UGANDA TECHNICAL COLLEGE LIRA

FABRICATION OF A CHOPPING MACHINE.

BY
LUKAAYI SHAFICK
REG: UBT005/2023/T/D/A/0252
DEPARTMENT OF MECHANICAL ENGINEERING

PROJECT SUPERIVSOR:
ANGENY MOSES
+256702375244
DEPARTMENT OF MECHANICAL ENGINEERING
UGANDA COLLEGE LIRA
APRIL 2024

THE REAL PROJECT REPORT SUBMITTED TO UGANDA BUSINESS AND TECHNICAL

EXAMINATION BORAD IN PARTIAL FULLFILMENT OF THE REQUIREMENT FOR THE
AWARD OF NATIONAL DIPLOMA IN MECHANICAL ENGINEERING.

pg. 1
Table of contents

Table of contents..............................................................................................................................2
Tables...........................................................................................................................................3
Table of figures............................................................................................................................4
APPROVAL BY PROJECT SUPERVISOR....................................................................................5
DECLEARATION...........................................................................................................................6
DEDICATION.................................................................................................................................7
ABSTRACT....................................................................................................................................8
ACKNOWLEDGMENT.................................................................................................................9
CHAPTER ONE:...........................................................................................................................10
1.0 INTRODUCTION............................................................................................................10
1.1 Background......................................................................................................................10
1.2 Objectives of the project...................................................................................................10
1.3 Justification for the project...............................................................................................10
1.4 Purpose of the project.......................................................................................................10
1.5 Significant of the projects.................................................................................................10
1.6 Limitation.........................................................................................................................10
1.7 Delimitation......................................................................................................................10
CHAPTER TWO:..........................................................................................................................12
Literature Review.......................................................................................................................12
2.1 Types of Biomasses..........................................................................................................12
2.2 Processing methods of Biomass.......................................................................................13
2.3 Types of machines............................................................................................................14
CHAPETER THREE:....................................................................................................................15
3.0 METHODOLOGY...........................................................................................................15
3.1 Introduction......................................................................................................................15
3.2Table 1 Tools and Equipment used....................................................................................15
3.3 Selection of the project.....................................................................................................16
3.4 Chopper production..........................................................................................................16
CHAPETER FOUR:......................................................................................................................16

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4.0 STAGES/STEP FOLLOWED DURING THE WORK PRODUCTION................................16
4.1 Stage 1: Measuring and cutting........................................................................................16
4.2 Stage 2 Welding................................................................................................................16
4.3 Stage 3 Grinding...............................................................................................................16
4.4 Stage 4 painting................................................................................................................16
CHAPTER FIVE...........................................................................................................................18
5.1 CHALLENGES FACED DURING THE PROJECT.......................................................18
5.2 CONCLUSION................................................................................................................18
5.3 RECOMMENDATION...........................................................................................................18
APPENDICIES..............................................................................................................................19
BILL OF QUANTITIES........................................................................................................19

Tables
Table 1 Bill of Quantities...............................................................................................................18

pg. 3
Table of figures
Figure 1 cutting of angle bars using the hand grinder...................................................................19
Figure 2 Cutting the disc plates using oxy-acetelene gas..............................................................19
Figure 3 welding parts together using arc welding........................................................................20
Figure 4 measuring and marking out of the diameters of the platess............................................21
Figure 5 Design of the system.......................................................................................................22

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APPROVAL BY PROJECT SUPERVISOR
I so attest that LUKAAYI SHAFICK has followed Uganda Technical College’s
rules and regulations in writing this project report.

Date

……………………………………………..

Signature

……………………...................................

pg. 5
DECLEARATION
To the best of my knowledge, I, LUKAAYI SHAFICK declare that this project
report has not been submitted by anyone else or presented for any academic award.
As such, I attest to its authenticity and originally as being my own, and where
appreciate credit has been given, it has been done so by referencing other people’s
ideas or work that is relevant to the project.

Date

……………………………………………..

Signature

………………………………………………

pg. 6
pg. 7
DEDICATION
This project is been dedicated to the lecturer of UGANDA TECHINICAL
COLLEGE LIRA and special dedication goes to my friends whom we cooperate
with them to make work goes smoothly.

My dedication also goes to my father MR SSERUWO BADRU and my brother

KIBUUKA MOHAMAD who works so hard to see me in school.

Another dedication goes to the administration of UTC LIRA for giving us enough
materials and tools which make our work to go on well.

May the almighty father bless you all AMEN.

Date

……………………………….

Signature

………………………………...

pg. 8
ABSTRACT
UGANDA TECHNICAL COLLEGE LIRA is equipped with a lot of plant biomass
in its compound and the mechanical students were tasked to design a machine that
can help in size reduction and easily process the biomass. The machine was tested
and proved to work efficiently in size reduction of the plant biomass and the
necessary recommendations suggested as well.

pg. 9
ACKNOWLEDGMENT
I would like to express my sincere gratitude to my supervisor, Angeny Moses, for
his guidance, support, and encouragement throughout my research project. I would
like to acknowledge my workshop technician Moses for his valuable feedback and
constructive criticism have been instrumental in shaping my production and
writing skills. I would also like to thank my colleagues, Reagan and Enock, to
mention but a few for their insightful comments, suggestions and input that helped
me improve the quality of my work and facilitate my learning process as well. I am
also grateful to [Name 4], [Name 5], and [Name 6] for their assistance in welding
and the fabrication process. I would like to extend my appreciation to my family
and friends for their unwavering support and encouragement. Finally, I would like
to thank the college, for making this project happen.

pg. 10
CHAPTER ONE:

1.0 INTRODUCTION

1.1 Background
This project of fabrication of a chopper machine was carried out at UTC LIRA
located in the heart lira city, Northern Uganda. Estimated about one kilometre
away from lira – Soroti high way. The project was chosen because there was agent
need for chopper machine for chopping the raw material in to small pieces that is
use for making biomass. The institution compound is located within estimate of 25
acres and it trained national diploma student, drawn from various background.

1.2 Objectives of the project

The project aims at the following objectives:

 To examine the possibility of transferring welding and fabrication from

theory to particle.
 To create confidence and equip students with knowledge in carrying out
welding and fabrication.
 To produce the chopper machine for the institution

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  To fulfil the personal requirement for the award of national diploma in
mechanical
Engineering.

1.3 Justification for the project

It is true, since the institution needed chopping machine, it was justifiable to carry
this project of fabrication of this chopping machine. Also the project was an
important tool in the development of skills of the students who were tasked in
undertaking it. Such skills like welding and fabrication are vital to uplifting the
production technology of the student.

1.4 Purpose of the project

The team intended to fabricate chopper machine that will help in size reduction of
material use for making biomass hence saving expense of hiring and buying.

1.5 Significant of the projects

 The institution infrastructure will improve on reference by the continuing student in
department of mechanical.
 Due to rapid need of fuel in UTC LIRA, there was need for copping machine

1.6 Limitation
The following were some of the limitation
 Lack of workshop facilities
 High cost of material
 The period was not enough

1.7 Delimitation
 There was close supervision and guidance by the supervisor
 There was financial assistance from the institution
 Cooperation and team work exhibited by the designer.

pg. 12
CHAPTER TWO:
Literature Review
What is Biomass? In ecological terms, biomass refers to any type of organic
matter. When it comes to energy, biomass is any organic matter that can be used to
generate energy, for example wood, forest residues or plant materials. (Drax, 2020)
Biomass refers to organic materials derived from plants and animals. It serves as a
renewable energy source, harnessing energy from the sun.

A plant farm includes Crop farming. Crop farming is the production of crops on a
large scale. Crops are typically planted in rows and are harvested using machines.
(Pasture.io, 2022) when harvested, only a small portion of the crop is taken out and
the rest is waste. A plant farm like any other farm, is going to produce waste, this
waste can be categorised as Biomass waste.

Plant biomass (W) is the weight of living plant material contained above and below
a unit of ground surface area at a given point in time. (M.J. ROBERTS, 1985,) The
effects of plant farm biomass waste can be both positive and negative depending
on how it is treated.

Carbon-enriched crop biomass becomes the primary food source for soil
microorganisms and fauna and as a result ‘nurtures’ nutrient cycling. (Maneesha
Mall, 2021) in other extreme cases, the amount of biomass wastes is rapidly
increasing, which leads to numerous disposal problems and governance issues.
(Zhou, 2020)
2.1 Types of Biomasses
Landfill Gas. Even in the airtight conditions of landfills, bacteria work to break
down our trash. This decomposition produces landfill gas, which primarily consists
of methane and carbon dioxide. Capturing and utilizing this gas can help generate
energy1.

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Solid Waste. Solid waste, such as municipal waste, agricultural residues, and
forestry by-products, can be converted into energy. By incinerating or processing
these materials, we can produce heat, electricity, or biofuels.
Wood and Agricultural Biomass. Wood debris, crop residues, and managed forests
are examples of this type of biomass. They can be used for various purposes:
Biofuels. Biomass can be transformed into liquid fuels for transportation, including
road vehicles and airplanes.
Bio power. Biomass serves as a reliable source of electricity and heating. It can be
burned directly or converted via bacterial decay to create a substitute for natural
gas.
Bio products. Bio refineries can produce bio products alongside biofuels. These
products can replace items made from fossil fuels, such as plastics, industrial
chemicals, and lubricants1.
Alcohol Fuels. Alcohol fuels, such as ethanol and methanol, can be derived from
biomass. These fuels are used in transportation, industrial processes, and as
additives to gasoline.
(Marlene, 2021)
2.2 Processing methods of Biomass
In order to use biomass as a valuable resource that it is, it has to be converted first
into various forms of energy. The different methods and technologies for doing this
are highlighted below.
Thermochemical Conversion. In this method, biomass is heated in the absence of
oxygen to produce energy-rich products. Key thermochemical processes include:
Pyrolysis. Biomass is rapidly heated to break down its components into bio char,
gases, and oils.
Gasification. Biomass reacts with steam or air to produce syngas (a mixture of
carbon monoxide and hydrogen).
Combustion. Biomass is burned directly to generate heat or electricity.
Biological Conversion. Biological processes involve microorganisms or enzymes
to break down biomass. Examples include;

pg. 14
Anaerobic Digestion. Bacteria break down organic matter in the absence of
oxygen, producing methane-rich biogas.
Fermentation. Sugars from biomass are converted into alcohols (e.g., ethanol) by
yeast or bacteria.
Physical Conversion. These methods alter the physical properties of biomass
without chemical changes. Examples include;
Densification. Biomass is compressed into pellets or briquettes for easier handling
and transport.
Size Reduction. Chipping, grinding, or shredding biomass to smaller particles.
Biochemical Conversion. Enzymes or microorganisms are used to convert biomass
into biofuels or other valuable products. Examples include;
Bioethanol Production. Fermentation of sugars (e.g., from corn or sugarcane) to
produce ethanol.
Biodiesel Production. Trans esterification of vegetable oils or animal fats to create
biodiesel.
(Azwifunimunwe Tshikovhi, 2023)

pg. 15
2.3 Types of machines
During the processing of biomass, various machines play crucial roles in different
stages of the conversion process. In this section, types of machines used in biomass
processing are described.
Chippers. Chippers are used for feedstock preparation. They break down large
pieces of biomass (such as logs, branches, or wood waste) into smaller chips or
chunks. These smaller pieces are easier to handle and process.
Grinders. Grinders further reduce the size of biomass materials. They can turn
wood chips, straw, or other feedstock into finer particles. These smaller particles
are suitable for subsequent conversion processes.
Boilers. Biomass boilers are essential for direct combustion. They burn biomass
directly to produce heat or steam. This heat can be used for industrial processes,
district heating, or electricity generation.
Reactors. Reactors are used in various biomass conversion technologies:
Anaerobic Digestion Reactors. These facilitate the breakdown of organic matter by
bacteria, producing methane-rich biogas.
Pyrolysis Reactors. In pyrolysis, biomass is heated in the absence of oxygen to
produce bio char, gases, and oils.
Gasification Reactors. Biomass reacts with steam or air to create syngas (carbon
monoxide and hydrogen).
Crushers. Crushers are employed to break down large biomass materials into
smaller particles. They are commonly used in processes like biochemical
conversion (e.g., ethanol production).
(Eubia, n.d.)

pg. 16
CHAPETER THREE:
3.0 METHODOLOGY

3.1 Introduction
This section describes and shows the methods, techniques and tools that
were used to achieve the specific objectives of the project. Method involve,
selecting of project, designed, safety precaution observed during welding
and grinding.
3.2Table 1 Tools and Equipment used
Tools
 Hack saw
 Try square
 Scriber
 Files
 Bend vices
 Tape measure
 Hammer
 Chisel
 G-clamp
 Vernier calliper
 Vernier height gauge
 Surface plate
 Centre punch
 Painting brush
 Angle plate

Equipment

 Bending machines
 Angle grinder
 Electric Shear cutting machines

pg. 17
  Notching machine
 Electric arc welding machine
 Lathe machine
 Oxy-acetylene gas
 Pillar drilling machine

3.3 Selection of the project

This was based on the on the availability of the resources, time and financial
position of the institution due to shortage of the fuel within the institution
hence need for biogas to support the kitchen.
3.4 Chopper production
In the production of chopper machine, the fundamental principle of metal
work was followed to obtain satisfactory especially by the use of welding,
planning, time tabling, and painting among others:
 Safety precaution and sequence of operation
 Stage and safety precaution
 The teams observed the precaution and stage followed during the
work.

CHAPETER FOUR:

4.0 STAGES/STEP FOLLOWED DURING THE WORK PRODUCTION

4.1 Stage 1: Measuring and cutting
 Measurement and cutting were taken from work plan to workshop on the
open space where the cutting blade can be fitted.
 Measuring and cutting into desired size.
 Joining of different parts of metal by use of spot welding and full welding
after.

4.2 Stage 2 Welding

 The different pieces of work were welded together to produce a required
shape and size.

pg. 18
  Welding goggle was used to prevent eyes from ultraviolent ray.
 Strong insulated shoes were used to protect foots from falling objects.
 Flammable materials such as paper, clothes, were taken away to prevent fire
accident in the workshop.

4.3 Stage 3 Grinding

 After welding (joining) each part together, grinding was done to enable work
piece for easy painting and the following precaution were observed.
 The work piece and grinding disc were held firmly.
 The flying chips were away from the worker material and mate.

4.4 Stage 4 painting

During this stage, we observe the following:
 The team used first under coat to pain the work piece.
 The work piece was left for 4 hours to dry.
 Finally, the oil paint was applied as then second coat.

pg. 19
CHAPTER FIVE

5.1 CHALLENGES FACED DURING THE PROJECT

 Power black out

 Inadequate number of tools
 Delay in the material supply by the school
 Time frame was too short
 Inappropriate personal protective equipment (PPE)

5.2 CONCLUSION

Despite the fact that there were some problems encountered, the project for fabricating was
achieved.
The project was a good learning experience for all the students

5.3 RECOMMENDATION.
During our time in the workshop, we noticed a few things that the college can do better in order
to improve on the future projects it aims to take on.
Adjust on the fabrication equipment.
The number and quality of the welding equipment and gear needs to be adjusted in order to
improve efficiency and capacity.
Proper planning for materials.
Materials should be delivered in time in order to eliminate rush and haste while working on the
projects to beat deadline.
Proper Supply of PPE
Students should be supplied with adequate PPE and in time. This applies as well to welding
shields and gloves which were not available.

pg. 20
APPENDICIES

BILL OF QUANTITIES

Table 1 Bill of Quantities

SN Dimension Quantity Rate Amount

Mild steel plate 1230x2x2440mm 01 120,000 120,000
Angle bar 40x40mm 01 30,000 30,000
Bearing(FK) UCP 208-24 02 25,000 50,000
Grinding disc 115X6X22.23mm 01 11,000 11,000
Welding rod E6013 1 box 30,000 30,000
Bolts and nuts  M12x1.5x55mm 04 2000 8000
 M8x1.25x150mm 08 1500 12000
Cutting disc 230x3x22.23mm 02 10,000 20,000
Mild steel shaft 38x540mm 01 50,000 50,000
PAINT  Undercoat 1 tin (500ml) 6000 6000
 Finally coat 1 tin (500ml) 6000 6000
MILD STEEL 1230x6x2440mm 01 390,000 390,000
PLATE
PULLEY 180x640x38mm 01 3,0000 30,000
Hacksaw blade 02 3000 6000
PARAFINE 500ml 2000 2000
Hollow section 40x20x1.5mm 01 25,000 25000
Angle bar 35x35mm 01 45,000 45000
Painting brush 01 3000 3000
Total 844,000

pg. 21
Figure 1 cutting of angle bar using the hand grinder

Figure 2 Cutting of disc plates using oxy-acetylene gas

pg. 22
Figugure 3 welding parts together using arc welding

Figure 5 measuring and marking out of the diameters of the plate

pg. 23
Figure 1 Design of the system

pg. 24
pg. 25