NNL factory tour

NIGACHEM NIGERIA LIMITED
FINAL PRESENTATION OF SERVICE YEAR
AT NIGACHEM NIGERIA LIMITED (NNL) FACTORY. ARO-
ERE, OGUN STATE.
PRESENTED
BY
OMOKPARIOLA ELSHALOM CHIOMA(SERVING CORPER).

• Introduction to Nigachem Nigeria Limited (NNL) Factory ( A Brief Tour/ Introduction)
• Safety Moment
• QAQC Department
• Job Task Requirement
• Practical Aspects Of The Department
• Sales Department
• Field Experiences And Practical
• Admin Block
• Weigh Bridge
• Engineering
• The Boiler Room
• Magazine Department
• Auditing
• Summary
NIGACHEM NIGERIA LIMITED (NNL)CONTENT

Nigachem Nigerian Limited (NNL) was established in 1997 by Engr., Sylvester C. Ghasarah
(FNSME) as a private company and it deals on chemicals (applied and extracts), emulsives,
and known for SUPERPOWER 90 90mm. It is located at Aro-Eere near Emulu Village Asu
ward, Obafemi Owode Local Government Area, Ogun State.
They manufacture various types of emulsions and our beand is called SUPERPOWER. This
is safe because it is only detonates upon the introduction of a suitable initiation stimulus.
They also engage in marketing and sales of commercial or civil explosives and related
products like Ammonium Nitrate, Detonating Cords, Non-Electrical Detonators (Nonels),
High Explosives, Bulk, etc.
Geological Aspect: Various ranges of blasting Accessories and drilling and blasting
consult- provides services in oil and gas (supplies seismic explosives from data
acquisition). For oil and gas it also applies to it.
Introduction To Nigachem Nigeria Limited (NNL) Factory
NIGACHEM NIGERIA LIMITED (NNL)

Introduction To Nigachem Nigeria Limited (NNL) Factory
Cont’d.
Various Departments In NNL With Personnel Heading It:
Administrative Department (Mr Sukanmi Bisiriyu)
Quality Assurance/ Quality Control Department (Engr Unde
Cornelius)
Storage Department (Mr Eko Williams)
Electrical/ Maintenance Department (Engr Vincent Olisa)
Sales Department (Engr. Yongo Gabriel)
Magazine Department (Mr Henry Ikhile)
Accounting Department (Mr Sylvester Ayetunde)

Safety at work is essential and it’s an individual responsibility which can be broken down into various
categories which include but not limited to;
Personal Attire:
Personal Protective Equipment – Ensure that all required PPE (e.g., Reflective Jackets, Safety glasses,
Gloves, Steel-toed shoes, and hard hats etc.) is worn.
Hair – Must be styled in a manner to prevent exposure to the hazard of entanglement or completely covered.
No Cellphones – Due to the explosive production; it is advisable to restrict any form of electrical appliance
that could cause ignition.
Risk Assessment:
The purpose of a risk assessment is to identify the risks to the Q/HSE connected with activities. The
assessment should identify how the risks arise and how they impact those affected. This information should
then be used to determine how best to manage those risks to ensure necessary controls are implemented
which are proportionate to the level of risk identified.
Risk assessments must be performed before the start of any workshop activity to identify the hazards
and evaluate risks. Significant risks with adequate controls must be documented by one of the following
forms:
Risk analysis (RA) record to determine the risk priority code (RPC),
Job safety analysis (JSA),
Toolbox talk form, and
Observe of the safety signages.
SAFETY MOMENTS

The QAQC DEPARTMENT (NNL)
JOB TASK REQUIREMENTS
Update The QAQC Reports like the Calibration of equipment, Mixing
Area, OB&OF Area, Sample Collection, Manual pH meters,
Viscometers, Thermometers, Hydrometers, Water Oven, Products Coming
in, Raw Materials, Finishing Goods, Incidences, Update on New Intakes,
etc and converting it into soft copy.
Raw material Analysis like the testing of NH3NO4 (Coated or Non-
Coated), Bulk Testing, Lay flats, Diesel, NaNO3, Furnace Oil, and
Polyphones and other Products Coming in.
Daily Report to the GM Technical (Mr. S. A. Rao) on the QAQC activities
performed, any materials tested, and products produced.

PRACTICAL ASPECTS OF THE DEPARTMENT
1. FURNACE OILANALYSIS PROCEDURE: Various Tests conducted are
A) Temperature Test: Use Of Thermometer to determine the temp. and making sure its same as NNL
Standard. It ranges from 21⁰C to 27⁰
B) Viscosity Test: Use of Viscometer to know the viscosity using spindle 2. The higher the viscosity the
lower the Temp. Viscosity = Dial Reading * Factor. . It ranges from 400 to 440.
C) Color Test: Use of Filter paper to determine the color index standard. It ranges from light brown to
darkish gold.
D) Density Test: This is used to determine the specific gravity range using a hygrometer. It ranges from
0.900mmgh to .940mmgh
E) Filtration Test: This is the use of ethylbenzole to determine if there are any impurities, It which is
added to 40gram of FO in a beaker and the addition of 25g of petroleum-Spirit, stir the solution for
about 5mins and filter using a sieve.
F) Odor Test: To determine if it has the sweet aromatic smell from a hydrocarbon aromatic compound.

PRACTICAL ASPECTS OF THE DEPARTMENT
2: AMMONIUM NITRATE TEST: Various Tests conducted are
A) Physical Test Such as; Color Test, Clear Content, Coldness and
B) Color and Texture Test: It has a white colour with a porous prills which has an angular shape.
AN can be coated or uncoated.
C) Oil Absorption Test: 100ml of Diesel is added to a 20g of AN in a beaker, stir for a few secs
and allow to absorb for 30 mins.
D) Filtration Test: Add 25ml of petroleum ether add it into a 20g of AN in a 500ml beaker, heat up
to a temperature of 45⁰c.
E) Type Specification: Coated AN when added to 200ml of water it gives off cloudy coloration
which is not clear and is more dense than Uncoated AN with tiny pore space. This is often
preferred by most clients because it is economical. While Uncoated AN has a clear coloration
with a low density compared to coated AN and gives off a chilly low degree temperature.
F) Water Absorption Ratio: We make use of the water oven after we have filtered it from
the paper. This is to determine the rate at which it can absorb water or any solution.

3: AMMONIUM NITRATE
DIFFERENCE BETWEEN COATED AND UNCOATED AMMONIUM NITRATE
S/N PARAMTERS COATED A.NITRATE UNCOATED A. NITRATE
1 Physical
Appearance
It’s crystalline granular and
warm when felt with the hands.
A.N + ANFO is coated.
White crystalline/ granular free
flowing solid.
A.N + Mg2NO3
2 Solubility in
water
It’s inoluble with cloudy
coloration and oily content
Completely Soluble with clear
coloration
3 pH 4.0 to 6.0
4 Moisture
Content
0.8% 0.6%
5 Quantitative
Identification
Sample dissolves completely in
water with residues like
particulates .
Sample + NaOH (Aq) and warm
will give off NH3 gas from NH4
Sample dissolves completely in
water with no residue.
Sample + NaOH (Aq) and
warm will give off NH3 gas
from NH4
6 Specific
Density
More Dense than Uncoated A. N Less Dense than Coated A. N
Table1: Showing the difference between coated and uncoated Ammonium Nitrate.

NIGACHEM NIGERIA LIMITED (NNL)A) COMPOSITION OF OXIDIZING BLEND AND FUEL BLEND
I: Oxidizing Blend (O. B):
A.N=76.98%, H20=23.0%, Sulphamic Acid=.02%, (Revolution Per Minute) R.P.M=70-73, Kg/Min=93.5.
II: Fuel Blend (F.B):
F. O=8.55%, S. M.0=18.45%, S.E.B, Diesel, Industrial Paraffin, R. P.M= 123-125, Kg/min=6.5. LLPO=44.18
III: Jet Mixer: R. P. M=800-1000,Kg/min=100,
IV: Matrix: Density=1.35mmgh, Matrix Temp=78⁰c, Matrix Velocity=86,000-92,000Psi.
Note: Matrix Ratio: O.B=93.5,F.B=6.5
O.B Parameters: Temp=80⁰c, Fudge Point: (Where the first cloud forms)= 55⁰c/60⁰c, Specific Gravity=
1.360g/cm³/1.37g/cm³, P.H=3.48/3.5(Very Acidic).
F. B Parameter: Temp=45⁰c, 0.920g/cm³.
V: Gassing Agents: Gassing takes place for 30 mins with a 0.5% increase which is the standard. The agents include
Formaldehyde=3%, H20=83.5%, NaNO3=13.5%.
4) PRINTED BOXES FOR CATRIADGE ANALYSIS
Parameters: Each flips should
I: Centre Meeting: meet at the center.
II: Pliers Number: It has 5 pliers
III: Flot Type: Flot B which is 127 and absorbs water compared to Flot C which absorbs less water and at 250 based on
the quality.
IV: Boosting Strength: Number of stacking heights it can attain, it must be for about able to show strength for 24 hrs.
V: GMS: It could be 200, 125, 275, 350 based on the content that will be carried by the box ranging from explosives,
tobacco, biscuits, wine bottles, etc.
VI: Printing: In printing the UN number must be included which is very essential.
TheQAQCDEPARTMENT(NNL)

TYPE LENGHT HEIGHT WIDTH WEIGHT
S. P 90 90 mm 430 mm 270 mm 260 mm 650 g
S.P 90 60mm 470 mm 240 mm 260 mm 590 g
S. P 80 90 mm 430 mm 260 mm 270 mm 640 g
S. P 80 60 mm 470mm 240 mm 260 mm 580 g
Solarprime-E 90 mm 430 mm 260 mm 270 mm 650 g
Solarprime- E 60 mm 470 mm 240 mm 260 mm 592 g
Seismic 50 * 400 g 570 mm 270 mm 330 mm 882 g
Solargel-E 90 mm 430 mm 260 mm 270 mm 630 g
Table 1: Showing the standards of each printed boxes for in process check analysis.

THE SALES DEPARTMENT (NNL)
JOB TASK REQUIREMENTS
 Monthly, Quarterly, Biannual, Annual Sales Report of West 1 and Western Territory.
 Creating of LPO’s, GDN, Waybills, and SAP Documents.
 Observation of Blasting Procedures at the Clients Base.
 Creation of Debtors List for clients and also scouting for clients
 Delivery of Products to Customer

MONTHLY SALES REPORT FORMAT:
Product Analysis
Customers Date Invoice No Quality Rate Amount Vat (5%) Delivery Total Remark
Sinotrust 01/01/19 016267 10,000 320 3,200,000 160,000 65,000 3,425,000 PBT (AN)
WESTERN TERRITORY SALES MONTHLY REPORT FORMAT
The Aim is to get the Gross Total from the net total, deliveries and Vat.
For the Value
S/N PRODUCTS UNIT 2019/20 SP/ UNIT
MONTHLY
VOLUME BUDGET
ACTUAL VALUE (Nm)
MONTHLY VALUE
BUDGET WEST 1 WEST 2 WEST 3
TOTAL ACTUAL
VALUE % ACH'VD % VARIANCE
1CATRIDGE MT 600 268 160,800 53.33 1.855 29.242 84.42
S/N PRODUCTS UNIT
2019/20
BUDGET
VOLUME
MONTHLY
BUDGET
ACTUALVOLUME
WEST 1 WEST 2 WEST 3
TOTALACTUAL
VOL % ACH'VD %VARIANCE
1CATRIDGE MT 3,212 268 91.75 2650 41.3 2,783.05 1039.74 939.74
For the Volume
VOLUME
WEST 1 WEST 2 WEST 3
PRODUCT UNIT JULY AUG SEPT NET JULY AUG SEPT NET JULY AUG SEPT NET TOTAL
HE MT 80.48 90.9 64.83 236.21 1.38 4.38 16.45 22.21 37.5 6.9 9 53.4 311.82
WESTERN TERRITORY QUARTERLY SALES REPORT FORMAT: Our Year begins at the month of April and its every three
months
Table2: Showing the Sales Report Format.

FIELD EXPERENCES
1: BLASTING OPERATIONS AT LAFARGE EWEKORO PLANT.
Product: Limestone (High Grade) Outcrop
Limestone is composed of calcite or aragonite (different crystal forms of CaCO3). Calcite exhibits an unusual characteristic called
retrograde solubility in which it becomes less soluble in water as the temperature increases.
It is a site for fossils which ranges from Antropodes (Trilobiites), ostracosa, foraminifera (Planktonic and benthic), Gastropods
(molluscs, corals) brachiopods. Etc. All these proves that limestone exist in a shallow marine environment of deposition. Its
classification can be by noted best by Durham scheme to know the sphericity, size, shape, pore space, compatibility, etc.
BLASTING PROCEDURE
 Safety Talk to prep the team members on the risk involved and how to mitigate the them.
 Working with the specifications; These are to be noted before, during and after blasting operation to achieve maximum
fragmentation.
Fig 1: Showing the blasting parameters and schematics Adopted from Dyno Nobel

Fig 2: Showing the blasting parameters formulas Adopted from Dyno Nobel

Fig 3 : Showing the Motorable Matrix Unit
MOBILE MANUFACTURE UNIT TANK
BULK EMULSION CHARGING OPERATIONS ON THE FIELD
MMU is used in the blasting field for blasting operations. It is a self mixing machine which combines the ANDO,
OB, FB and Gassing agent, It can be coated or uncoated.

NIGACHEM NIGERIA LIMITED (NNL)BULK EXPLOSIVES
AN LIQUOR
C.N.LIQUOR
WATER
STABILISER
GASSING
AGENT
PREPARATION
SODIUM NITRITE WATER
OXIDISER
SOLUTION
PREPARATION
FUEL BLEND
PREPARATION
DIESEL OIL
SURFACTANT
EMULSIFICATION
(CONTINUOUS MIXER)
MATRIX
STORAGE
TANK
BULK DELIVERY SYSTEM
EMULSION
MATRIX
GA
SOLUTION
MIXER
GAINJECTION
STATICMIXER
TO BORE HOLE
CHARGING
HOSE REEL
Fig 4; Showing the schematic diagram of Bulk operation process flow. Adapted From Google

NIGACHEM NIGERIA LIMITED (NNL)BLASTING PROCEDURES
I: Drilling of the Blasthole:
II: Priming:
III: Gassing: This is done to determine the reaction/ explosives/ know the primary features it will display in the
field. Components of gassing includes; Formaldehyde, Water, Sodium nitrate. We get coated A.N (200g), Bulk
Emulsion (1000ml), Formaldehyde(5% – 8%). We stir it put it into a beaker, tap it properly and cut with the
spatula, leave for 30 minutes and weigh it. The bubbles coming out is a proof of the gassing process taken place.
Fig 5; Showing the gassing process during an Bulk operation process flow. Adapted From Lafarge Field Ops
IV: Steming:
V: Addition of Cast Boasters:
V: Connecting of the Cables to the Geophones
VI: Pattern of Blasting
VII: Shooting.

A: Tool box meeting on risk analysis of the job with the need for proper PPE checks.
B: Drilling of 20 ft depth hole at equal series of 17m to 25m apart.
C: Placing of the detonating cords at each line according to the field engineer’s specification.
D: Assembling of the geophones.
E: Connecting the detonating cords and explosives properly.
F: Priming of the explosives to the detonating cords and placing them into the holes of 20ft
G: Positioning of the Mobile Manufacturing Unit (MMU)Truck
H: Get a cup and put a little quantity then measure and weigh after 30mins; measure the increased length and
weight from the gassing process
I: Releasing the hose from the truck and doing a first flushing away from the pit.

J: Proceed to the first hole and aim the nose and charge them serially.
K: Charging each hole with 35kg of Bulk Emulsion matrix by the operator (Based on the specification)/
L: Stem properly to make sure it gets to the base.
M: Allow them to gas for 30 mins to determine the actual length and weight due to the oxidizers such as NO2,
ANFO’s reacting with Oxidized blend releasing H2.
N: Stem again to make sure the bulk matrix is down the hole without pulling the detonating cords or shock
tubes into the hole and leave room for good delay time so as to have an excellent blast.
O: Apply the sand dug to refill the hole leaving the cables for proper connection.
P: Interconnect the cables either serially or parallel to the cast boasters and connect the geophones to the
blasting machine cables of 500m distance from the blasting site. It could be electrical to electrical or non-
electrical (Rubber or plastic) to electrical material.
Q: Make sure that the environment is clear before proceeding to blast at the specific time.

Ignition
Source
Localised
Initiation and
Decomposition
Energy Transfer
to Explosive
Propagation of
Decomposition
Mass
Decomposition
Primary
NG
Emulsion
Instantaneous
Microseconds to Minutes
15 – 30 Minutes
P-1 P-2 P-3 P-4
P-5
P-6
P-7
Fig 6; Showing the blasting stages. Adapted From Google

THE ADMINISTRATIVE DEPARTMENT (NNL)
OPERATION OF THE WEIGHBRIGDE
This deals with the continuous weighing in and out of a truck to get the initial weight, gross weight and net
weight so as to determine the actual measurement of the product contained in the truck. The type of
weighbridge we use here is called PIT TYPE TRUCK SCALE where the Ross sensors are buried on the
ground. The Procedures involved in the weighing of a truck are
A) Safety Inspection Checklist: This is used to determine if the vehicle is safe to be allowed to
carry the load(Product).

B) Booting of the Weighbridge Software: We first switch on the power supply switch, proceed to the
Universal Power System (UPS), click on the Central Processing Unit (CPU) and finally click on the
Monitor Power bottom.
C) Initiating and proceeding to the user unit for weighing: We click F1 – Put in the Username and
Password – Click on the Option stating User – Slot in the Vehicle Number – Click on the Start
Measurement – Making sure that the vehicle is properly placed on the weigh scale – Click on
Record Measurement, (Initial weight)
D) Putting In Various Parameters: Click on the Client, Haulier, Product, destination, Weigh Delivery
Number and install the information gotten from the magazine number.
E) Final Weighing: This comprises of the Gross and Net Weigh to give the actual measurement of the
product. We then proceed to printing, signing of the three parties (Driver, Operator and
Authorization Signatories) before the driver can be issued a gate pass.

NIGACHEM NIGERIA LIMITED (NNL)COMPONENTS OF A WEIGHBRIGDE
Fig 7; Showing the components of weighbridge. Adapted From Google

MAINTENANCE DEPARTMENT
THE BOILER UNIT OPERATION PROCEDURE
Fig. 8: Showing the components of a Boiler for a chemical plant

Daily Operation Of The Boiler
The boiler is a steaming electromagnetic machine which generate steams from hot water to the production
plant. This type of boiler is designed basically for chemical production purposes and it aids as the major
Oxidizing Blend component in the O.B area.
Procedures Include;
1: Check the diesel ~ put on the heater=(Thermostatic and Strainer)~ blower (blows the air) ~ oil pump ~ 2
nozzles ~ combustion chamber/ firing side=( Atomizer and Boiler control panel) ~ breaker devices puts on
the component ~electrical circuit ~ contactor ~ water level gauge.
2: Put on the water and allow to pump in ~ manual pumping is ½ of the water gauge ~ Press reset button ~
Pick the blower..
3: To start production, turn the plug anticlockwise direction.
Mechanism of the firing Chamber
Atomizer aids to fire the fuel in the firing chamber. We horsts which are +ve and –ve electrode. They’re
two of them. It has a small opening at the base which releases oil into the fire chamber; as the oil gets into
the two electrodes strikes igniting a spark in the fire chamber.

Reverse Osmosis Plant (RO Plant)
The RO Plant is a water treatment plant that takes care of the cation and anions which causes water. A boiler
needs a treated water to work effectively to have a pH which is the alkaline medium to avid scaling of the
cube. This could reduce the efficiency of the machine to avoid 15m explosion.
Regeneration is the process of mixing common salt solution that takes place of the softening to reduce the
cation and anion. Regeneration is done in the softener.
At every 20 minutes, we add common salt (NaCl) solution and the rinse it.
Fudge Point:
This is the point at which a solvent begins to crystallizes or solidifies due to temperature change of the
medium; examples are Oxidized blend, Paraffin wax, etc.
Spat Test: This has to do with the analysis of anions and cations to determine their properties.

THE MAGAZINEDEPARTMENT (NNL)
This is a standard storage platform for the storing of explosives, seismic explosives (S. P 90 90mm, S. P 90 32mm,
S.P 80 90mm, S. P 80 70mm, Solarprime-E 70mm, Solargel-E 125mm, S. P Seismic 63* 400gms, etc), accessories
which includes (Detonating Cords, Combidants, Nonels, Shock Tubes, Electric Detonators, Copper Connecting
wire (CCW), etc.)
The Standard safety measures taken includes; Heap, Fire extinguisher, Water bucket. Also, the temperature is
recorded at least three times a day. Also no electrical gadgets or lightening system should be permitted.
Fig. 9: Showing a Standard magazine

NIGACHEM NIGERIA LIMITED (NNL)Products that can be found in the magazine includes:
Fig. 10: Showing a the various accessories and explosives stored in the magazine. Adopted from Google

AUDITING
This is referred to the inspection of finance, quality management, environmental management, safety management. It involves
documentation with identification numbers, procedure and it’s requirement for standard objectives varies from department to
department.
The aim of the audit is to check if conditions are put in place according to ISO 9001, 2015 version. Audit could be periodically,
monthly, quarterly, yearly to show our compliance to the standard like updating our records, weekly, monthly, quarterly, etc.
 Quality Management System ISO 9001: 2015 (QMS) Version: Is a standard operating system that set a pace on how the
company should be operated by maintaining the standard objectives of each process checks, customers’ satisfaction, welfare
package of staffs, safety compliance.
 Non Conformance Report: This is issued to a department or client if he fails to comply to the QMS standards, he is to state
his reason and also futuristic measure on how to avoid such failure from happening in the future.
Risk is involved when it comes to Health Safety and Environment System ISO 18001.
 Key Performance Index, (KPI): This deals with how effective the performance of a staff to the standards on a day to day
activities. It broadens on the staffs contribution to work, regulations, objectives and output he brings out from job task. It can be a
key note for the increment of staff’s salary. KPI varies from Grade A- E (Grade A=90-100%, Grade B= 80-89%, Grade C=
70=79%, Grade D= 60-69%, Grade E= 59%-Below).

SUMMARY
From the first safety factory induction till the magazine department. I have been able to have a first hand
exposure to the operations of a factory, understand the objectives involved I Customer Persuasiveness,
Documentations, Blasting Operations, Weigh Bridge Operations, Boiler Room, Operations at the Production
Plants, Creeping Plants, Idea on Auditing, QAQC procedures, Safety Inspection, Geological Field
Experiences and measures applied in the case of fire incident, Accounting procedures in the execution of
Excel Sheets, Cultural Variations and Work Ethics while working among men.
The overall experience has been a basket of many tales, filled with so much educative, moral development
intrapersonal and interpersonal skill acquisition both in the office and field.

NNL factory tour

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