KALUWORKS LIMITED COMPANY (K.A.R.M DIVISION)

MARIAKANI

An Industrial Attachment Report

Submitted by:

Dickson Mulewa Kazungu

N39/PU/0513/13

In partial fulfillment of Industrial Attachment for the award of the

Degree in

BACHELOR OF ENVIRONMENTAL STUDIES

AND COMMUNITY DEVELOPMENT

Pwani University

Kilifi-Kenya

5TH AUGUST 2016

ACKNOWLEDGEMENT

I would like to dedicate this work to all stakeholders who have given me support. I would like to thank entire Pwani University, especially to the School of Environmental and Earth Sciences, department of Environmental Studies and Community Development and Kaluworks Limited Company for providing me with the opportunity to do this internship where I have learnt more about the company’s operation as environmental Management is concerned.Special gratitude goes to my industrial attachment supervisors; Mr. James Chege and Eng. Albert Wafula for availing their time to ensure my success during the attachment period, despite their busy schedule they helped me to gain a better understanding and appreciation in the field of Environmental Science.

To crown it all, immense gratitude goes to the Almighty God for making the attachment possible and successful and for granting me life.

ABSTRACT

Attachment period is a critical period for students as it equips one with the knowledge and skills in applying the concepts learnt in class, it is the policy of the university for the purpose of fulfillment of the course. Every student must be attached to an institution to get exposure of what is happening outside class.

Kaluworks Limited is known as a manufacturer of Quality Aluminum Rolling Products like Cookware, roofing sheet Aluminium Circles etc. which is ISO 9001 and 14001 certified. I was exposed to practical application of the value addition as it focuses on Quality Product production with environment in mind guided by the Environmental Policy and the interactions between employees to ensure success of the institution. The report contains various activities carried out during the attachment period. Fire and Personal Training, Effluent Treatment, Sewage Treatment, Solid Waste Management, ETP and Municipal water quality improvement, Cooling Tower Water Treatment, Quality Control inspection and tests and Environmental Aspects evaluation of the Company’s activities.

Conclusion and Recommendations on the institution and on the attachment programme are also highlighted in the report.

CHAPTER ONE

1.0.0 INTRODUCTION

1.1.0 BACKGROUND OF THE ESTABLISHMENT OF KALUWORK LTD COMPANY

Kaluworks Limited was set up in 1929 in Kenya and the company has created history by continuously growing over the last 80 years.

Predominantly a Cookware Manufacturer, Kaluworks in 1988, diversified into Aluminium Rolled Products, by setting up a state of the art Aluminium Rolling Plant in Mariakani near Mombasa. Since then, after a series of upgrades on the process and machinery, Kalworks started rolling out high quality Aluminium Coils, Sheets, Circles and Roofing Products.

The company has established its mark as a manufacturer of Quality Aluminium Roofing Products and carved a niche for excellence in performance and quality in the Eastern & Sub-Sahara African Region.

The Company is ISO 9001 and 14001 certified, recognized for the high quality products it supplies to the market.

1.2.0 GEOGRAPHICAL LOCATION/MAP

Kaluworks Limited Company is located in Coastal Kenya, 36 kilometers northwest of port city Mombasa. It is found in Kilifi County, Kaloleni sub-county, Kaloleni constituency, Mariakani location and along Mombasa-Nairobi Highway. It is located next to Mabati Rolling Mill on the left.

1.3.0 KALUWORKS’ ORGANOGRAM

RESPONSIBILITIES

Chief Operation Officer

• Overall responsibility of Quality System

• Approving Quality Manual

• Chairing Management Review Meetings

• Identification of training Needs

• General Administration

Assistant General Manager

• Responsible for the Quality System

• Chairs Management Review Meetings in the absence of the General Manager

• Document and data control

• Product identification and traceability

• Process control

• Incoming, In-process and Final inspection of products

• Control of non-conformance

• Corrective and Preventive action on non-conformance

• Control of quality records

• Identification of training needs

• Calibration and control of instruments

Operations Manager

• Finished goods (FG) Production.

• Oversees Mill operations.

• In charge of all Finishing operations.

• In charge of dispatch

• In charge of slitting operations.

• Corrective and Preventive action

• Control of quality records

• Identification of training needs

Production Planning Engineer

• Production Planning.• FG Packing, Storage and dispatch.• FG and WIP management.• Corrective and Preventive action.• Control of quality records.• Identification of training needs.• Weekly and monthly stock reconciliation

Quality Assurance Manager

• In-charge of the entire QC system

• Checks and approves incoming raw materials.

• Checks and approves Cast coils for further operation.

• Checks and approves WIP.

• Checks and approves FG for dispatch.

• Advises the production and management on quality issues.

• Handles returns and customer complaints.

• Corrective and Preventive action.

• Control of quality records.

• Identification of training needs.

• Continuous improvement.

• Product/Process development.

Human Resource Manager

• Personnel recruitment and Manpower development

• Staff welfare including canteen operations

• Developing industrial relations

• General administration of safety and security measures of staff and property

• Document and data control

• Identification of training needs and organizing training programmes

• Corrective and preventive action on non- conformance

• Agricultural operations.

• Legal Affairs.

Senior Engineer Cast House

• Document and data control

• Product identification and traceability

• Process control

• Incoming, In-process and Final inspection of products

• Control of non-conformance

• Corrective and Preventive action on non-conformance

• Control of quality records

• Identification of training needs

Works Accountant

• Document and data control

• Preparing import documents such as IDF, etc

• Product Identification for raw materials, spare parts, consumables etc.

• Control of non-conforming incoming product

• Corrective and preventive action on the system

• Handling and storage of the incoming goods

• Control of quality records (Purchasing records)

• Identification of training needs

•

Purchasing Manager.

• Sales coordination activities including -:

– Pricing

– Tendering and quotations.

– Receipts and orders.

– Order Acknowledgement

– Order Follow-up

– Credit control

• Dispatch operations

• Purchasing. This will also include imports and raw material logistics.

• Overall management of port operations.

• Maintaining purchasing activities as per the Purchasing Procedures.

• Establishing and updating the list of approved suppliers

Sales and Marketing Manager

• Receipt of approved orders from the General Manager, verification of the price, discount, temper, and delivery date required by the customer.

• Liaison with customers on order verification, acknowledgement of orders, and determination in conjunction with production and planning department for delivery dates and change in delivery schedules.

• Collection of material from KARM or ALUWARE for sheets customers. (Fax the invoice to the customer)

• Collection of material from KARM by Export customers once the production and documents are ready.

• Receipt of customers at the main office: Provide information and pricing on our products. Handling of customer’s inquiries on aluminium products and order follow-up

• Co-ordinate with dispatch department for sheets dispatch to Nairobi customers through Aluware and dispatch to Mombasa customers with our lorry.

• Release work order to Planning, Production and Quality Control departments• Ensuring that export orders have all the documents: PFI, IDF/IAN, order break up

MAINTENANCE ENGINEER

• Plan schedule and control preventive maintenance programs• Attend to breakdowns of machines and or plant equipment• Identify critical spares and ensure their availability• Prepare monthly reports on maintenance activities done and submit to senior engineer• Supervision and allocation of duties of duties to junior staff• Raise orders for any required machine parts/components• Ensure daily monitoring of machines in operation and any abnormality is attended to

immediately • Custodian of all preventive maintenance records - log books ,preventive maintenance

cards• Coordination of day to day mechanical maintenance activities• Any other professional duties assigned by the senior engineer• Oversee the functions of mechanical stores

CIVIC SUPERVISOR

• Preparation of sites for grouting of machines, building erection and roofing.• Provide estimates for material required for civic works that need to be undertaken• Handling and storage of required material when available• Supervision of all civic works.

CASTER & REMELT DEPARTMENT

HEAD OF DEPARTMENT – Caster:

Implementation of management policies in the department. Requisition of raw materials Control and monitoring of raw materials consumption Overall in-charge of the running of the caster department Training and appraisal of personnel Planning, scheduling and allocation of work programmes Co-ordination with other departments Manpower control Looks after the functions of the engineer in the general shift in his absence Departmental WIP and stock control

ENGINEER - CASTER & REMELT

Weekly and monthly stock taking of metal, consumable & reports Organization of departmental meetings and follow –up Implementation of improvement and development programs Coordinate between shifts and manpower Assign duties to staff in general shift look after the functions of head of department in his absence

SUPERVISOR - METAL STOR

Receive all metal Keep records of bonded warehouse Keep records of metal receipts, issues and stock Supervises box making group and scavenging group Arranges for offloading of metal received

SUPERVISOR – ROTARY

Supervision of all rotary furnace operations Supervision and control of manpower in dross picking , Scavenging, and dross shifting crew. Coordinate between rotary furnace operators Control and optimize on the use of consumables at rotary Act in place of supervisor - metal store in his absence.

Caster Shift Supervisor

Supervision of shift activities and operations Allocation of jobs to junior staff Ensure good house keeping Assist shift engineer and takes charge of shift in his absence

QUALITY CONTROL DEPARTMENT

DEPARTMENTAL HEAD

Checking and Approving Cast Coils. Outlining Correctives and Preventives Actions. Handling Customer Complaints. Water Treatment. Spectrometer Cleaning, Profile Operations and Standardization. Training and Recruitment in the Department Manpower Needs. New Products Development. Outlining Experiments and Interpretation of Results. In charge of the Departmental Quality Management Systems [ISO Standards] Rejection Handling and Interpretation of results

QUALITY CONTROL SUPERVISORS

Man-power distribution and supervision Conduct Experiments Raw Material/Received Goods Analysis Non-Conformance Reports Preparation-Customer Complaints. Co-coordinating and Checking All Laboratory Analysis of WIP materials and Finished

Goods. Checking on Casting Quality and Produced Cast Coils.

COLD MILL DEPARTMENT

HEAD OF DEPARTMENT

• Organisation of mill and slitter production activities• Mill manpower training • Motoring rolling and rolling oil hygiene• Material requisition• Cutter grinding arrangement• Identification and making of slitter requisition• Departmental WIP and stock control• Coil cleaning • Coil strapping and transferring to the required area• Loading of sleeve

• Assisting in sample cutting and roll coolant sample collecting

PLANNING DEPARTMENT

DEPARTMENTAL HEAD

• Coordinating all sales activities• Production planning of all customer orders• Conducting despatches to customers• Monthly production planning• Order receiving, validation and acknowledgement• Giving delivery schedules• Stock allocation• Casting program preparation• Setting production targets

PLANNING AND SALES ASSISTANT

• Order receiving and preparation of acknowledgement letters• Received order data entry• Stock allocation• Communicating with customers

PLANNING SUPERVISOR

• Stock allocation and updating of production display boards• Order follow-up• Preparation of mill program, slitting program, blanking program, shearing/circle cutting

program, and annealing program• Overall supervision of all planning activities

ACCOUNT DEPARTMENT

WORKS ACCOUNTANT

• Handling invoice, credit note s, accounts statements reconciliation and payment voucher of supplier.

• E.P.P.O reconciliation• Insurance follow-up• E.DP checklist verification• Maintenance of accounts files• General correspondence • Preparation of management reports• General administration• Review of pending orders

ACCOUNTANT

• Handling payroll

• Bank accounts, bill preparation & discounting ,monthly statements• Sales invoice preparation, payment follow-up ,receipt & arrangement for banking of

traveler’s cheques/ U.S dollars , monthly dispatch report and monthly sales analysis statement

• Prepation of management reports / board papers

ELECTRICAL DEPARTMENT

1. DEPARTMENTAL HEAD • Stores functions • Control of imported and direct charge items for electrical/electronic instruments• Instrumentation, calibration, electronics, and LT switchgear• Manpower control in the department• Ac/Dc motor maintenance, Ac panel maintenance and lt switch gear maintenance.• Coordinating general electrical/electronic maintenance and electrical/electronic

equipment • Commissioning

2. TRAINEE ELECTRICAL ENGINEER

• Assisting the head of department in coordinating electrical maintenance (breakdown & preventive)

• Supervision of maintenance jobs

3. ELECTRICAL SUPERVISOR

• Supervision of electrical maintenance (break down and preventive)• organising shifts

4. ELECTRICIANS

• Attending to electrical maintenance (breakdown & preventive• Daily checklist execution

FINISHING DEPARTMENT

DEPARTMENTAL HEAD:

• Coordinating all finishing operations• Training and recruiting of departmental manpower requirements.• Ensuring production targets are achieved in all finishing sections.• Ensuring proper finished goods packing, into pallets and boxes• Coordinating all finishing maintenance jobs (breakdowns& preventive).• Departmental WIP and stock control.

2. BLANKING SUPERVISOR

• Manpower distribution in machine centres• Setting of machine-wise targets.• Ensuring production targets are met.• Ensuring good housekeeping and safety• Ensuring production targets are met.• Supervising of all finishing activities• Ensuring good housekeeping and safety.• Ensuring shearing, c/cutting and bailing targets are met.• Supervision of sharing, c/cutting and bailing activities.• Ensuring good housekeeping in the concerned areas

3. PACKING SUPERVISOR

• Supervision of packing and box annealing activities.• Ensuring good housekeeping and safety.• Ensuring production targets are met.• Supervision of stores activities.

4. DISPATCH SUPERVISOR

• Coordinating with the invoicing clerks on material to be dispatched.• Supervision of dispatch activities.• Coordinating with logistic manager on trucks to be loaded.• Inspecting of truck if they are leaking from the top.

MANAGEMENT REPRESENTATIVE

Management Representative

• Maintenance of the quality and environmental system• Document and data control• Reporting on the performance of the system for management review• Control of quality records• Internal quality and Environmental audits• Corrective and preventive action on non-conformance• Liaise with external parties on matters relating to the quality and environmental system• Arrange the Management Review Meetings.

Assistant Management Representative

• Assisting the management representative• Secretary of the management review meetings.• Custodian of the quality and environmental documentation.• Act in absence of the Management representative.• Co-ordinate duties in relation to health, safety and environment

GENERAL STORES

STOREKEEPER (IMPORTED GOODS & GENERAL STORES)

• Identification of all items in stores by bin codes &tagging.• Notifying department head of unidentified items.• Making of racks for stores.• Making of requisitions and follow- up, including bin purchase for items below reorder

level.• Updating transactions in stores in bin cards and computer and handling over updates to • Head of department.• Preparation and submission of monthly report for issues and receipt and stock

reconciliation.• Reporting of weekly perpetual inventory to head of department.• Preparation of daily goods receipt report and handling to head of department.• Making daily fuel/gas/oil consumption report to head of caster department

STOREKEEPER (TOOLS STORE)

• Identification of all tools.• Keep and update tools inventory record.• Making entries for issue and receipts of tools.• Conducting physical inventory weekly and monthly and report to the head of department.• Preparation of requisition for loss / damaged tools.• Housekeeping.• Keeping track of tools lost by personnel to facilitate replacement by concerned personnel• Keeping track on proper handling of tools by personnel to prevent damages.

STORE CLERK

• Daily receipt of items from suppliers and quantity, quality against delivery orders, purchase order.

• Preparation of goods inspection note and forwarding to respective head f department for goods inspection.

• Preparation of returnable / non – returnable gate pass for outgoing goods.• Issuing stock items posting of issues in computer.• Offloading fuel, oil, gases and other oils.

IT DEPARTMENT

Identification of IT Hardware/software needs

Write new programs as per current requirements and provide documentation for the same.

Maintain existing programs

Maintain the Network system

Review of needs with the user departments

Seeking approval for the purchase of IT hardware & software

Issue of IT equipment

Attending to the breakdowns of the IT equipment in the organisation i.e. maintaining computer hardware

Undertake preventive maintenance on the existing computer systems

Ensure daily backup of the system is taken

Routine Antivirus updates

CHAPTER TWO

STRATEGIC THEMES OF THE COMPANY

2.1.0 MISSION

The mission of Kaluworks Limited is that the Company shall endeavor to innovatively revitalize homes and institutions by providing quality products through socially responsible processes.

2.2.0 VISION

Kaluworks’ vision is to be respected household name providing solutions with a passion for excellence and innovations.

2.3.0 CORE VALUES

Kaluworks’ Core values and principles include:

2.3.1 Integrity

Guided by honesty and commitment to duty thus enhancing their customers’ confidence and loyalty.

2.3.2 Transparence

Every business transaction and dealing must be open and with clear communication.

2.3.3 Customer Focus

The company always mind its customers on what would be the best for them.

2.3.4 Ownership

The company shall take responsibility for the outcome of its actions, and view each action positively.

2.3.5 Innovation

The company encourages creativity amongst all staff as this gives the company the edge in a competitive market.

2.4.0 GOALS

The company has set specific strategic priorities to attain. i.e.

i. The company has set to attain profitable of 100% for their products they sell.ii. Enhance corporation image to accommodate product diversification

iii. Improve process efficiency by 30%iv. To be employer of choicev. To promote a performance based culture

CHAPTER THREE

FUNCTIONS OF THE ORGANISATION

3.1.0 QUALITY ASSURANCE DEPARTMENT

3.1.1 Introduction

This department is in-charge of the entire Quality Control System. Check and approves the incoming raw materials, Cast coils and the Final goods or products for dispatch. It gives correctives and preventive actions and handles all returns and customers complaints so that the company satisfies both the internal and external customers.

3.1.2 Organization of the department

Quality Assurance Manager

Environmental Analyst

DEPARTMENTAL Head

ClerkTKW InspectionCCL InspectionTLL InspectionProcess Control Inspector

Random Checks

Palletizing/Export Packing

Packing

Laboratory Analyst

Supervisors

3.1.3 Brief description of staff jobs

QUALITY ASSURANCE MANAGER

• In-charge of the entire Quality Control system

• Checks and approves incoming raw materials.

• Checks and approves Cast coils for further operation.

• Checks and approves Finished Goods for dispatch.

• Advises the production and management on quality issues.

• Handles returns and customer complaints.

• Corrective and Preventive action.

• Control of quality records.

• Identification of training needs.

• Continuous improvement

• Product/Process development.

DEPARTMENTAL HEAD

Checking and Approving Cast Coils. Outlining Correctives and Preventives Actions. Handling Customer Complaints. Water Treatment. Spectrometer Cleaning, Profile Operations and Standardization. Training and Recruitment in the Department Manpower Needs. New Products Development. Outlining Experiments and Interpretation of Results. In charge of the Departmental Quality Management Systems [ISO Standards] Rejection Handling and Interpretation of results.

ENVIRONMENTAL ANALYST

Conduct regular inspections of the ETP/STP/Cooling tower/Water lines. Ensure that preventative maintenance program of the above plants are conducted. Maintain the general administration of water system in order to ensure effective

operations of the plants. Prepare budgets and water consumption reports. Monitor the use and effectiveness of plant water treatment chemicals at

ETP/STP/Washing line and cooling water tower. Ensure water tests and analysis for both cooling tower water, STP & ETP are conducted

on regular basis and records of the results maintained.

Ensure the cooling tower water treatment is conducted as per schedule. Ensure whenever water is purchased from other suppliers, its tested and verified before

use in the company. Monitor plant water consumption to ensure that they are within the set targets and budget Conduct inspection of the entire plant on regular basis to check on the environmental

conservation and pollution prevention. Interpret variations in test results to determine and propose corrective and preventive

actions. Ensure that laboratory test for both internal and external tests are conducted. Ensure that housekeeping is maintained at STP/ETP Monitor consumption of all water treatment chemicals. Ensure that all the visual display boards on water treatment, consumption and test result

are updated as planned.

QUALITY CONTROL SUPERVISORS

Man-power distribution and supervision Conduct Experiments Raw Material/Received Goods Analysis Non-Conformance Reports Preparation-Customer Complaints. Co-coordinating and Checking All Laboratory Analysis of WIP materials and Finished

Goods. Checking on Casting Quality and Produced Cast Coils.

PROCESS INSPECTION-RANDOM QUALITY CONTROL

Carrying out Random checks on all materials. Approving all Materials in Progress [WIP] Corrective Action on Defective Materials in WIP and Finished Goods Sampling from various Machine Centers House keeping Records keeping

LABORATORY ANALYSTS

Water Treatment Caster Rolling Flashing Chemical composition Analysis Mechanical Analysis of Finished Goods and WIP Material. Moisture Analysis Cast Coil Profiling House keeping

QUALITY CONTROL CLERKS Daily report Preparation

Data entry Documentation and records keeping Monthly Reports Preparation Stock Take

PACKING QUALITY CONTROLLER

Sampling of all finished product for Test and packing Confirmation of material gauge/size as per the order. Checking surface quality of material Segregation of material Weighing, recording & disposal of rejected material Checking & Confirming Annealing Cycle & material Temper House keeping Records keeping

PALLETIZING/DIPATCH QUALITY CONTROLLER

Checking surface quality of material before dispatch. Confirmation of Material Gauge/size as per the order before dispatch. Weighing, recording and disposal of rejected materials Inspection of pallets condition and Truck canvas condition before loading. House keeping Records keeping.

COLOUR COATING LINE INSPECTORS [C.C.L]

QUV weathering tests i.e. performance of different paint batches & suppliers Salt spray analysis of painted material for all paint batches and suppliers Analysis of paint samples and batches from supplies, viscosity, both Wet and dry film

tests i.e. WFT & DFT Raw coil inspection; edge bars, edge damage, edge waves, buckle, degreasing and

passivation. Line parameters inspection i.e. oven set paints as per quality plan. Monitor line speed. Applicator roll status, check quality of the applicator rolls. PMT checks i.e. after every change of program. Painted coil inspection i.e. M.E.K, colour, gloss, DFT check. Mechanical tests i.e. Impact test, flexibility, pencil hardness, T-Bend adhesion, Cross-

Hatch. Monitor consumption of paints & thinner. Make reports for the above process and keep records of the process. CCL LOG-BOOK.

TENSION LEVELLER LINE [T.L.L]

Raw coil inspection; edge damage, edge bars, edge waves, buckle, graphite holes. Monitor bath levels as per T.L.L quality plan and checklist.

Monitor pH and concentration of degreasing and passivation baths. Submit samples from degreasing and passivation baths for analysis. Ensure proper degreasing and passivation of coils. Oven inspection i.e. oven set points and PMT checks. Ensure proper coil winding. Monitor consumption of chemicals. Monitor Effluent treatment from passivation section. Monitor conditions of degreasing & passivation chemicals and change baths Reporting-Keep records, T.L.L log-book KARM/LB/LAB/073

TKW SECTION-ROOFING QC

Inspection of profiled sheets as per quality plan. Inspection of coils at embosser. Inspection of plain sheets, chequered plates and mini coils. Analysis of scrap generated at machine centre and disposal of rejected material. Report writing and records keeping Inspection of finished profiled products at all machine centre’s. Sampling of material for the test before processing. Housekeeping.

3.1.4 Equipment, uses and their capacity

DEPARTMENT/SITE EQUIPMENT USE CapacityETP AND STP EC/TDS meter To determine the level of

TDS of the treated watern/a

MAIN LAB/ETP/STP pH meter For testing the water pH before, during and after treatment.

Measures from pH 0 up to 14

Ericksen cupping machine

Used for cupping to determine the depth at which a material can be drawn before it breaks and to expose the grains

From 0-20 ml

Erickson grains comparator machine

Used to determine the grain sizes by comparing the drawn cup grains size with the standard cup grains size

Scale running from 5000-64,000 micrometre squared

Tensometer machine

It is used to stretch the sample to determine its elongation measurements before it breaks.It also gives the maximum force a metal can withstand before it breaks.

Set depending on the hardness of the metal

Optical Emission Spectrometer

Used to spark the sample to give the chemical composition of the alloy metal in %

Set as per the % of aluminium

MAIN LAB/FINISHING/CCL

Micrometer Screw gauge

To find the thickness of the coil and the finished product

From 0-50mm

INCINERATOR Weighing machine

To measure the weight of the waste solid wastes

From 0-100kgs

COLOUR COATING LINE (CCL)

Colour guide spectrometer

To measure the gloss or degree of shininess of the painted coil for roofing.To determine the colour of the painted coil if it match with the samples at the lab.

Gloss range from40-60 with a ±5 units.Colour range from 0-1 with a ± 0.5 units.

Ultrasonic coating thickness gauge

Used to measure the dry film thickness of the painted roofing coil within a 15cm diameter

A set standard

Cross-hatch Used to determine loss of adhesion of the painted surface by scoring the surface to make a cross cut.

n/a

Accelerated salt spray cabinet

To test the resistance of the painted coil sample when exposed to harsh environmental conditions facilitating to rusting

Samples are placed in the cabinet for a ranging period of 100-1000 hours.

UV accelerated weathering machine

To determine the duration the colour or gloss can fade when exposed to UV light and moisture.

Samples are placed in the machine chambers for a period ranging from 100-1000 hours.

3.1.5 Service methods

The EC/TDS meter and the pH are cleared with deionized water after use and they are calibrated after one month. The Ericksen cupping machine is greased and calibrated to minimize the errors after every one month. The accelerated salt spray cabinet and the UV accelerated weathering machine are checked after every one or two days to determine the progression of the painted samples and the pressure oat which the atomizing nozzle sprays the salty solution to form a mist in the accelerated salt spray cabinet.

All the other equipment are calibrated every month to reduce or omit their errors when they are used.

CHAPTER FOUR

DESCRIPTION OF THE RULES, REGULATIONS AND POLICIES.

Kaluworks Company is ISO 9001 and 14001 certified, thus recognized for the high quality products and is committed in ensuring environmentally clean, healthy and safe working area. Kaluworks operates within the stipulated regulations of the factory and other places of work as indicated in its policies.

4.1.0 Environmental Policy

Kaluworks Environmental certificate ISO 14001 gives the right tools for improvement and tells the company’s stakeholders of the company’s responsible attitude towards environmental issues.

The company is committed to protect the environment while manufacturing Aluminium rolled products. It strives to comply with the stated legal requirements and other relevant standards as applicable. These are achieved by monitoring and controlling the impacts of pollutants generated in its various processes on the environment.

The company shall also endeavor to continually improve the performance of environmental management programme by adopting better processes and technology. All members within Kaluworks are continually made aware of their roles in environmental management.

4.2.0 Occupational Health and Safety Policy

The company shall strive to manage its operations in a manner that protects and promotes safety and health of the employees, contractors and neighbours. Kaluworks Company, shall ensure that the standards set on the same meet and preferably exceed the stated legal requirements and that continual improvement is done.

4.2.1 Occupational Health and safety Objectives

To train the employees in occupational health and safety issues so as to;

Ensure competence in the workplace. Be aware of the potential hazards implicit in work activities.

Manage occupational health and safety to acceptable standards.

Enforce health and safety measures with discipline in the work place.

Protect the public and persons other than the company employees from health and safety hazards associated with the work.

4.2.2 Responsibilities

Achievement of these objectives is and will be the responsibility of all management structures.

Duties are assigned to the company personnel with the aim of managing Occupational Health and Safety procedures

The commitment of management and employees to these objectives will ensure high standards of occupational Health and Safety control.

4.3.0 Energy Policy

Kaluworks Company will strive to achieve a world-class reputation for energy management. The company is committed to a high performance portfolio that uses energy in the most efficient, cost-effective and environmentally responsible manner to maximize profitability, strengthen their competitive position, and provide customers with the highest quality of services in manufacturing aluminium products.

The company will continuously improve energy performance in all activities, products and services while ensuring that its operations comply with energy regulation commission rules and standards and by reviewing the energy policy yearly.

The company will also continue to inculcate energy awareness among its employees, customers and suppliers through the process of communication, education and participation.

4.4.0 Quality Policy

Kaluworks limited, shall strive to supply high quality aluminium coils, circles, sheets foundry products, building products and hollow-ware that meet and exceed all stated and implied quality needs and statutory requirements of their internal and external customers every time. This shall be achieved with utmost care and concern in maintaining and continually improving on the Quality Management System, the environment and society at large.

CHAPTER FIVE

5.0.0 DESCRIPTION OF STUDENT’S ENGAGEMENT

5.1.0 FIRE AND PERSONAL SAFETY TRAINING

This is done to all employees and workers in the company as safety first and other duties follow. The first two days of my internship I was involved in Occupational Safety Training which involved both Personal and Fire Safety.

5.1.1 Personal Safety

Hazards exist in every work place in many forms; sharp edges, falling objects, flying sparks, chemical, Noise and other potentially dangerous situations. Industrial Companies provide Personal Protective Equipment [PPE] training for Personal Safety to the employees to minimize exposure to a variety of hazards.

Training involves; understanding the types of PPE, Knowing the basics conducting a hazard assessment of the work place, selecting appropriate PPE for a variety for circumstances, understanding the proper use & care of the PPE.

Body protection, potential injuries protected from and the PPE uses.

Eye protection

Protecting eye injuries resulting from;

i. Dust, dirt, metal and wood chips entering the eye from activities such as chipping, hammering, grinding, sawing etc.

ii. Chemical splashes from corrosive substances, hot liquids, solvents or other hazards solution

PPE used

Goggles these are tight-fitting eyes protection that completely cover the eyes, eye sockets and the facial area which provide protection from impact, dust and splashes. The goggles should provide unrestricted vision and movement and should be durable and clearable.

Head protection

Protecting the head injuries which can impair an employee for life or it can be fatal. The injuries can be from;

i. Objects might fall from above and strike the headii. Might bump the head against fixed objects such as coils, pipes etc.

iii. Possibility of accidental head contact with electrical hazards.

PPE used

Helmets have hard outer shell and a shock-absorbing lining that incorporate a headband and straps that suspend the shell from (2.54cm to 3.18cm) away from the head.

Foot and Leg protection

Offer protection of possible foot or leg injuries from falling or rolling objects or crushing or penetrating, poisonous and corrosive materials.

PPE used

Safety shoes have impact-resistant toes and heat-resistant soles that protect the feet against hot work surfaces. The metal insole of the safety shoes protect against puncture wounds.

Safety shoes are designed to be electrically conductive to prevent the buildup of static electricity in areas with potential for explosive atmospheres or non-conductive to protect workers from workplace electrical hazards.

Hands & Arm protection

Potential hands include skin absorption of harmful substances, chemical or thermal burns electrical dangers, bruises, abrasions, cuts, punctures, fractures and amputations.

PPE used

Fabric gloves protect against dirt, slivers, chafing and abrasions. They do not provide sufficient protection for use with rough, sharp or heavy materials.

Chemical and liquid-resistant gloves (Butyl glove) are made of synthetic rubber and protect against chemicals such as peroxide, rocket fuels, highly corrosive acids, strong bases, alcohols, aldehydes, ketones etc.

Hearing protection

Protect employees from exposure to excessive noise i.e. Noise pollution

PPE used

Earmuffs require perfect seal around the ear.

5.1.2 Fire Safety Training

I was undertaken through fire safety where I was taught things to do with fire outbreaks. The company has fire alarm bells connected in different areas of the company departments. The company also has fire assemblies where people gather when there is fire emergence.

Here are various fires actions to be taken when fire emerge;

Any person discovering fire

i. Should raise alarm by breaking the nearest fire glass on the wall.ii. Raise alarm by shouting FIRE! FIRE! FIRE!

iii. Alert security control office about the fire indicating location through emergency Tel. Exit

iv. Call the NCC Fire Brigade through 02-2222181 or 999 and give the information of the location of the fire.

v. Restrict the spread of fire/smoke by closing the doors behind youvi. Switch off electricity and all electrical appliances.

vii. Attack the fire using the nearest FIRE EXTINGUISHER from the nearest FIRE POINT.

On Hearing the Alarm Bell

i. Do not panic vacate the building in an orderly manner with your important documentsii. Do not use the nearest emergency exit which is not affected by fire/smoke

iii. Walk calmly to avoid stampedeiv. Move to the safe distance of about 50metres away from the affected building and await

for further instructions from the security personnelv. Do not RE-ENTER the building.

5.1.3 Fire Extinguisher Use

Water for use on burning wood, textile and furniture grains.

Dry powder for use on electrical fires, burning liquids, burning oil and flammable liquids.

Foam for use on petroleum fires, diesel fires and burning oils.

Carbon dioxide for use on electrical fires, electrical equipment.

Hose reel for use on burning wood, textile and burning grain.

5.2.0 EFFLUENT TREATMENT

This was the first place I was assigned to where all the industrial effluents are pumped to the Effluent treatment plant to be treated and re-used back for other purposes. The effluent we treat at the ETP are from the Washing line, Caster, Tension levelling line, Colour Coating Line and from Floor Washing. Mostly this effluent is made up of chromium ions, grease, oil and basic pH of about 9-11 this is from the use of Caustic soda (Sodium Hydroxide) in some industrial activities like degreasing and washing the final products.

Effluent treatment process involves the following steps;

5.2.1 Effluent treatment process.

Effluent Inlet

This is the entry point of the effluent from the effluent reservoir tank. It enters the treatment site from an inlet pipe. For the chromium effluent from the color coating line is pre-treated first with Sodium thio-sulphate to be discolored before mixed with the other effluent at this point.

Hydrochloric Acid Addition tank

This is the first tank of the treatment process tanks, where the initial treatment of the effluent starts. Hydrochloric acid is added in this tank using a dosing pump at a speed of 50 dose/min. Hydrochloric acid is used in the process because it is a strong pH reducer, since the effluent is of a higher pH of about 9-11 hence basic therefore need to be neutralized with the acid. It is also used as an emulsion breaker as it breaks the bound between the basic water with the oil. The acid is added in a larger amount so as it lowers the pH of the water to pH 3-4

Oil Removal tank.

This is the second tank of the treatment process where the oil which floats on the water is removed using a skimmer. After adding acid in the previous tank which led to separation of oil and water, because water is denser than oil thus the oil will float on water.

We regulate the pH of water in this tank to be at pH 3-4 so as to increase the efficiency of breaking the effluent into water and oil part to enhance the oil removal.

Chemical reaction tank (Neutralization tank)

After oil removal, the acidic effluent at pH 3-4 is transferred to this tank where Caustic Soda i.e. Sodium Hydroxide is added to neutralize the acidity of the effluent water from the oil removal tank. After neutralization, polymer is also added. It is used as a coagulant, where it makes the suspended particles settle faster and bind them together for easy settlement. The pH of the water here should be around 6.5-7.5 i.e. neutral.

Lamella Clarifier (Settling tank)

In this tank, the sludge (effluent suspended solids) separates from the clear water and it is found at the lower level of the tank. The clarifier separates the treated slurry from the clean water. The sludge settles down and the clean water at the top flows Supernatant tank. From here the sludge is pumped to the sludge tanks (sludge beds).

Sludge tank

In the sludge tank the sludge is continuously agitated in order to prevent settlement of the sludge. There are four sludge beds/tanks with each tank has a capacity of 224 cubic metre. The main purpose of the tank is to hold sludge for transfer to filter press. From the sludge beds, it is pumped to the filter press by the filter press feed pump.

Filter press

Sludge from the beds are pumped here for dewatering purpose. According to the performance guarantee the cake moisture should not be more than the 20%. Filter press is more efficient and economical than all other presses because it has both high pressure capability and efficient filter cake removal. The filtered water from the filter press is pumped back to the reaction tank.

Supernatant tank

The clear water from the lamella clarifier flows to this tank. Sodium hypochlorite is added which is a disinfectant. It kills the harmful micro-organism which may be present in the water, gives water its colour and also remove odour.

Sodium-Thiosulphste is also added here where it is used to de-chlorinate the water where chlorine chemicals are used. Sodium-Thiosulphate lowers the level of chlorine and treat settled backwash water prior to release or disposal.

Graded Filtration Colensing Column

This absorption or filtration column has layers of Gravel, sand and activated charcoal.

Gravel layer removes large pieces of debris from the water.

Sand layer removes smaller particulate matter that managed to pass through the gravel

Activated charcoal removes bacteria and some chemicals. It is called activated charcoal because air is blown through it. The air causes thousands of pores to open up on the surface of the charcoal, making convenient places for absorption of chemicals via bonding and capture of bacteria. Then after filtration, the filtered water is pumped to the aeration Fountain

Aeration Fountain

This is the final stage of effluent treatment process where the clean water allowed to mix with the atmospheric oxygen. Water flows on a fountain made of stairs before dropping down in the aeration tank. The significance of the stairs is to split the water into small droplets. Collectively these small droplets have large surface area through which oxygen can be transferred. Upon return, these droplets mix with the rest of water and thus transfer their oxygen back. This reduces both the Biological Oxygen Demand and Chemical Oxygen Demand.

5.3.0 SEWAGE TREATMENT

This was another task that I was assigned for during my internship program. Was required do the initial sewage treatment, analyze the possible impacts when release raw to the environment and also to analyze the water quality parameters.

The sewage we treat is the wastewater from toilet flushing, washing sinks, bathing and general cleaning which are connected to the septic tanks before released to the treatment center.

5.3.1 Sewage treatment process

In sewage treatment, the process is the same as the effluent treatment plant but here it is modified to stages which combine two or more steps of the Effluent treatment. The other difference is the chemicals used for the treatment process.

Sewage treatment is the process of removing contaminants from wastewater, primarily from household sewage. The process includes physical, chemical and biological processes to remove these contaminants and produce environmentally safe treated water.

1. Screening stage (physical process)

Screening is the first stage of the sewage treatment process. This mostly done at the Septic tank and at the sewage collection tank where all the large objects like cotton buds, face wipes, broken bottles, bottle tops, rags, tomato piles and any plastic objects which may block or damage special equipment.

2. Primary treatment (physical process)

This also happens at the Sewage collection tank where after screening, the sieved sewer flows in a large tank where there is aeration of the atmospheric air. Aeration helps the sewer to mix and

form uniform mixture. It also helps to remove finer particles like grit and sand. By the time a uniform mixture of the sewer has been attained at the sewage equalization/collection tank it is pumped to the raised Bacteria respiration tank for secondary treatment.

3. Secondary treatment (biological process)

The sewer enters in a large rectangular tank that is the Bacteria respiration tank. The secondary treatment is designed to substantially degrade the biological content of the sewage which are derived from human waste, food waste, soaps and detergent. The tank contains millions of replicating micro-organisms hence treating the settled sewage liquor using aerobic biological processes. To be effective, the biota require both oxygen and food to live. We pump atmospheric air into the water through the diffuser grid aeration systems attached at the floor to encourage bacteria and protozoa to consume and breakdown the biodegradable soluble organic contaminants like the human wastes and bind much of the less soluble fractions into floc.

In the bacteria respiration tank, there are many rotating biological contractors where the biomass grows on these contactors and sewage passes over its surface. The disc consist of plastic sheets ranging from 2-4 m in diameter and it contacts the wastewater with the atmospheric air for oxidation as it rotates. It also give the micro-organisms a suitable position to consume the contaminants as the contactors rotate or move from one point to another.

Secondary treatment also include the Sludge settlement tank where the biological floc/sludge is set to settle down and clear water to flow and enter the chemical reaction tank for the tertiary treatment. The settled sludge at the settlement tank is recycled back to the Bacteria respiration tank this helps to maintain the population of the micro-organisms in the Bacteria tank.

4. Tertiary treatment (chemical process)

The clear sewer after the sludge settlement tank it flows to the chemical reaction tank for further treatment. The tertiary treatment involves chemical addition and settlement of the final clear water in the lamella clarifier.

At the Chemical reaction tank, aluminium Sulphate is one (alum) of the chemicals added. It is used as a coagulant due to its high efficiency, effectiveness in clarification and utility as a sludge de-watering agent. The chemical leaves no residual colour and turbidity removal hence used as flocculant. Aluminium sulphate is also used to destabilize the ammonia which is present in the urine. Aluminium sulphate is an acidic chemical which also provide an acidity nature in the clear sewer therefore killing some of the micro-organisms entering the chemical reaction tank from the biological treatment stage.

Sodium hydroxide (caustic soda) is also used to neutralize the acidity of sewer after alum addition. After neutralization, polymer is also added. It is used also as a coagulant, where it makes the suspended particles settle faster and bind them together for easy settlement.

From the chemical reaction tank the treated sewer flows to the lamella clarifier. The clarifier separates the treated slurry (formed after polymerization) from the clean water. The sludge settles down and the clean water at the top flows Supernatant tank. The V-shaped nature of the

Lamella clarifier is to provide high gravity for the settlement of the sediments and other untreated particles at the bottom. From here the sludge is pumped to the sludge tanks (sludge beds) for drying.

5. Final treatment

This is the last treatment stage of the sewage which includes disinfection, odour control, filtration and oxidation. The treatment process parts included in this stage are Supernatant tank, Graded Filtration Colensing Column (GFCC) and Aeration Column.

At the supernatant tank, Sodium hypochlorite is added which is a disinfectant. It kills the harmful micro-organism which may be present in the water even after adding Alum at the chemical reaction tank. It also gives water its colour and also remove odour.

Filtration takes place at the GFCC through the aid of the activated charcoal, sand and gravels which the treated is rinsed and backwashed by passing through the 3 layers of these filtering materials. The activated charcoals in the GFCC also purifies the water and gives it its colour and also remove the odour.

Oxidation of the treated sewage water take place at the Aeration Fountain it mixes with the atmospheric oxygen. The fountain has stairs which help to slit the water to droplets to increase its efficiency of trapping the oxygen, also the stairs help to increase the distance at which the oxygen to react with the treated water to reduce both the BOD and COD.

After completion of all processes, both the effluent and sewage water become purify and safe for other uses like floor washing, toilet flushing and even drained to the environment. Before re-use and drain to the environment, the water is checked by the different lab tests. Different standards are maintained during discharge of the treated sewage and effluent.

5.3.2 STANDARDS FOR EFFLUENT AND SEWAGE DISCHARGE INTO THE ENVIRONMENT

PARAMETER TESTING INTERVAL

UNITS MAXIMUM STANDARDS

REMARKS

pH Daily 6.5-8.5 InternalBOD @ 20 degrees Celsius

Monthly mg/l 30 SGS

COD Monthly mg/l 50 SGSColour Monthly Hazen 15 SGS

Total dissolved solids (TDS)

Daily mg/l 1200 Internal

Total suspended solids (TSS)

Weekly mg/l 30 Internal

Nitrates as NO3 Monthly mg/l 100 SGSAmmonia as NH3 Monthly mg/l 100 SGSOil & Grease Weekly mg/l Nil InternalFaecal coliform counts

Monthly MPN/100ml Nil SGS

Aluminium as Al Monthly mg/l 100 SGSLead as Pb Monthly mg/l 0.01 SGSSilica as Sl Monthly mg/l 0.05 SGSZinc as Zn Monthly mg/l 0.05 SGSIron as Fe Monthly mg/l 10 SGS

5.4.0 SOLIDS WASTE MANAGEMENT

I was also assigned the duty on how to manage the solid wastes, their impact to the environment and to find the legal statutes established and standards set in managing environment and its pollutants.

The company uses the incineration method to manage its solid waste. I operated the incineration plant for a period of 2 weeks.

5.4.0 Incineration process

Incineration process is a waste management process that involves combustion of organic substances contained in waste materials. Incineration of waste materials converts the waste into ash, flue gas and heat.

The type of incinerator used by the company is the modern incinerator specifically thermal incinerator. The incineration process of this type of incinerator is divided into 3 stages in three different chambers.

Combustion of the waste in the 1st Chamber (Primary Chamber)

All the combustible waste materials like the waste papers, boxes, sacks, scum, polythene bags plastics and the oil from the ETP and waste industrial oil from the plants are placed. For combustion to take place, it requires fuel (combustible wastes), supply of oxygen and high temperature.

This chamber has adjustable force supply of air drawn from the atmosphere by the force draft fun (FDF) bringing any dust and odours with it to be destroyed in the combustion chamber thus ensuring that the odour and the dust do not escape the building.

The chamber is also connected with a burner which is the source of the fire for combustion to take place. The burner uses the industrial diesel oil as its fuel to produce the flames to burn the combustible wastes.

The chamber is designed to achieve thorough mixing of the wastes and the gases release with the supplied air to ensure complete combustion. If the wastes are burnt completely, all carbon is converted to carbon dioxide, hydrogen to water vapour, sulphur to sulphur dioxide, and nitrogen to nitrous oxide. Less than 10% weight of the wastes are converted to solid residues. Some ash remains suspended in the exhaust gasses.

When the wastes are not burnt completely due to insufficient supply of oxygen, large undesirable organic molecules will be generated and released together with the exhaust gases. Incomplete burning of chlorine produces substances called dioxin and furans.

Suspended heavy particles removal in 2nd Chamber (Secondary Chamber)

The fly ash full of heavy and light particles enter secondary chamber of the incinerator. In this chamber, heavy particles which are unable to take a longer distance cover they separate from the light particles which proceed to the 3rd chamber.

Air filtration or Flue gas cleaning in the 3rd Chamber (Scrubber)

The chamber contains the air filters and also there is showering using basic water. The air filters prevent escape of many hazardous emissions such as ultra-fine particles and carbons, which are produced from burning materials including dioxins and furans.

Flue gases are acid producing chemicals such as traces of HCl and sulphur dioxide and other toxic heavy metals such as lead and mercury which may be present in the wastes are removed by the wet scrubbing where a mist containing alkaline solution (sodium hydroxide) is showered in this chamber.

The wastewater which comes out of this chamber i.e. the scrubber is then passed through the wastewater treatment plant i.e. Effluent Treatment Plant.

Disposal of the treated smoke to the environment

The Scrubber is connected with the Induced Draft Fun (IDF) which sucks or absorbs the light treated smoke from chamber to the tall chimney of about 9m above the ground. In the chimney, also the heavy particle which have managed to pass through all the 3 chambers are also eliminated as they ascend through the chimney due to their heaviness they cannot cover the 9m distance of the chimney hence collected at the bottom of the chimney. Finally, the fine treated smoke is disposed to the atmosphere thro the chimney.

Impacts of the untreated smoke

When the air or smoke is not treated before release, people living near the incinerator would be at a risk of exposure to dioxins and pollutants that can contaminate air, water and soil which may enter the food supply and concentrate up through the food chain.

The flue gases and the ultra-fine particles can be lethal, causing cancer, heart attacks, stroke, asthma and pulmonary diseases. Statistics show that airborne particulates cause deaths of over 2 million people worldwide each year.

5.4.2 STANDARDS, GUIDELINES, CRITERIA, PROCEDURE FOR INSTALLING/OPERATING INCINERATORS.

A. Classification of Incinerators Class 1: Industrial Plants Burning Waste as an Additional/Alternative Fuel These are Incinerators in which the waste serves as the fuel or supplementary fuel in an industrial process e.g. the use of cement kilns or any other industrial boilers or furnaces for the disposal of noxious or hazardous materials.

Class 2 Industrial Incinerators Class 2A: Commercial These are Incinerators for the disposal of waste that contains hazardous, potential hazardous and bio-medical waste where the operator exceeds 100 Kg/day. Class 2B: Small Scale Incinerators for Private Use These are Incinerators for the disposal of hazardous, potential hazardous and bio-medical waste where the operator does not exceed 100 kg/ day. Class 3: General waste Incinerators Incinerators for general waste that is non toxic, non hazardous, non medical or does not contain organic halogens, i.e., selected customs, police, contraband goods, offices waste, commercial waste and industrial wastes) where the operator does not exceed 1 ton/ day.

No.

Parameter Standards, Guideline, Criteria and Procedure

1 Basic Plant Design An approved plant must have four distinct sections that demonstrate three principles of Turbulence, Residence Time and Temperature are inbuilt in the plant design .The regulated sections may include but not limited to:Overall plant layout.Feed chamber/ chargingPrimary Combustion Chamber.Secondary Combustion Chamber.Particulate ScrubbersAcid Gas ScrubbersThe stack/ chimney

2 Feeding And Charging

Controlled hygienic, mechanical or automatic feeding methods have to be used which will not influence the air temperature in the primary and secondary chambers of the incinerator negatively.

No waste is to be fed into the incinerator:

1. Until the minimum temperatures have been reached.

2. If the minimum combustion temperatures are not maintained.

3. Whenever the previous charge has not been completely combusted in the case of batch feeding.

4. Until such time as the addition of more waste will not cause the design parameters of the incinerator to be exceeded

3 Primary Combustion Chamber

The primary combustion chamber must:

1. Be accepted as the primary combustion zone.

2. Be equipped with a burner/s burning gas/fuel or low sulphur liquid fuels. Other combustion methods will be judged on merits.

3. Ensure primary air supply is controlled efficiently

4. Ensure minimum exit temperature is not less than 850oC

4 Secondary Combustion Chamber (Afterburner).

The secondary combustion chamber must:

1. Be accepted as secondary combustion zone.

2. Be fitted with secondary burner/s burning gas or low sulphur liquid fuel or any suitable fuel.

3. Ensure secondary air supply is controlled efficiently.

4. Ensure flame contact with all gases is achieved.

5. Ensure residence time is not less than two (2) seconds.

6. Ensure the gas temperature as measured against the inside wall in the secondary chamber & not in the flame zone, is not less than 1100oC.

7. Ensure the oxygen content of the emitted gases is not less than 11%.

8. Ensure both primary and the combustion temperatures are maintained until all waste has been completely combusted

5 Particulate Removers A mechanical particulate collector must be incorporated after secondary combustion chamber for removal of particulate pollutants entrained in the flue gas stream. The particulate collectors may include any of the following or a combination

thereof:

Cyclone separator Electrostatic precipitators Fabric filters

6 Chimney / Stack 1. The chimney should have a minimum height of 10 meters above ground level and clear the highest point of the building by not less than 3 meters for all roofs. The topography and height of adjacent buildings within 50 meters radius should be taken into account.

2. If possible the chimney should be visible to the operator from the feeding area.

3. The addition of dilution air after combustion in order to achieve the requirement of these guidelines is unacceptable.

4. The minimum exit velocity should be 10 m/s and at least twice the surrounding wind speed (Efflux velocity = wind speed x 2) whichever is higher to ensure no down washing of exiting gases.

5. Point for the measurement of emissions shall be provided.

7 Instrumentation Instrument for determining the inside wall temperature and not burner flame temperature must be provided for both primary and secondary chambers.

2. An audible and visible alarm must be installed to warn the operator when the secondary temperature drops to below the required temperature.

3. In addition to the above the following instruments may also be required.

A carbon monoxide and/or oxygen meter/recorder A smoke density meter/recorder A gas flow meter/recorder A solid particulate meter/recorder

Any other instrument or measurement that may be considered necessary

8 Location / Siting 1. Must be sited in accordance with the relevant local municipal authority planning scheme, the topography of the area and be compatible with premises in the neighborhood,

2. Must be housed in a suitably ventilated room.

9 Emission Limits 1.Combustion efficiency:Combustion efficiency (CE) shall be at least 99.00% The Combustion efficiency is computed as follows;

C . E= %CO2%CO2+CO ×1OO

2. The temperature of the primary chamber shall be 800 ± 50o C

3. The secondary chamber gas residence time shall be at least 1 (one) second at 1050 ± 50o C, with 3% Oxygen in the stack gas.

4 Opacity of the smoke must not exceed 20% Viewed from 50 meters with naked eyes5. All the emission to the air other than steam or water vapour must be odourless and free from mist, fume and droplets.6. The Authority may require that the certificate holder have tests carried out by an accredited institution to determine stack and/or ground level concentrations of the following substances.

Cadmium and compounds as CdMercury HgThallium TlChromium CrBeryllium BeArsenic AsAntimony SbBarium BaLead PbSilver Ag Cobalt CoCopper CuManganese MnTin SnVanadium VNickel NiHydrochloric HCLHydrofluoric acid HFSulphur dioxide S027. A 99.99% destruction and removal efficiency (DRE) for each principal organic hazardous constituent (POHC) in the waste feed where:

DRE = [(W-in – W-out)/Win]*100

Where: Win = mass feed rate of the POHC in the waste stream fed to incinerator, and

W-out = mass emission rate of POHC in the stack prior to the release to the atmosphere.

8. The average dioxin and furan concentration in the emissions should not exceed 80ng/m3 total dioxins and furans if measured for a period of 6 to 16 hours.Note:All pollutant concentrations must be expressed at O degrees Celsius and 1.013 x 10 5 N/m2, dry gas and 11% oxygen correction.

Oxygen correction is computed as:

Es= 21−Os21−OM

× EM

Where: Es = Calculated emission concentration at the standard percentage oxygen concentrationEM = Measured emission concentrationOs = Standard oxygen concentrationOM = measured oxygen concentration

10 Operation 1. Materials destined for incineration should be of known origin and composition and must be only incinerated in a furnace that is registered for the particular type of waste.2. A record must be kept of the quantity, type and origin of the waste to be incinerated.3. The incinerator must be preheated to working temperature before charging any waste.4. The incinerator must not be overcharged.5. The incinerator must be in good working order at all times and must not be used if any component fails. Any malfunction should be recorded in a log book and reported to the relevant authority.6. The incinerator operator and all relevant staff must be trained to the satisfaction of the relevant control authority.

11 Housekeeping The site where the incinerator is built must:1. Have running water. 2. Have a solid floor.3. Have lighting if 24hrs operation

4. Have fly ash containerization and storage before disposal.

12 Health & Safety (Protective Gear)

1. Staff handling waste must be well trained on safe handling of hazardous wastes2. Staff must be provided with appropriate protective gear such as, gas mask, aprons, gumboots, helmets, gloves, goggles.3. Caution and Warning signs must be provided.4. Firefighting equipment must be provided5. There should be no smoking or eating on the site.

5.5.0 ETP AND MUNICIPAL WATER QUALITY IMPROVEMENT

Water quality improvement of both the ETP and Municipal water was another duty I was assigned to do. This is done using the De-mineralization (DM) Plant and the Reverse Osmosis (RO) Plant. The de-mineralized water is the one used at the washing line, accelerated salt spray and for drinking.

5.5.1 Water De-mineralization/De-ionization by DM plant

De-mineralization is a process of removing mineral salts from water by using the ion exchange process. Minerals such as cations of sodium, calcium, iron, aluminium etc. and anions of chloride, sulphate, nitrous etc. are the common ions present mostly in the water we treat at the ETP.

DM is a physical process which uses specifically manufactured ion exchange resins which provide ions exchange site for the replacement of the mineral salts in water with water forming ions of Hydrogen and Hydroxyl. Due to the high TDS levels of the ETP water, de-ionization produces a high purity water that is generally similar to distilled water and this process is quick and without scale forming.

Principle used

Raw water from the ETP is passed via two big ion exchange resins while the cations get exchanged with hydrogen ions in the first bed and the anions are exchanged with hydroxyl ions in the second bed.

Water flows through the cation column where upon all cations are exchanged for hydrogen ions. To keep the water electrically balanced, for every monovalent cation, e.g. Na one hydrogen ion is exchanged and every divalent cation e.g. Ca or Mg, two hydrogen ions are exchanged. The

same principle applies when considering anions exchange. The de-cationised water then flows through the anion column. This time, all the negatively charged ions are exchanged for hydroxyl ions which the combine with the hydrogen ions to form water (H2O).

Application of ion-exchange to water treatment and purification

1. Cation-exchange resins alone can be used to soften water by Base Exchange.2. Anion-exchange resins alone can be used for organic scavenging or nitrate removal.3. Combination of cation-exchange an anion-exchange resins can be used to remove

virtually all the ionic impurities present in the feed water process known as de-ionization.

5.5.2 Reverse Osmosis by the RO plant

Reverse Osmosis is a water purification technology that uses a semipermeable membrane to remove ions, molecules and larger particles from the Municipal water for drinking. This technology we only use it to purify municipal water only but not ETP water due to high TDS levels of the ETP water which may be more expensive to replace the membranes frequently.

Principle used

In the normal osmosis process, the solvent naturally moves from an area of low solute concentration through a semipermeable membrane to an area of high solute concentration.

In reverse osmosis, an applied pressure is used to overcome the osmotic pressure driven by the chemical potential difference of the solvent. The result is that the solute is retained on the pressurize side of the membrane and pure solvent is allowed to pass to the other side. The selective membrane only allows the smaller components of the solution i.e. the solvent molecules to pass freely.

Then after the reverse osmosis the Municipal water passes through a Mixed-bed De-ionization chamber for further removal of the dissolved salts. Here the cations-exchange and anion exchange are intimately mixed and contained in a single pressure vessel. Thorough mixture of the cations and anions exchangers in a single column makes the mixed-bed deionizer equivalent to the lengthy series of the two-bed plants. As a result, the water quality obtained from the mixed bed de-ionizer is more appreciably higher than that produced by the two-bed plant.

Mixed-bed de-ionizers are normally used to polish the water in higher levels of purity after it has been initially treated by the reverse osmosis plant

5.6.0 COOLING TOWER WATER TREAMENT

Water treatment of cooling tower is an integral part of process operations in the industry, with the possibility of productivity and product quality being diversely affected by scale, corrosion, fouling and microbiological contamination. The cooling system operation directly affect reliability, efficiency, and cost of the industrial process. Monitoring and maintaining control of corrosion, deposition, microbial growth, and system operation is essential to provide the optimum Total Cost of Operation (TCO).

5.6.1 Problems associated with cooling water system

The following four problems are normally associated with cooling water systems.

1. CORROSION; Manufacturing of common metals used in cooling systems, such as the aluminium, involves removing oxygen from the natural ore. Cooling water systems are an ideal environment for the reversion of the metal to the original oxide state. This reversion process is called corrosion.

2. SCALE; Minerals such as calcium carbonate, calcium phosphate, and magnesium silicate are relatively insoluble in water and can precipitate out of the water to form scale deposits when exposed to conditions commonly found in cooling water systems.

3. FOULING; The deposition of suspended material in heat exchange equipment is called fouling. Foulants can come from external sources such as dust around a cooling tower or internal sources such as by-products of corrosion.

4. BIOLOGICAL CONTAMINATION; Cooling water systems provide an ideal environment for microbial organisms to grow, multiply, and cause deposit problems in heat exchange equipment. Microbial growth can strongly influence corrosion, fouling, and scale formation, if not controlled properly.

5.6.2Treatment

The cooling tower has two ponds, where treatment is done daily, weekly and fortnight. We use 3 types of acids for the treatment i.e. Aquatreat 8640 for daily treatment, Aquacide 2360for weekly treatment and Aquacide 2370 for fortnight treatment.

5.6.3 Significance of the chemicals in water treatment

Aquatreat 8640 used on daily to disperse sludge, control scale formation, corrosion, inhibits yellow metal and against hard water.

Aquacide 2360 used on weekly basis to control algae, slime, bacteria, anaerobes and also effective in controlling organisms causing corrosion in the system.

Aquacide 2370 used after every two weeks (fortnight) to control the growth of bio-films in the system.

5.6.4 Cooling Water system dosage

AQUATREAT 8640

AQUACIDE 2360

AQUACIDE 2370

POND CAPACITY

DAILY DOSAGE

WEEKLY DOSAGE

FORTNIGHT DOSAGE

POND 1 (OLD) 0.5 KGS 9 KGS 9 KGS 163,000 LTSPOND 2 (NEW) 0.5 KGS 24 KGS 24 KGS 405,000 LTSCONCENTRATION 75 PPM 55 PPM 55 PPM

Daily Water consumption is 30cubic metre

5.6.4 Calculation of % ratio

POND 1

Daily dosage

(Daily consumption × concentration) ÷concentration cycle

(30×75) ÷1000

=0.5 kgs

Weekly and fortnight dosage

(Pond capacity× concentration) ÷ 1000

(163000×55) ÷1000

=9 kgs

POND 2 Weekly and Fortnight Dosage (Pond capacity × concentration) ÷ 1000

(405000×55) ÷1000= 24 kgs

5.7.0 QUALITY CONTROL INSPECTION AND TESTS.

Quality control include product inspection, where every product is examined visually for fine details before the product is sold into both the internal and external markets. QC emphasizes testing of products to uncover defects and reporting to the management who make the decision or deny product release, whereas quality assurance attempts to improve and stabilize production and associated processes to avoid, or at least minimize, issues which lead to the defect(s).

Some of the quality control tests I was assigned to do were as follows;

5.7.1 Mechanical tests and Chemical Composition analysis at the main lab.

Sample Cupping

Used Ericksen Capping machine which consists of a wheel-like adjuster and a small ball bearing. Cupping is a mechanical test to determine the depth at which a material can be drawn to a particular product before it breaks. It also expose the grains to see the size of the grains.

After cupping we use Ericksen Grain comparator machine to determine the size of the grains by comparing the drawn cuo to that of the standard cup. The grain comparator has a scale from 500-64,000 micrometre squared.

The finer the grains the better the quality of the material because finer grains are closly packed hence making it durable.

Metal Elasticity (Elongation)

Metal elasticity is determined using a Tensometer Machine, where the blanked sample measuring 18cm is placed on the tensometer machine and pulled to its maximum point of elongation to break.

The significance of calculating the % elongation is to show the degree a material can elongates and also to determine its elasticity.

% Elongation= final elongation−original elongationoriginal elongation

× 100

Finding the UTS (ultimate tensile strength)

UTS is calculated in order to determine the degree of softness and hardness of the metal material. UTS is calculated by;

UTS=(Maximum force)÷(X−sectional area)

Given in kgf/mm2

Chemical composition of the aluminium alloy

Use an Optical Emission Spectrometer to spark the alloy samples obtained from the scrap yard after melting furnace, after the holding furnace and before the coil formation. The sample is placed on the spectrometer after cleaning the carbon electrode with the presence of argon to creat an inert zone for successful sparking. The spark light is passed through a prism which diverts the light into different wavelengths depending on the quantity of the alloy metals present in the sample.

The results are displayed on the read-out system computer desk-top which stores the information for printing.

5.7.2 Mechanical and Chemical Tests in the Colour Coating and Tension Leveling Lines

Impact Adhesion Test

This test is used to determine the impact resistance of the coating against set specification of the product. We use a hammer of 15.87 mm which is raised to a given height then released and hit

the substrate making a cup. Then use a scotch tape and to determine whether the paint will peel off on the cupped area.

Cross-hatch test

We use a cross-cut kit to determine the loss adhesion of the painted surface by scoring the surface to make cross cuts. Then we rate the coating adhesion as per adhesion scale. After scoring the paint should not peel off for it to pass the test.

Dry film thickness (DFT)

We use machine called ultrasonic coating thickness gauge to determine the coating thickness of the painted substrate by the means of electromagnetic radiation patterns in a diameter within 15cm.

M.E.K test (Methylethylketone)

We use the MEK solvent to determine paint curing of the painted surface by soaking a cotton wool into the solvent and rub the surface of the painted substrate more than 100 times. Then we determine the ease at which the paint can be scratched using a finger. After rubbing the substrate with the solvent, no paint to peel off for the paint to pass the test.

Gloss and Colour of the paint

We use a colour guide spectrometer to determine the colour and the gloss at 45 & 60 degrees respectively. We range the gloss and the colour of the paint per set standards.

Chemical tests

1. Accelerated salt spray test

We use this test to determine the resistance of the painted coil when exposed to harsh environmental conditions facilitating to rusting process like the coastal region. We use sodium chloride the normal salt and the deionized water as reagents.

Preparation of the alt solution

We take 2 kgs of the salt and dilute it with 40 litres of the DM water to produce concentration of 50g/l. the solution is then put in a tank to be sprayed in the salt spray chamber.

The spraying cabinet

The chamber is made of corrosion resistant components where the capacity of the tank should be of moderate size because it is necessary to ensure that the conditions of homogeneity and distribution of the spray are met. The upper parts of the cabinet is designed so as the drops of the sprayed solution formed on its surface do not fall on the specimen being tested.

Spraying device

The spray device comprises a supply of clean air of controlled pressure and the humidity, a reservoir to contain the solution to be sprayed and one atomizer. The atomizing nozzle have a critical pressure at which an abnormal increase in the corrosiveness of the salt spray occurs.

In order to prevent evaporation of water from the sprayed droplets, air is humidified before entering the atomizer by passing through a saturation tower containing hot distilled water at a temperature of 10 degrees above that of the cabinet.

The samples are kept in the cabinet in number of hours ranging from 100 to 1000 hour equivalent to literal days or years.

Limitations of the salt spray test

There is a weak correlation between the duration in salt spray test and expected life of coating since the correlation is complicated and can be influenced by many external factors.

2. Ultra Violet acceleration weathering test

In this test, we are exposing the painted samples of the coil to alternating cyclones of UV light and moisture of controlled elevated temperature. This test is done using the UV weathering machine which gives the damage that occurs within a certain duration of time like years in just equivalent hours in the machine like in the case of accelerated salt spray.

The machine contains UV lamps of different wavelengths and the samples are placed in the racks made of inert materials. The empty spaces are filled with blank or unpainted samples to maintain the conditions within the chamber.

Limitations of the test

Due to sand conditions during natural weathering and extreme accelerated testing, weak correlation between the 2 can be expected

Not all organic coating will perform on all equal basis and degree of correlating the same genetic type may be observed

5.7.3 The Tension Levelling Line Process.

The line mainly do the coil pretreatment before painting and levelling. If only levelling is required, then the pretreatment is ignored. The line involves the following stages.

1. Degreasing tank

The coil first passed through the degreasing tank where we use Sodium Hydroxide solution to remove the grease, stains, rolling oil and other impurities at a set concentration, pressure and temperature.

The coil is moved to the line made of brush-like scrubbers to scrap and brush off the impurities and other resistant-stains.

2. Hot rinse 1&2

After the degreasing treatment from the degreasing tank, the coil the passes through the double rinsing tank with hot water of 35 degrees to facilitate cleaning and removal of the grease which may be present and also to rinse the NAOH chemical used in the previous tank.

3. Air knife

This chamber consists of a blower that cools and at the same time blows way the rust, dust and particles on the surface of the coil.

The coil is tension leveled before entering the chem-coater.

4. Chem-coater

Here chromate is used for chemical surface conversion. Aluminium-chromating treatment leaves the aluminium surface indecent yellow chromium oxide. Chromating is done to increase adhesion of the paints and also to form an oxide on the substrate to protect the metal from oxidation and corrosion of the base metal.

5.7.4 Colour Coating Line Process

After pretreatment of the coil, now the coil should undergo the colour coating process. The line is very long to facilitate proper coating of the metal. The line consists of the following sections;

1. Stitching of the coil

The pretreated coil to be passed through the CCL, need to be stitched with the dammy coils. After stitching the coils leads to the entry accumulator by the aid of continuous moving rollers and then it moves to the coater room.

2. Coater room

This is the point where the painting of the coil occurs using different paints e.g. sky blue, rick red bucker grey etc. painting is done using both on the top and at the bottom. Painting is aide by the pick-up roller then transfers the paint to the applicator rollers which paints the surface of the coil smoothly. The Wet Film Thickness and viscosity of the paint are checked here.

3. The three Ovens.

The line has 3 oven operating at different temperature from may be 250, 255, and 260 degrees Celsius. The painted coil is baked through the 3 ovens so as to ensure that the high temperatures makes the paint to adhere strongly on the surface of the coil. The high temperature acts as a catalyst drying the paint quickly on the substrate.

PMT- Peak Metal Temperature is determined after it has pass through the oven using the PMT strips and the PMT is always placed on the coil surface in the coater room.

4. Water Quencher

The coil passes through the water quencher to cool the hot metal coil after baking. Cold water is sprinkled on the surface of the passing coil as it gets into the exist accumulator.

5. Printer Section

Here is where the batch number, the gauge of the coil are the correctly dispatched on the surface of the passing painted metal using a printer.

The coil is then cut for lab analysis both mechanical and chemical lab test after which the coil is sheared out.

6. Inspection Table

The cut coil is bought to the table and inspected and all the mechanical tests listed above are are done to ensure that it is of the quality required for export.

5.8.0 AREA I USED MY SKILLS FOR THE BENEFIT OF THE ORGANISATION

Environmental aspect evaluation of the company’s operational activities.

ACTIVITY

ENVIRONMENTAL THEMES

ENVIRONMENTAL ASPECT

ENVIRONMENTAL IMPACT

LEGAL REQUIREMENTS

SURROUNDINGS/COMPLAINTS

DEGREE OF CONTROL

POSSIBLE MEASURES

Transportation and storage

Waste Dross, used oil; spillage

Depleting natural resources, Land degradation and soil pollution

No No Good Transported using closed containers to disposal areas

Noise and vibrations

Noise from the forklift as a result of delivery and disposal movements of raw materials

Noise pollution and disturbance to the surrounding

Yes Occasional Good Proper mechanical maintenance and services to the Forklif

and waste materials

ts

Air and soil (only from an incident)

Emissions from transport vehicles, dust blown out.Leakage from vehicles, storage of materials, over ground tanks, spillage

Acidification, greenhouse effect and respiratory problems.

Contaminated soils or soil pollution

Yes Yes frequent about dust.

Yes about leakage from storage over ground tanks.

Proper mechanical maintenance and services to the Forklifts.

Energy Energy consumption from external (diesel) and internal transportation (LPG diesel)

Depletion of natural resources. i.e. Petroleum ore

Modifying driving habits, motors and vehicles

Metal Casting and coil production

Wastes Dross production as a by-product of casting the alloy and the scrap

Land degradation and soil pollution

No because it is disposed within the company compound

GoodIt is re-melted by the TTRF to drain all the aluminium that might be present after casting

The dross can be used as a raw material for cement and fertilizer production

Air Emissions limited by the Bag-house

Acidification, greenhouse effect, climate

Yes No ExcellentThe emissions

Maintenance of the bag-house

change, respiratory diseases and even death of organism toxic gases inhalation.

are passed through alkaline injection to remove the Flue gas and any acidic compound.The smoke particles like the fly gas are removed the filtering bags at the bag-house.

and the alkalinity injector.Introduce carbon injector also to remove all the carbon compounds like the greenhouse gases.

Water Cooling water from the cooling tower for solidification (coil formation) of the melted metal

Impact to water ecosystem if discharged to surface water due to its high temperature i.e. thermal pollution.

No Good controlled by the Cooling water tower.

Energy Electricity consumption to run the operations.Petroleum fuel consumptio

Depletion of the natural resources i.e. energy resources.

Energy saving plans.

n.Colour Coating and Tension Leveling.

Water Rinse water from the Hot rinse 1 and 2 Chambers, Sodium Hydroxide solution used for treatment and the Chromate used for pretreatment processes of the coil.

Impact on the ecosystem (hot water) if discharged to surface water i.e. thermal pollutionWater pollution due to presence of oil & grease and basic water from the degreasing chamber

Yes No GoodDone at the ETP

Effluent produced to be channeled to the Effluent treatment plant

Waste Cotton waste generation

Solid waste, land pollution during & after disposal of used cotton.

No Good. Burnt at the incinerator

Efficient use of the Cotton wool.

Energy Electric motors used to run the process and to heat the rinsing water.

Depletion of the energy resource

Energy saving plans.

Pressing at the Circle Production and Blanking.

Noise Noise generation from the pressing and blanking machines

Noise pollution due to the pressing and blanking operations.

Yes Frequently Fair Using earmuffs when operating the machines.

House Keeping

Water Generation of effluent during floor cleaning

Water pollution

Yes No Good The effluent is channeled to

the ETP

Waste Disposal of waste papers/polythene paper and wood

Land degradation and soil pollution

No No GoodBurnt at the incinerator

Reduction in paper consumption.

Advisory Services and internal organization

Air Employee car emissions (leased and private)

Acidification, greenhouse effect

No proposed law

“Green” lease scheme, smaller cars, reduce no. of km, change driving habits.

Energy Energy consumption of computer equipment. Energy consumption for heating and lighting offices.

Depletion of the energy resources

No Small Use energy-efficient computer equipment.Use energy saving bulbs and fluorescent tubes for lighting

Waste Products of office activities

Land degradation due to solid waste accumulation.

Yes Limited Reduction in paper consumption

Water Floor washing (house-keeping)

Effluent generation during floor washing of

Yes No Good Uses water efficiently

the offices. while mopping.

Various Environmental aspects associated with recommendations about structures and materials to be used.

Various Sometimes

Can be relatively large depending on project

CHAPTER SIX

CONCLUSION AND RECOMMENDATION

6.1.0 CONCLUSION

I successfully completed a three-month attachment running from 12th May to 5th August 2016 at Kaluworks Limited Company as a requirement for the completion of my degree course. Through the attachment, I managed to obtain practical skills in environmental monitoring and management in terms of waste management. The attachment also exposed me to the practical application of the things I have studied in the University and brought me in contact with my potential employers.

Relationship between university training and practicum experience

During the practicum period, I realized that there are very many areas where the university training was relevant to the activities carried out during the attachment, such relationships include:

Solid waste management; we have been taught a unit on solid waste management, the different methods of solid waste management like dumping, incineration, recycling, etc. Kaluworks Company carries out waste management activities on daily basis; they enact the EMCA law that provides that for any organization to handle wastes, they have to apply for a waste handling license, waste transporting license, and waste dumping license.

Water quality management; in the University, we are taught the various sources of water pollution including the point and non-point sources. The point sources include processing plants, industries, institutions, residential areas among others. In Kaluworks, we treat all the effluent and sewage before disposed to the environment.

6.2.0 RECOMENDATIONS

Recommendations for university training

Students should be involved in more practical work by their lecturers than in theory work.

Lecturers should cover their units extensively and not just concentrate on the basics; students should be assigned individual supervisors who guide them in research and extensive studies.

Recommendations for the organization

The company should involve all attaches in fire and personal safety, Quality Management System and Environmental Management System Meetings.

Environmental Science Students should be involved in both the internal and external environmental auditing so as they can acquire skills on how the auditing is done.

The operators of the ETP and STP should go with the standards and measurements of the chemicals to be used for treatment as more application of the chemicals leads to high level of TDS and TSS of the final treated water.

The company should look for more customers to re-use or dispose the dross which is the main problem in terms of solid waste management. The treated dross can be used as a raw material of cement and fertilizers producing companies.

The company should adopt with other energy efficiency practices like using solar panels to provide power for STP, ETP and Incinerator plants which requires less energy to run.

The incinerator itself can be a source of energy; the hot exhaust or flue gases can be passed through a heat exchanger and the heat removed is used to raise steam. This can be used to supply a local heat demand or to drive turbines which will generate electricity.

REFERENCE

EMCA (Waste Management) Regulations 2006

ISO 14001: Identifying and evaluating environmental aspects.