subsequent loading, hauling and crushing operations.

These patterns are defined by the burden (the shortest distance between the hole and the

exposed bench face) and the spacing between holes.

Before blast hole drilling takes places, points to be drilled must be marked depending on the

fragmentation desired for production. Hence based on the spacing and burden, blast hole

drilling pattern are mainly three types namely;

1. Square pattern: in this pattern, points to be drilled are marked in a square shape in

which spacing and burden are equal.

2. Staggered pattern: this pattern, the burden is perpendicular to the spacing portraying a

triangular shape

3. Rectangular pattern: this pattern is similar to the square pattern but the spacing and

burden are not equal.

20
Staggered and square pattern are usually used at Dangote marble mine because the pattern

produce good fragmentation on rocks after blasting. Since spacing and burden defines blast

hole drilling pattern, the factors that determines the spacing and burden to be used are the

same factors that are to be considered when choosing blast hole drilling pattern which are as

follows:

i. The nature and characteristics of the rock deposit which include the hardness and

structure of the rock

ii. Bench height which determines the drilling depth

iii. Drilling bit diameter or the diameter of the hole to be drilled

iv. Degree of fragmentation desired

v. The volume and performance of the explosives used can also be considered

3.4 BLASTING SECTION

Blasting is the controlled use of explosive to excavate rock into smaller fragments. It is a

process of deformation of blasting charge or a group of blasting charges. It is a technique

employed widely in mining and structural engineering. Blasting operation follows drilling

operation during which holes are drilled at uniform spacing for the placement of explosives

and precedes loading, haulage and crushing operation.

In this section the major processes which includes priming of holes (that is dropping the

primer charged into the hole), charging of holes (that is loading the holes with explosive) and

stemming of holes (that is confining the charged holes with material). After all these

processes the charged holes are connected together using the detonating cord before initiating

the blast for rock fragmentation. Blasting accessories used at Dangote cement plc includes;

explosives (pentolite, solar gel, superpower gel, bulk explosives, detonating cord, ANFO

ammonium nitrate and fuel oil, cartridges and the delay nonels).After blasting, the

fragmented raw material is loaded into the hauling machine (dumper) by the excavator. The

21
material is then transported (haul) using the dumper to the crushing plant where further

processes take place.

Plate 3.8 Non Electric detonator Plate 3.9 Pentolite

3.5 CRUSHING SECTION

Crushing is the first step of mineral/rock processing where the ore/rock from the mines site is

fed to mechanical equipment in order to reduce the size for subsequent stages. Crusher is the

machine used to achieve this aim. It is a machine design to reduce large rocks into smaller

sizes. There are various types of crushing machine namely; Impact crusher, Roller crusher,

Cone crusher, Jaw crusher, Hammer crusher.

At Dangote cement plc, the impact and roller crusher is used with reference to line 1 and line

2 respectively. The formal is used to crush marble while the latter is used to crush the

additives such as laterites and clay. Excavated materials are dumped into the hopper of the

crushing plant, the apron feeder and chain scrapper helps in conveying the material into the

crusher where the material is crushed by the impact action of the blow bars (impact crusher)

and the rolling action of the rollers moving in opposite direction (roller crusher).

Materials are crushed to the maximum size of about 80-90mm and are transported to mix

storage at the factory through the conveying belt for further cement production process.

22
 Fig

3.10 Digital schematic of a crusher

From the mix storage the crushed raw material is conveyed to the raw mill where it is milled

into powder known as raw meal. The raw meal is then heated and burn into molten at

temperature above 12000C at kiln before cooling into lumps called clinkers. The clinker is

then milled at the cement mill into powder (cement), from there it is then packed in bags as

cement.

3.6 QUALITY ASSURANCE AND LABORATORY

This department is centred on ensuring that the company is providing the best possible

products or services. It focuses on the end result such as testing samples of item from batch

after or before production. This is a unit concerned with the physical and chemical analyses

of samples of various origins whether Rock, Mineral, Water and cement to determine their

chemical and/or mineralogical composition.

At Dangote cement plc. the Quality assurance department consists of physical laboratory

where the physical strength of cement produced at tested, chemical laboratory where Blaine

23
test and loss on ignition is carried out, sample preparation room and robo laboratory where

XRF (X-ray fluorescence) analysis is majorly carried out.

3.6.1 SAMPLE PREPARATION ROOM

This unit deals with the preparation on samples such as rocks, mineral, soil and cement for

chemical analysis. It involves processes that produce a powder/homogenous sample, which

aids the accuracy and reproducibility of results when subjected to further analysis. Equipment

used in sample preparation room includes; milling machine, crushing machine, weighing

balance and the pressing/binding machine.

The following procedures are involved in Sample preparation;

i. Receiving and ordering: Samples are received from the field and immediately ordered

and cross-checked against the list of field sample numbers

ii. Sample drying: Wet samples are dried in the oven to remove the moisture in it before

grinding

iii. Milling of samples: samples are milled into powder to an homogenous sample but

first the sample must be crushed into smaller grain sizes but grinding/milling

iv. Binding: After milling the powder sample are pressed in a ring.

v.

Plate 3.11 Milling machine Plate 3.12 Binding machine

24
 Plate 3.13 Crusher

The above plates (Plate 3.11, Plate 3.12 and Plate 3.13) are equipment used in the sample

preparation room in preparing samples for XRF analysis. The crusher is used for

disintegrating the sample into smaller size, the milling machine is used to grind the sample

into powder through the violent shaking in the mill. A tablet binder containing cellulose or

starch is blended thoroughly with the sample and the resulting mixtures are placed in a ring

and are pressed into pellet. The binder holds the material together to make a more resilient

pellet. Binders are typically free of contaminating element because it contains a very light

matrix, element that can’t be detected by XRF.

Plate 3.14 Prepared Sample

25
3.6.2 X-RAY FLUORESCENCE ANALYSIS

X-ray fluorescence spectrometry is an elemental analysis technique with broad application in

science and industry. It is based on the principle that individual atoms, when excited by an

external energy source, emit x-ray photons of a characteristic energy or wavelength. By

counting the number of photons of each energy emitted from a sample, the element present

may be identified and quantitated. This analytical technique can be used to determine the

chemical composition of a wide variety of samples types including solids, liquids, slurries,

loose powder and pressed pellet.

Plate 3.15 XRF

Analyzing Machine

This XRF technique is utilized in Dangote cement plc. to analyze various samples such as

rock samples (marble, laterites and clay mostly), cement and clinker samples. The XRF

machine is operated with analytical software called OXSAS on the computer system. It is

powerful and flexible analytical software that perform fast and high quality analysis.

3.6.3 OPERATIONAL PROCEDURE OF XRF ANALYSIS

This involves the step that is followed in running the XRF analysis in the robo laboratory.

a) Go to OXSAS on the system, run the program and click on qualitative analysis

b) Click on batches a submenu will be displayed

26
 c) Click on any of the analysis from the sub menu you want to carried out such as

“limestone special” for carbonate rocks, “cement full analysis” for cement sample or

“clay special” for clay and laterite samples

d) Move the radar to the right and enter correctly the sample details including the sample

label, batch no. and the sample chamber number where you place the sample in the

machine.

e) Put samples into the XRF machine in the sample chambers (there are up to 41

chambers) by placing them in the right chamber number as stated in (d)

f) Highlight all the samples enter on the system and click on include all

g) Then click run to start the analysis.

The XRF analyzing machine picks each sample one by one and emits x-ray photon on the

samples to analyze the sample. Each result on the sample analyzed will be displayed on the

screen of the system. Maximum time of four to five minutes is required for the machine to

analyze a sample.

3.6.4 RESULTS OF XRF ANALYSIS

The results of samples analyzed will be display on the screen of the system showing the

various chemical compositions of the samples. The results of the analysis maybe in oxide or

elemental form depending on the XRF analysis used. The following tables below show some

of the results of XRF analysis carried out on various sample at Dangote cement plc. Obajana

plant Quality assurance department.

27
 Sampl
e
SiO2 Al2O3 Fe2O3 CaO MgO K2O Na SO3 LSF SIM ALM
A 53.03 2417.99
0.660 0.199 0.169 9 0.635 0.049 0.097 0.154 7 1.179 3.343
B 52.77 1664.80
0.997 0.243 0.141 2 1.148 0.056 0.068 0.089 9 1.723 4.251
C
53.16 2272.99
0.685 0.261 0.177 6 0.438 0.046 0.112 0.133 4 1.473 2.803
D
51.73
1.922 0.517 0.295 3 0.777 0.099 0.086 0.316 836.578 1.755 4.012
Table 3.1 XRF Analysis Result for Marble Blast hole samples A-D from pit 2 (06-6-2017)

From the result above the Chemical data presented in Table 3.1 shows the major and some

selected trace elements composition of the marble. The SiO2 concentrations of the marble are

generally low, indicating a range of 0.66 to 1.922 wt. % The CaO contents of the marble

range between 51.73 and 53.04 wt. %, showing 52.68 wt.% as the average value. The high

CaO (52.68 wt.%) concentrations of the marble reflect its calcitic nature while the average

MgO (0.749 wt. %) contents of the marble portray its non-dolomitic nature and the absence

of calc-silicate rocks in the marble bodies

The LSF, SIM and ALM are specific requirement or quality control factors used in cement

production. LSF is actually called the lime saturation factor. It is the ratio of lime (CaO) to

other factors. It is calculated as:

LSF= CaO/ (2.8SiO2+ 1,2Al2O3 +0.65Fe2O3)

SIM stands for silica modulus it is the ratio SiO 2 to Al2O3 and Fe2O3 while ALM is for

alumina modulus and it is the ratio of Al 2O3 to Fe2O3. High silica ratio means that more

calcium silicates are present. Hence the higher the concentration of SiO 2 the lesser the LSF,

the standard LSF required for cement production ranges from 98 to 106 wt%. Additives such

as clay and laterites required to be crushed along the marble to balance the chemistry and

reduced the LSF content of marble to the required range.

28
SAMPLE Si Al Fe Ca Mg K Na S

A 58.8386 14.3700 16.1529 0.0254 0.0347 0.0044 0.1142 0.0148

B 50.5584 7.8152 19.3636 0.2684 0.0265 0.2602 0.0272 0.0164

C 43.4290 3.9351 14.1904 0.0773 0.0684 0.1206 0.0023 0.0121

Table 3.2 XRF Analysis Result for Laterite sample 12/06/2017

From Table 3.2 the XRF analysis shows the elemental composition of Laterite sample

analyzed with an average Si concentration of 50.94 wt%, Al concentration of 8.71 wt % and

Fe concentration of 16.57 wt %.

XRF analysis can also be performed on cement sample to test for the element in cement

produced especially for sulphur concentration before releasing the the product into the market

because sulphur concentration above 3.00 wt % is harmful.

SAMPL Si Al Fe Ca S

Cem Pac 3.9594 2.8675 3.660 58.7243 1.9138

Av Cem 3.9404 2.8675 3.6522 59.6702 1.6157

Pac L3 3.5532 2.8680 3.3691 59.6155 1.8971

Cem L3 3.5528 2.8674 3.4282 61.7270 2.0152

Pac L4 3.4838 2.8677 3.5161 61.6379 1.9048

Table 3.3 Cement Full XRF analysis result

3.6.5 LOSS ON IGNITION TEST FOR CEMENT

The Loss on Ignition Test is designed to measure the amount of moisture or impurities (CO 2)

from CaCO3 lost when the sample is ignited under the conditions specified in the individual

monograph.

Theory: loss on ignition is calculated thus:

LOI = (W1– W2) X 100%

Where; W1 = weight of empty crucible + 1g of cement

29
 W2 = weight of ignited crucible

Procedure: Weigh and record an empty platinum crucible. Weigh 1g of cement and pour

everything in the weighed platinum crucible and record its weight (W1).

Place the platinum crucible with the cement in it inside a furnace it at temperature of 950 to

10000C for one hour (1hr). Remove the platinum crucible from the furnace and allow Cooling

to room temperature. Weigh the mass of the resultant crucible (W2)

SAMPLES A B C D

W1 26.5915 17.8996 26,3507 18.3142

W2 26.4629 17.7769 26.2275 18.9925

(W1-W2) 0.1286 0.1227 0.1232 0.1217

LOI 12.87 12.27 12.32 12.17

Table 3.4 Loss on ignition Result

Table 3.4 shows the LOI test carried out on four different cement samples. The LOI required

for a good cement product should be approximately 10% , but from the result the average

LOI on the cement tested is 12.40% that is the volatile content in the cement is approximately

12% pointing to the fact that the is either stored for long at the cement silo before packing it

for sale or the raw material used is high in volatiles such as H2O or CO2.

3.6.6 FINENESS OF CEMENT TEST

The fineness of cement test is used to determine the porosity of cement. It has an important

role in the cement production. It enhances the efficiency of the comminution (reduction of

solid materials) process. Finer cement offers a greater surface area for hydration.

Fineness of cement is tested in two ways:

 Sieve method.

 Blaine method.

30
By Sieve method

Theory: Fineness of cement using sieve method is done by agitating the sample (Cement) on

a mesh sieve. The production of cement of which the grain sizes are larger than the specified

mesh size is determined.

F = R0 /C X 100%

Where R0 = mass of residue in grams

C = mass of cement measured (10g or 5g)

F = Correction factor (Percentage residue)

Procedure: Weigh 10g of cement to the nearest 0.01g and place it on the sieve. Stir the

resulting cement powder gently using a clean dry rod to distribute the fineness throughout.

Attach a pan under the sieve to collect the cement passing the sieve, fit the lid over the sieve.

Agitate the sieve by swirling, planetary and linear movement until no more fine material

passes through. Remove and weigh the residue. Express its mass as a percentage of the

quantity first placed in the sieve. It can also be done using sieve machine.

Precautions

 Before sieving, air set lumps of cement should be broken.

 Sieving should be done by rotating the sieve and not by translation.

SAMPLE WEIGHT(g) RESIDUE WEIGHT SIZE (µm)

C R0 F
Packer AV sample 10 0.00 0.00
Cement mill B 10 0.00 0.00
42.5N
Cement mill B L4 10 0.08 0.80
L4 packer 10 0.03 0.30
Bulk loading sample 10 0.34 3.40
Table 3.5 Result for Sieve Analysis on Cement

The above analysis is carried on the various cement samples using the 90 µm sieve mesh. It
shows the fineness on the cement produce from the company.

31
Plate 3.16 Sieving Machine Plate 3.17 Sieve Mesh

By Blaine test

Theory: This method is by means of drawing a definite quantity of air through a prepared bed

of cement of definite porosity using the Blaine apparatus. The fineness is expressed as total

surface area in square centimetres per gram.

S = √t * k Cm2/g

Where S = Specific surface area in cm2/g

K = Apparatus constant (520),

t = time.

Procedure: Weigh 2.59g of cement, so as to give the cement bed of porosity. Place the

perforated disc at the edge of the bottom of the cell and place on it a new filter paper. Place

the weighed quantity of cement in the cell taking care to avoid loss. Tap the cell to level the

cement. Place new filter paper on the levelled cement and compress the cement with the

plunger until the plunger collar is in contact with the top of the cell. Slowly withdraw the

plunger a short distance, rotate 900, repress the cement bed, and then slowly withdraw. Attach

the permeability cell to the manometer tube with an air tight connection and slowly evacuate

the air in the manometer U-tube until the liquid reaches the top mark, then tightly close the

32
value. Start the timer when the bottom of the meniscus reaches next to the top mark and stop

the time when the bottom of the meniscus reaches the bottom mark. Record the time it takes

using stop watch.

NOTE: The apparatus constant varies from one apparatus to the other depending on the

density of the calibration of the apparatus and the density of the cement sample to be tested

with the apparatus.

Precautions

 The time taken by the manometer liquid to fall from one mark to the other should be

measured very accurately.

 Avoid loss when placing the weighed cement in the cell.

Plate 3.18 Blaine Apparatus

Other tests carried on cement at the Quality Control department includes Strength and

Flexural tests on cement using the compressive and Flexural machine, setting time test and

soundness test. These test are carried out on daily bases to test for the quality of cement

produce by the company.

33
 CHAPTER FOUR

4.0. SUMMMARY

The lessons learnt and Dangote Cement plc. Obajana Plant impacts on me during this

industrial training is enormous, to mention but the few; I learnt the local geology of the area

and observed some geotectonic features including identification of minerals found within the

area. I also learnt the various stages in mining and the various mining process which include

drilling of blast holes, load the holes with explosives for blasting to fragment the raw

material. These raw materials (marble) are loaded into the dumper and haul to the crushing

plant where it is crushed and conveyed through belts to the factory for the production of

cement. The chemical composition is noted through XRF analysis of the raw materials.

4.1. CONCLUSION

The SIWES Program is an effective medium to educate and expose students to the required

knowledge and experiences outside the lecture room. The exposure during the 24 weeks of

training period provides students with invaluable lessons on technical knowledge, working

experience, teamwork, integrity, diligence, commitment, time management and interpersonal

skills.

My industrial training program with Dangote cement plc. Obajana Plant has indeed exposed

me to a good working culture, ethics (such as being able to handle situation/work with little

or no help) and environment. I was able to learn how to apply the basic geoscientific

principles of which I was taught in the class to the real life experience which has broadened

my horizon. The Industrial Training Program has afforded me practical experience in

Geology and other Mining fields. It has also helped me to bridge a gap between theory and

practical knowledge. The program should be encouraged and strengthened in order to

continually provide the needed experience and impacts that will boost the economy of this

country

34
4.2. RECOMMEMDATION

I suggest the following recommendations based on my experience during the 6-month period

of Industrial Training:

 The Department and University should assist students in securing IT placements.

 The Industrial Training should be encouraged twice at Undergraduate Level.

 The University and ITF should ensure that students are adequately monitored during

the program.

 Students should be visited regularly by ITF officials during SIWES.

 Adequate remuneration should be paid to the students by the firm to which they are

attached as a form of encouragement.

35
 REFERENCE

Okeke,J.G., (2004): Comprehensive manual of students industrial work experience scheme

(SIWES), Gostak printing, Enugu

Abati. R, (n.d), Local and Regional Geology of Oyo- Iwah unpublished pg 4-5

History of Dangote Cement Plc. and Obajana PLant (n.d), Retrieved from
http://www.google.com/dangote.com/aboutus/historyaspx

Felix, B.F, Gideon,Y.B (2013). Geology and Occurrence of Limestone and Marble in
Nigeria.Journal of Natural science Research, Vol 3 No.11(2013) pp 60-65

Elueze, A.A, Jimoh, A.O and Aromolaron, O.K (2015). Compositional characteristics and
functional Application of Obajana marble depositional in the Precambrian basement
Complex of central Nigeria.Ife journal of science, Vol 17 N0.3(2015) pp 591-603

Daku, S.S., Wazoh, H.N and Ojo, O.A (2017). Engineering properties of Jakura Marble and
it's suitability for tiles production. ISOR journal of Applied Geology and Geophysis
(ISOR-JAGG) Vol 5 (jan-feb 2017) pp 57-66

Surface Mining (Mine Techniques). Retrieved from http://www.greatmining.com/ surface-

mining.html

Pit and Quarry (2015, June 26th). P&Q university lesson 4- drilling and blasting. Retrieved
from http://www.pitandquarry.com/pq-university-lesson-4-drilling-and-blasting/

Carlos, L.J, Francisco, J.C and Yvonne, D.R (1995). Drilling and Blasting of rocks. AA
Balkenna publisher pp 2-6

Filatov, S.A. (1990-1979). Mine Surveying. Retrieved from http:// encyclopedia2.thefree-

dictionay.com/mine+surveying.

Total station-Operation, Uses and Advantages (n.d). Retrieved from

http://theconstructor.org/surveying/total-station-operation-uses-advantages/66051

36