Professional Documents
Culture Documents
REPORT
REPORT
FACULTY OF ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING
Students WEIGHT
CATEGORIES SO MARK
/100
Name, Surname:
MUHIEDDINE Record and Logbook Keeping - -
KAJ
Company’s Supervisor Evaluation 4 50
Report 3, 7
Number: Ch1 Introduction - 10
18700231
Ch2 Product Information - 10
Ch3 Performed Work - 10
Personal
Ch4 Development and - 10
Awareness about
Contemporary Issues
Appendix Standards 10
TOTAL 100
Student Outcomes
an ability to identify, formulate, and solve complex engineering problems by applying principles
1
of engineering, science, and mathematics
an ability to apply engineering design to produce solutions that meet specified needs with
2 consideration of public health, safety, and welfare, as well as global, cultural, social,
environmental, and economic factors
Fall 2020-2021
Faculty of Engineering
2
LIST OF CONTENTS
LIST OF FIGURES.............................................................................................................................................4
ACKNOWLEDGEMENT...................................................................................................................................5
CHAPTER 1 INTRODUCTION........................................................................................................................6
1.1 Background...........................................................................................................................................6
1.2 Company Information..........................................................................................................................7
1.3 Structure of the Report.........................................................................................................................7
CHAPTER 2 PRODUCT INFORMATION.....................................................................................................8
2.1 Products of the Company..........................................................................................................................8
CHAPTER 3 PERFORMED WORK..............................................................................................................11
3.1 Daily Activities and Performed Work at the Workplace........................................................................11
3.1.1 Week1: (Days1-7) EXCAVATION..............................................................................................11
3.1.2 Week2: (Days8-14) CRUSHING................................................................................................12
3.1.3 Week3: (Days 15-21) CALCINER..............................................................................................13
3.1.4 Week4: (Days 22-28) GRINDING..............................................................................................14
3.1.5 Week5 (Days 29-35) MIXING RAW MATERIALS..................................................................15
3.1.6 Week6 (days 36-42) Forming Station.......................................................................................16
3.1.7 Week7 (days 43-49) Klin (DRYER)...........................................................................................17
CHAPTER 4 PERSONAL DEVELOPMENT AND AWARENESS ABOUT CONTEMPORARY
ISSUES…………................................................................................................................................................18
4.1 Acquired Skills and Recognition of Contemporary Issues.....................................................................18
REFERENCES…...............................................................................................................................................19
APPENDICES…................................................................................................................................................21
APPENDIX A STANDARDS.........................................................................................................................21
APPENDIX B Gypsum products:....................................................................................................................22
CURRICULUM VITAE..............................................................................................................................29
3
LIST OF FIGURES
4
ACKNOWLEDGEMENT
The Internship opportunity I had with Taksim Gypsum Co. gave me a head start building
my career especially during the hard times the world is facing due to the pandemic and the
global economic crisis that led most factories and companies into closing its doors for
interns, and some of its own working staff to reduce cost.
I would like to thank the supervisor Mahmoud Hanaktah that was standing behind all the
hard work and assisting me throughout all my internship period, and introduced me to all
the facilities of their factory, in addition to supplying me with all the necessary information
needed for the completion of this report.
Lastly, I take this opportunity to give credits to the company owner Mr. Naji Hanaktah for
allowing me to be a part of his company for the duration of the internship, and showing
interest in offering me job as soon as I graduate from my university.
5
1. CHAPTER 1 INTRODUCTION
1.1 Background
Taksim Co LLC established for supporting the process of developing the Jordanian economy
by making local production and exporting these products to neighborhood countries. The
management team in the factory is specializing in areas of processing gypsum mine for the
production of gypsum products and gypsum board as well as construction chemicals. It is the
first plant in Jordan to manufacture national gypsum board by using national sources and
local manpower.
Company Vision
Support the Jordanian economy through combining Jordanian and Turkish Raw Materials
with state of the art technology and processing techniques to produce best quality products
and become known one of the worldwide companies in construction sector. [1]
Company Mission
Continuous investment on research and development to supply the market with best products
and create a reputable Jordanian brand known all over the world. [2]
I was an intern at Taksim Gypsum Co. (TGC) where my job was to learn about
manufacturing processes of producing gypsum boards starting from raw materials reaching
the final product to be sold to the costumer. The duration of the Internship (40 working days)
was distributed by Eng. Mahmoud Al Hanaktah into different sectors in the factory on a
span of 8 weeks. During the training period my daily work was to meet engineers under the
supervision of Mr. Mahmoud and discuss with them their duties and what machines, and
units they have to deal with, In addition to what procedures or standards they have to abide
with. Also, I had limited access to the gypsum excavation site where raw gypsum is
excavated. The nature of the interaction I had with my Co-workers was so professional, and
ethical. After the completion of my training period successfully, I was able to achieve
important progress by:
6
1.2 Company Information
Under the grace of God and allowance of His Majesty King Abdullah Il Bin Al Hussein,
Taksim Co LLC is established in the year in 2018 as a 100% Jordanian Company for
manufacturing gypsum products from natural sources that are available in the town of Al
Tafileh.
Feeling a sense of responsibility and to meet the desire of His Majesty King Abdullah il Bin Al
Hussein, to strengthen the ties between the public and private sector to promote the economic
sphere of the Kingdom in the field of industry, Taksim Co LLC focused on establishing a
factory for the production of gypsum and gypsum board, making the raw materials available in
the country useful for industry, instead of importing them from abroad and providing 70 new
job opportunities for the youth to fight unemployment and consequent social problems.
Taksim Gypsum consists of 8 main sectors were each section is responsible for a part of the
manufacturing process, and these sectors are:
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2. CHAPTER 2 PRODUCT INFORMATION
TAKSIM Co LLC management decided to operate this facility by bringing the latest
technological machinery and equipment to renovate the factory and make it operate
properly with correct know how and state of the art technology. In order to protect the
environment from pollution, the plant have been provided with filter units at all
production stages as well as providing it with all means of public safety control
system, fire distinguishing system and early alarms systems. They plan to produce
120 Ton/day gypsum powder and 3600 pieces of gypsum boards per day, and have
all products qualified by EN and JS Certificates.
The second stage is crushing gypsum stones of 80% to 97% purity so that the size of the
particles is from 4 mm to 8 mm.
The third stage is oven roasting, so that these granules are stored in the silos for the
grinding process afterwards, and the roasting process takes place in the oven at
temperatures up to 800 Celsius at the entrance and to the exit 200 Celsius.
The fourth stage is grinding according to the need for size. If we want to produce packing
bags of gypsum, we use fine engagement in the mill, reaching from 2 microns to 5 microns,
and coarse materials when needed to manufacture gypsum boards.
Fifthly, after crushing, roasting and grinding, we collect the crushed materials and distribute
them to silos according to the production, and demand.
sixthly, in the production of gypsum boards, gypsum boards and suspended ceilings, a
machine for mixing the raw materials is used, which mixes the upper and lower papers,
glue and chemicals auxiliary to the gypsum reaction process and affecting its physical
properties in terms of flexibility and rigidity, and this process is the basic in the manufacture of
an excellent and competitive product.
Finally, bringing this product to ovens so that the water in the panels is withdrawn, and the
panels, after cutting, according to the required lengths, enter the dryer for a period of 30 to
35 minutes, and then to storage and sale in the market.
8
Gypsum products:
TAKSIM SATIN PLASTER: It is a kind of gypsum that was developed to easily be applied in
any type of repair, filling, spilling, and ceiling floor operation at construction.
TAKSIM PLASTER OF PARIS: It is a kind of gypsum that was developed for various
decorations and special works, fine granular, providing smooth surfaces.
Grouting mortars:
AGGAFIX-FUGA-ST: white cement based, joint filler mortar with color options (CG1)
AGGAFLEX-FUGA-CG2W: white cement based, improved with additional properties, with
reduced water absorption joint filler mortar with 30 color options (CG2W)
AGGAPOOL-FUGA-CG2WA: white cement based, improved with additional properties, with
reduced water absorption, with high abrasion strength joint filler mortar with 30 color options
(CG2WA)
Tile adhesives:
AGGAFLEX-C1TES1: normal setting, deformable-flexible, white cement based tile adhesive
with reduced slip, with extended open time (C1TES1)
AGGAFIX-MEGA-C2TE: chemicals added, reduced dislocation, increase wait time in the
open, water resistant ceramic adhesive mortar.
Improved, antibacterial, white/grey cement based, tile adhesive with reduced slip, with
extended open time (C2TE)
AGGAFLEX-MEGA-C2TES2: improved, highly deformable-super flexible, white cement
based tile-granite-marble-stone adhesive with reduced slip, with extended open time (C2TES2)
9
AGGAFIX C1TE: white cement based tile adhesive with reduced slip and extended waiting
time (C1TE)
AGGAPOOL-C2TE: improved, white cement based, tile-granite-marble-stone adhesive with
reduced slip, with extended open time (C2TE)
TAKSIM-C1T: white/grey cement based tile adhesive with reduced slip (C1T)
NOTE: (characteristics and information about all 11 products are provided in details in
appendix B)
10
3. CHAPTER 3 PERFORMED WORK
The duration of the industrial training (40 working days) was distributed into different
divisions on a span of 7 weeks as follows:
Week 1: EXCAVATION
Week 2: CRUSHING
Week 3: CALCINER
Week 4: GRINDING & DISTRIBUTION
Week 5: MIXING RAW MATERIALS
Week 6: Forming Station
Week 7: Klin (DRYER)
In the first week I was sent to the excavation sites to know how high-quality gypsum rocks are
extracted by excavators from quarries which is carried out by digging out an area of ground
where the gypsum is located using open-cast techniques. During the time spent on the site
my supervisor explained for me that drilling and digging equipment is applied to dig out the
gypsum ore in excavation stages, and the extracted rocks are sent to the factory where it
undergoes the manufacturing process, and he explained to me that to reach deeper deposits
drift or shaft mines may be needed.
Moreover, I discussed with my supervisor the vehicles used during this stage which are:
Hydraulic excavators
Jack hammer excavators
Mining trucks
11
3.1.2 Week2: (Days8-14) CRUSHING
On the second week I was transferred to the crushing section where we were responsible to
crush gypsum stones of 80% to 97% purity so that the size of the particles is from 4 mm to 8
mm. The crushing process is done by using a crushing machine named “jaw crusher”. My
supervisor explained for me the sections of the jaw crushed, and how it is used to crush the
gypsum stones, and he gave me the benefits of using a jaw crusher instead of different types
of crushers which are: Gyratory Crusher, Impact Crusher, and Cone Crusher.
12
3.1.3 Week3: (Days 15-21) CALCINER
On the third week, I was transferred to the Calcine section where typically, free water is
removed in an initial process at approximately 45℃ and crystalline bound water is removed
in a second process at 120-180℃. In kettle calciners, the gypsum is indirectly heated by hot
combustion gas passed through fluesin the kettle, and the stucco product is discharged into
a "hot pit" located below the kettle. Kettle calciners may be operated in either batch or
continuous mode.
In this section engineers responsible explained for me the operation modes of the Calciners
which are:
Batch mode: process that consists of a sequence of one or more steps that should be
performed in a defined order. A finite quantity of the product is produced at the end of
the sequence, which is repeated in order to produce another product batch.
Continuous mode: process that involves moving a single work unit at a time between
every step of the process without any breaks in time, substance, sequence or extend.
As the name suggests, the flow of product or material is continuous.
13
3.1.4 Week4: (Days 22-28) GRINDING
On the fourth week I was transferred to the grinding & distribution sector where gypsum is
grinded according to the need for size. Where we used fine engagement in the mill, reaching
from 2 microns to 5 microns, and coarse materials when needed to manufacture gypsum
boards.
During this period, I discussed with the engineers the input size, the capacity, and the
materials that can be used in the grinding mill which are as follows:
Input size: 0-55mm
Capacity: 2.-83 TPH
Material: Limestone, calcite, dolomite, petroleum coal, gypsum, barite, marble, talc, coal
powder, etc.
In addition to that we discussed the advantages of this machine compared to other machines
which are:
Lower Maintenance Costs
Higher Grinding Efficiency
Lower Energy Consumption
Sufficient Supply of Spare Parts
Higher Precision
DISTRIBUTION
After crushing, roasting and grinding, we collect the crushed materials and distributed them
to silos according to the production, and demand to be used later.
14
3.1.5 Week5 (Days 29-35) MIXING RAW MATERIALS
On the fifth week I was transferred to the mixing raw materials section where in the
production of gypsum boards, gypsum boards and suspended ceilings we used a machine
which mixes the upper and lower papers, glue and chemicals auxiliary to the gypsum
reaction process, affecting its physical properties in terms of flexibility and rigidity.
The supervisor explained for me that this process is the base of the manufacture of an
excellent and competitive product, and mentioned how important this step is to create high-
quality gypsum boards as gypsum mixer equipment can make calcium plaster with sound
fluidity and low air content rapidly, enhance the using times of the plaster mold and enhance
the smoothness of surfaces.
In addition to that the workers responsible for machining the mixer insisted on the importance of
maintenance, and recommended that a little bit of time invested in maintenance each week which can
save a lot of money, keep the slurry smooth, prevent paper breaks and keep gypsum mixer running
longer.
15
3.1.6 Week6 (days 36-42) Forming Station
On the sixth week I was transferred to the forming station where the board forming line starts with 2
large rolls of recycled paper or fiberglass mats. We poured the slurry onto the bottom sheet which will
be directly covered by the facing sheet from the other roll.
Moreover, during this process my supervisor gave me some important details about the forming table
such as it being fabricated from stainless steel, and it integrates a vibration device driven by a variable
frequency motor, and that the vibration unit supports convenient adjustment of vibration frequency
and amplitude
Then at the end of the line, we have a cutting machine that cuts the hardened board into various length
according to what dimensions we need.
16
3.1.7 Week7 (days 43-49) Kiln (DRYER)
Finally, on the seventh week, and after cutting according to the required lengths I was
transferred to the kiln section where we take the product to ovens to withdraw the water in
the panels by inserting them into the dryer which called a rotary kiln for a period of 30 to 35
minutes, and then to storage and sale in the market.
During this stage fellow engineers explained for me that a Gypsum Rotary Kiln a kind of
thermal equipment for calcining gypsum. Its appearance and shape are similar to lime
rotary kiln and cement rotary kiln, and its main structure includes kiln head, kiln tail sealing
device, rotary cylinder, supporting device, back-up roll device as shown in the figure below.
Moreover, I had the chance to get my hands on two samples of gypsum powder one is
before and the other is after drying and I was able to notice the difference between the two
samples so clearly as the first sample was wet while the other sample was dry as shown in
the figure below.
Figure 3- 14 Gypsum powder before and after the rotary kiln [13]
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4. CHAPTER 4 PERSONAL DEVELOPMENT AND
AWARENESS ABOUT CONTEMPORARY ISSUES
The industrial training, I had with Taksim Gypsum Co. was so beneficial it helped me gain
many skills and helped me develop my knowledge through applying some of what I learned in
university.
After the completion of my training period, I was able to achieve the following:
Gain valuable work experience
Explore a career path
Give yourself an edge in the job market
Develop and refine skills
Receive financial compensation
Network with professionals in the field
Gain confidence
Probable transition into a job
18
REFERENCES
[4] ZKG Cement Lime GYPSUM. (2020). Outlook on the gypsum industry. Retrieved from
https://www.zkg.de/en/artikel/zkg_Outlook_on_the_gypsum_industry_3562195.html
[6] ZKG Cement Lime GYPSUM. (2014). Grinding and calcining of gypsum with Pfeiffer grinding
plants. Retrieved from
https://www.zkg.de/en/artikel/zkg_Grinding_and_calcining_of_gypsum_with_Pfeiffer_grinding_
plants_2209976.html
[10] Forbo Movement Systems. (2018). Gypsum Board Industry. Retrieved from
https://www.forbo.com/movement/en-gl/industries-applications/raw-materials/gypsum-board-
industry/p6lq3i#panel_0
[12] Directindustry. (n.d). How Does A Rotary Kiln Work?. Retrieved from
https://trends.directindustry.com/xinxiang-great-wall-machinery-co-ltd/project-201653-
1115555.html
19
[13] In Pinterest. (n.d). Gypsum Powder Dryer. Retrieved from
https://in.pinterest.com/pin/594475219552447115/
20
APPENDICES
APPENDIX A STANDARDS
21
APPENDIX B Gypsum products:
22
23
Grout Mortars
24
25
Tile adhesives
26
27
28
CURRICULUM VITAE
MUHIEDDINE KAJ
Mechanical Engineer
EUCATION
Bchamoun-Lebanon.
Personal Profile:
- Lebanese.
7 / 2021 – 8/ 2021, Summer Internship
Taksim Gypsum Co./ Tafileh, Jordan.
-Mechanical engineering with 7 / 2019– 9/ 2019, Sales Assistant
Micro-city / Beirut, Lebanon.
multiple internships in different
7 / 2018 – 9 / 2018, Summer Internship
sectors. Looking forward to earning Blom Bank / Aramoun, Lebanon.
Time Management.