TABLE OF CONTENTS
Contents pages
Title Page – – – – – i
Declaration – – – – – ii
Attestation – – – – – – – – iii
Dedication – – – – – – – – iv
Acknowledgment – – – – v
Contents – – – – – – – vi-vii
List of Table – – – – – – – – Viii
List of Figures – – – – – – ix
Abstract – – – – x
Background of the study – – – – – – xi
CHAPTER ONE:
1.1 Introduction – – – – – – – 1
1.2 Concept involved – – – – – – 1
1.3 Statement of Problem – – – – – – 3
1.4 Aims of the Study – – – – – 3
1.5 Methodology – – – – – – – 3
CHAPTER TWO: Literature Review
2.1 Cement – – – – 4
2.2 Types of Cement – – – – – 4
2.3 Portland Cement – – – – – – 4
2.4 Slag Cement – – – – 7
2.5 Pozzolanic Cement – – – 8
2.6 High Alumina Cement – – 9
2.7 Cement Manufacture – – – 9
2.8 Basic Characteristics of Portland Cement — 11
2.9 Gypsum – – – – 13
CHAPTER THREE: Production
3.1 Procedure – – – – – – – 14
3.2 Manufacturing Processes – – – – – 20
CHAPTER FOUR: The Role of Cement Industry in the Economy
(A case of Edo Cement Factory Ukpilla.
4.1 The relevance of Cement Industry to
National Economy and Industrial Development – – 22
4.2 The Structure of the Nigeria Cement Industry – – 23
4.3 Problems and Constraints of the Nigeria Cement
Industry (A case of Edo Cement Factory Ukpilla. – – 24
4.4 Recommendation and Strategies for the
Development of the Cement Industry – – – – 27
4.5.1 Packaging Materials – – – – – – 27
4.5.2 Acquisition of Funds – – – – – – 28
4.5.3 Energy – – – – – – – 28
4.5.4 Man power – – – – – – – 28
4.5.5 Conversion Process – – – – – – 28
4.6 Mini- Cement Plants – .- – – – – 29
4.7 Local Raw Material Sourcing – – – – 30
4.8 Components and Spare Parts – – – – – 30
4.9 A Diversification of Fuel Types – – – – 31
4.10 Product Diversification – – – – – 31
CHAPTER FIVE: Company
5.1 Staff Strength – – – – – – – 33
5.2 Cost Analysis – – – – – – – 33
CHAPTER SIX: Conclusion and Recommendation
6.1 Conclusion – – – – – – – 36
6.2 Recommendations – – – – – – 36
Pl4n Layout – – – – – – – 48
Organizational Chart of Nigerian – – – – 49
References – – – – – – 50
LIST OF TABLES
Table 1: Main Chemical Compounds of Port land cements
Table 2: A typical Chemical Composition of Ordinary Portland Cement
Table 3: British Standard Requirement for the Chemical Composition of the Principal
Portland cement
Table 4: Time taken to achieve 80 percent hydration of the main compounds Portland
cement based on Goetz (1969)
Table 5: Heat of hydration of the main chemical Compound of Portland cement based on
Goetz (1960)
Table 6: Typical initial and final setting times for the main Portland cement.
Table 7: British standard requirements for strength of the principal Portland cement.
Table 8: Major Federal Government. Manufacturing Programmes and Project.
Table 9: Distribution of GDP at 1984 constant factor cost by major section (%)
Table 10: Data on existing cement manufacturing companies in Nigeria
Table 11: Local production of cement in Nigeria 1981-1990 % capacity utilization
Table 12: Comparative analysis of companies and sector’s capacity utilization (%) 1981-
1990
Table 13: Relative specific costs for various conversions from wet process (in N millions)
FIGURES
Plan layout
Organization chart of Nigeria
ABSTRACT
The project studied the manufacture of cement production in Nigeria using
Ukpilla as a case study. It enables us to compare the differences between
Ukpilla cement factory production and other cement company in the nation.
Furthermore to look into the problems of Raw material acquisition e.g. Gypsum
and supply of power which affects maximum production, the types of cement
produced with particular reference to Portland cement, the problems of
transportation and solution of conveyance from the site to the factory. The way
forward on how to raise fund from National Banks and Foreign Banks has been
suggested.
BACKGROUND OF THE STUDY
Right from the Colonial era, reports have indicated the presence of extensive limestone
deposits at Ukpilla from which good quality cement could be produced.
The limestone deposit covers a belt upwards of thirty kilometers long stretching from Ukpilla
in the present Edo State to Okene in Kwara State.
However, owing to both economic and technical reasons, the deposits were not exploited
then.
In 1950, the Nigerian government invited a British company, Associated Portland Cement
Manufactures Limited (APCM) who imported over 50% of the cement used in the country to
establish an indigenous cement plant.
After two years of study and negotiation, (APCM) could not go ahead with the project.
In 1952, the Nigerian government set aside the sum of $1.2 million for the establishment of a
cement plant in Nigeria. In 1954, government reached an agreement with the Danish film of
F.L Smith and its British associate Turnel Portland cement company ltd.
On 13th November, 1954, the Nigerian cement company limited was incorporated with a
nominal capital of $ 1.75 million
TRANSPORTATION OF RAW MATERIAL
The transportation of the Raw material is of paramount importance: The
presence of non – availability of factory trucks or wagons to transport Raw
material from the mining sit when the over burden has been removed left with
limestone gives much concern. The limestone detonated by explosives must be
transported to the Jaw Crushers. Due to insufficient of fund to purchase trucks
raw materials were left in the quarry. When there is rain, the problem is more
pronounced. It becomes evidently clear that limestone detonated by explosives
need immediate transportation. The hired trucks are more expensive to rent.
Furthermore, the fund is not even available.
CHAPTER ONE
INTRODUCTION
1.1 GENERAL STATEMENT
This project is titled- cement manufacturing! production in Nigeria- a case
study of Edo cement factory, Ukpilla. The project is about the production of
cement, the processes that the raw materials undergo from the start to the
finishing point, the layout of plant and the distribution of the products.
1.2 CONCEPTS INVOLVED
The main concepts involved are the raw materials setting up of the plant,
production of cement and finally distribution and costs of labour and
maintenance.
1.2.1 THE CONCEPT OF THE RAW MATERIALS
The raw materials are the substances used in the production of the
cement. The materials include:
i. Limestone
ii. Gypsum
iii. Water
THE CONCEPT OF THE LAYOUT OF PLANT
This concept deals with the design and the agreement of the
components of the production plant from the start of production to the final
point where the products are realized. These components are:
i. Jaw crusher-s
ii. Raw mills
iii. Kilns
iv. Coal mills
v. Cement mills
vi. Packing plant (Silos)
1.2.3 THE CONCEPT OF PRODUCTION
The concept deals with the production itself. The various processes that the raw
materials wider went to become the finished product (cement).
1.2.4 THE CONCEPT OF DISTRIBUTION
Here, the distribution is done through lorries. These takes the finished products
to the purchasers (end users).
1.2.5 THE CONCEPT OF MAINTENANCE
This deals with the servicing and maintenance of the various components of the
production plants. The techniques used are:
i. Greasing
ii. Oiling
iii. Cleaning
iv. General servicing
THE CONCEPT OF I.ABOURS
This deals with labour and its costs. The strength of the work force and nearness
of the raw materials to the production plant. It also involves the cost of
maintenance of the production plant.
1.3 STATEMENT OF PROBLEM
Cement being a very important actor in the provision of housing and
accommodation for Nigeria. Its production needs to be streamlined for
maximum efficiency and output The plant has to be properly designed and
installed. These are basically engineering
problems.
1.4 AIMS AND OBJECTIVES OF THE STUDY
1. To examine the manufacture of cement production in Nigeria an Ukpilla as a
case study
2. To compare the differences between Ukpilla cement factors production and
other cement company in the nation
3. To look into the problems of Raw material acquisition eg Gypsum and the
supply of power which affects maximum production.
L5 METHODOLOGY
The method use in this project was research and visits to Edo cement factory
Ukpilla
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