Arrived in Dakar Early on the Morning and Met with Mr. Joohyun Kim and Mr. Je-Min Lee

Wednesday September 17, 2008

Arrived in Dakar early on the morning and met with Mr. Joohyun Kim and Mr. Je-Min Lee. I rested and traveled to plastic manufacturer to examine possible receptacles for the finished filters. Heidi Kilsby accompanied me from Quesnel, BC. She has volunteered her time to assist with the project set up.

Thursday September 18th, 2008

In the morning we met with KOICA project coordinator at his office and Mr. Kim and I signed the official contract papers. Met Mr. Chou the Korean ambassador to Senegal introduced the project and share lunch together.

In the afternoon Mr. Joohyun Kim and Mr. Je- Min Lee and I traveled to a hardware store and a machine shop to search for project materials. We purchased a hydraulic jack and looked at parts for the propane burner system. We must still purchase plastic bags. Mr. Kim has arranged for steel to be purchased in Ourossogui for the steel plates, and Mr. Lee has arranged for transport of the brick from the brickyards outside of Dakar to Ourossogui.

While we are in Dakar the workers in Ourossogui are organizing the workshop, drying clay and preparing sawdust.

Still to organize-

drill bit for spigots-
plastic water pipe for flow testing
Screens
Plastic garbage bags
Digital scale 0-5kg
0-20 kg balance scale
Water pipe for flow tester
propane tanks
burners hose and regulators
brushes

Friday, September 19, 2008

In the morning we Je-Min and Joohyun and I went to the Sandaga market place and purchased most of the materials in the list

Including 6 propane tanks to transport to Matam on Saturday. The truck will be pretty full because we are also taking food because some things are difficult to find in the area.

We were able to find plastic bags- although a little larger then we need. Scales- both digital and a spring were also found first thing. I am concerned about the supply of propane gas in the area- We may need to replenish gas to advance the temperature. To insure that this would not be a problem we chose to purchase 6 tanks. There still may be a problem with pressure drop if gas is withdrawn to quickly from the tanks during the firing. We may have to warm the tanks while we are firing.

Saturday- September 20th 2008

Traveled to Matam all night-

Sunday September 21st, 2008.

Woke up after a couple of hours sleep and went to the new KOICA ceramic filter workshop to briefly look at the workshop to meet with the workers see what had been prepared.

There is only about 5 X 25kg of clay crushed and screened. Evidently went the workers attempted to mill the clay it was too damp. There is some sawdust but none of it has been screened.

Monday September 22, 2008

Went from Matam to Ourossogui to with Je-Min and Joohyun Lee to prepare materials for the filters. In the morning we met with the mason and scheduled his work to begin the kiln. We planned the construction on the kiln roof. We assembled the filter press and aligned it.
I looked at the clay and made a shrinkage test then examined the clay’s plasticity and found it to be very plastic.

In the afternoon we traveled with the water district truck and dug and transported clay to the filter project HQ from the village of Oggo. Joohyun contracted for more clay to be transported by donkey cart from the village. The clay that we dug was put outside to dry. Clay that was already in the sun was sacked and transported to the neighboring mechanics shop to be run through the hammer mill. Arranged to make base plates for the filters.

Tuesday, September 23, 2008

Heidi Kilsby worked with the women potters screening sawdust. (Found a hedgehog underneath the sacks)

Worked with the neighboring mechanics shop. The mechanic welded legs on the ejection rod and made some filter base plates. The hammer mill screen was too small (.9mm). We had a screen with 1.5mm holes put on the hammer mill and set some of the water district workers to mill clay. I think that the screen may still be too small but the clay that is now dry seems to go through. The hammer mill is a fixed hammer design and not quite as noisy as

Flail types.

The first clay was transported by cart and put out to dry,

We prepared a first mix to test the press and realized that the hydraulic jack that had been purchased was too tall for the press. In the afternoon we attempted to find a smaller 20-ton jack but in the end it was easier to purchase a 6-ton and then exchange it with the larger 20-ton to complete each filter. We pressed a filter successfully. Our plan is to now prepare the first batch of filters in the series- this will be the 50/50 mix.

50/50 clay-sawdust by volume equates to- 85.6% clay 14.4% sawdust by weight. This 50/50 mix was given the mark- #1 in iron oxide

Single Filter sample is:

Clay 5992 gr85.6%

Sawdust 1008 gr14.4%

Total7000 gr100%

Water 2500 gr.

This mix was somewhat wet-

We evaluated the cost of the clay based on 160 sacks which will be delivered to the workshop at a cost of 70,000 cfa/$152 – Per sack= 438cfa/. 95cents

Wednesday September 24th, 2008

In the morning I conducted instruction in the mixing and pressing of filters with the team. The team included our two women potters from the village of Ogo.

I taught the two women first and with the help of Je-Min, Joohyun and Heidi we made sure that the women had the first chance to learn the process. Only then did we start the training with the men from the Department of hydrology who are in the filter team.

We formed a total of 15 Mix #1 Filters mostly from 2-6pm.

In the night a torrential thunderstorm came through the area and poured rain. This was unfortunate as most of the clay was outside drying at the time. We also lost clay that had been hammer milled and not covered.

Thursday September 25, 2008

Brought the computer into the workshop and met with the mason to begin on the kiln. I guided him through the construction process step by step until he felt confident.

Heidi Kilsby and Je-Min worked with the filter crew making the next mix- ( #2)

They were able to form the full 15 mixes over the course of the day.

KOICA Filter Batch Series Tests

Mix#1-

Clay 5992 gr85.6%

Sawdust 1008 gr14.4%

Total7000 gr100%

Water 2500 gr.

Mix #2

Mix#2- (Represents 20% more sawdust in comparison with mix #1)

Clay 5790 gr82.7%

Sawdust 1210 gr17.3%

Total7000 gr100%

Water 2500 gr.

Mix#3-80 % Clay

Clay 5600 gr80%

Sawdust 1400 gr20%

Total7000 gr100%

Water 2500 gr.

Mix#4-77.5% Clay

Clay 5425 gr77.5%

Sawdust 1575 gr22.5%

Total7000 gr100%

Water 2500 gr.

Mix#5-75% Clay

Clay 5250 gr77.5%

Sawdust 1750 gr22.5%

Total7000 gr100%

Water 2500 gr

Mix#6-72.5% Clay

Clay 5075 gr77.5%

Sawdust 1925 gr22.5%

Total7000 gr100%

Water 2500 gr

In the afternoon we worked to develop a system to quickly prepare mortar for building the kiln using what clay we have as we don t want to use hammer milled dry clay as it is scarce. We prepared some mortar using a drill with an agitator but the clay was difficult to blend into a mortar. We worked with the mason and lined out the base of the kiln and then set the base bricks in place.

We will need to organize a way to burn waste oil and we will need some wood.

Friday September 26, 2008

This morning I was working with the mason on the kiln fireboxes. We had hydrology workshop workers working with the Je-Min and Heidi Kilsby forming filters. I went to make a brick chisel with the neighboring welder.

In forming one of the filters the male mold caved in at the base. When I looked at the casting it appeared to be turned out too thin but the mix was also quite dry.

We spent most of the rest of the day trying to figure out how to repair the mold and in the end we were introduced to a master welder machinist who just happened to have experience with aluminum. He also had aluminum welding rod. He re welded and then resurfaced the mold. We then cast two inches of cement in the bottom of the mold. Tomorrow we will have the mechanic cut a steel disc to insert in the base weld a 5 cm diameter pipe up right on top and them another larger plate at the top of the mold. This will be a kind of interior support for the mold, which we hope will prevent it from collapsing again.

Saturday September 27th 2008

We spent much of the day repairing the mold. We were able to cast cement in the male mold base and then Joohyun worked with the neighboring mechanic and welded up a brace and installed it inside the mold and we then bolted to the press. We then cast 6 filters and compared them to the filters before the mold broke and found that they were the same. I bought a radio for the workers at the site.

At the same time I worked with the mason and he completed the base of the kiln. We received all the remaining brick from Dakar, so we are ready to work on the kiln and the press on Monday.

Sunday September 28th – Wednesday October 1st

We had to take a day off for Korite but then we have continued to mill clay, make filters and work on the kiln at the same time.

Thursday October 2, 2008

Transportation from Matam to Ourossogui has been a struggle. We had a visit from Mr. Cheng from Dakar, the Coordinator of KOICA programmes. I explained our need to have consistent transportation for the advancement of the project during this last eight days of my stay in the area. I am hoping to have the kiln fire twice but I will settle for once.

Today we are now nearly at the top of the wall of the kiln and have started to put together the wood mold for the arch. Today is the second day of the fete of Korite and we are lucky enough to have KOICA volunteers who are pitching in to make up for the lack of Senegalese workers.

We have completed forming filters for the batch series test and they are now drying. We will push dry some of the last formed. Now everybody will concentrate on getting the kiln completed.

Tomorrow we will weld nuts on the steel corner pieces and make up the rebar rods with bolts on the ends.
We must make scaffolding
We will put up the kiln arch form-
We need to organize a method of burning waste oil for the first firing-

Friday, October 03, 2008

Today we put steel bracing on the kiln. Shek , the blacksmith made two waste oil ladder type burners for the kiln. The wall of the kiln was completed- steel angle iron was placed at the top of the kiln wall. The wood mold for the arch was placed and braced in the kiln.

Tomorrow we must

set the springer coarse at the base of the kiln and lay the arch.
Arrange scaffolding for the kiln and the chimney
Finish the chimney
Begin warming the kiln

Saturday, October 5, 2008

We worked much of the day and formed the kilns arched roof. All that remains is a meter of chimney. There are not many small bricks remaining.

Sunday, October 05, 2008

Today we removed the wooden kiln arch form and chinked the inside of the kiln with mortar and small brick pieces. Mr. Sou the mason finished the chimney, which is a little less than 4 meters. We immediately bricked up the front of the kiln and began a wood fire in both fireboxes. We heated the kiln from early afternoon until 8 pm.

Monday October 6th 2008

We spent the morning organizing filters and drying them outside. We then opened the kiln and I looked at the inside of the kiln, which appeared dry enough to begin stacking the filters for firing. I showed how to stack filters using a soft clay balls. We made up Pyrometric cone packs using Cones 012, 011, 010 and 09. After stacking the filters we put in both Pyrometric cones and draw trials, we also installed the thermocouples for the digital pyrometer. We closed the door of the kiln with loose brick and sealed it with mortar.

The hydrology office members helped to clean and organize the warehouse. They then worked with a plumber to install a water tank and a tank for waste oil. We have dry wood, waste oil, propane and even some rice husk. Joohyun was able to go to town and purchase a small barrel pump. Everything is in place to start the firing except a hose to run the waste oil up to the storage tank. Heidi Kilsby agreed to start the firing in the morning around 6:30.

Tuesday October 7, 2008

Fired the kiln for a batch series filter firing

Pyrometric small Cones 012- 900 C.melted

Cones 011- 915 C.melted

Cones 010- 919 C.

Cones 09- 955 C.

Firing Schedule

Hour / Time / Target temperature (Celcius) / Actual top reading / bottom reading
30minutes / 7:15am / 32.5
1hr / 7:45am / 75 / 46
1hr 30 minutes / 8:15am / 112.5
2hr / 8:45am / 150 / 151 / 70.5
2hr 30 minutes / 9:15am / 187.5 / 187
3 hr / 9:45am / 225 / 228
3hr 30 minutes / 10:15am / 262.5 / 277 / 160
4hr / 10:45am / 300 / 341 / 252
4 hr 30 minutes / 11:15am / 350 / 362 / 295
5hr / 11:45am / 400 / 392 / 315
5 hr 30 minutes / 12:15am / 450 / 473 / 350
6 hr / 12:45pm / 500 / 518 / 372
6 hr 30 minutes / 1:15pm / 550 / 550 / 406
7 hr / 1:45pm / 600 / 607 / 423
7 hr 30 minutes / 2:15pm / 650 / 663 / 473
8 hr / 2:45pm / 700 / 701 / 504
8hr 30 minutes / 3:15pm / 750 / 753 / 538
9 hr / 3:45pm / 800 / 793 / 583
9 hr30 minutes / 4:15pm / 850 / 867 / 615
10 hr / 4:45pm / 900 / 901 / Soaking
10hr 30 minutes / 5:15pm / 900 / Soaking
11hr / 5:45pm / 900 / Kiln off

Pyrometric cones distributed through the kiln were very even in the kiln.

Wednesday October 8th, 2008

Opened kiln- looked at the filters. Repacked with filters and started kiln warming.

Of 41 filters fired in the first firing:

15 filters cracked in firing

Of 26 filters which will be tested there are:

#1 filter-7

#2filter-5

#3 filter-6

#4filter-4

#5 filter-3

#6 filter-1

The filters could not be put into water for soaking because there was no water in Ourossogui.

Thursday October 9th, 2008

Kiln was fired a second time. The schedule was adhered to very closely

Je-Min Lee was the lead person firing the kiln with Amadou and Ibrahim.

At the end of the firing we tried out the waste oil system to see that it functioned

Correctly. Kiln finished about 6 pm. The workshop purchased water and filed up

The water tank and soaked all the filters for the flow tests.

Friday October 10, 2008

Flow test revealed that all the filters except a single #1 filter were too fast. It appears that there is either too much sawdust or there are cracks in the filters due probably too fast drying.

We also made a sieve/screening table.

Saturday October 11, 2008

We applied Colloidal Silver to two #1 Mix filters- and discussed the method for making the CS working solution.

After analyzing the flow rates we decided to make another mix (A below)

Saturday the workshop made Mix A.

Two of the #Mix 1 filters had a correct flow rate. One was dried in the sun and in the afternoon I taught the correct method of colloidal silver dip application.

We took most of the filters from the two firings and broke them to look for the presence of carbon in the wall. We found a number of the filters had carbon in the walls. The Pyrometric cones were evenly melted on both bottom and top of the kiln, but the pyrometer showed the lower part of the kiln was much cooler.

Increase the space between the filters when they are stacked in the kiln in order to allow heat to penetrate completely. Note that if you have filters that show carbon on them, they may be re fired to burn out the carbon.

In order to make the temperature more even from top to bottom I made the flue exit into the chimney smaller.

I suggested that the firing schedule should be changed so that kiln is held at the top temperature of 900 C for 75minutes instead of 45 minutes.

In order to arrive at a filter in the 1-2.5 liter per hour range it is necessary to produce another two mix proportions of filters along with the Mix #1

Mix#1-

Clay 5992 gr85.6%

Sawdust 1008 gr14.4%

Total7000 gr100%

Water 2500 gr.

Mix# A- (10 % less sawdust then mix #1)

Clay 6092.8 gr87%

Sawdust 907.2 gr 13%

Total7000 gr100%

Water 2500 gr.

Mix# B- (20 % less sawdust then mix #1)

Clay 6192.8 gr88.5%

Sawdust 807.2 gr 11.5%

Total7000 gr100%

Water 2500 gr.

Kadder Fall

Djby BaIbrahim Ba (le grande)

AhmadouShar, the older fellow

Ramata Lam, the elder potter

Oan Ji, the younger potter

Rugen Ji, the youngest potter

Saydu Ji, also known as Mandemba, the potter's son

Seku Sou, the Mason

Sheque, the handyman

Mandemba the watchman