FABRICATION OF A CERAMICWATER FILTER PRESS MACHINE
USING INDIGENOUS MATERIALS IN NIGERIA
PRESENTED BY:
AFAM AUGUSTINE OKWUDILI
DEPARTMENT OF ARTS AND INDUSTRIAL DESIGN
LAGOS STATE POLYTECHNIC IKORODU, LAGOS STATE
afampotman@gmail.com
08065184544
AND
SASA JOHN MOFOLORUNSHO
DEPARTMENT OF INDUSTRIAL DESIGN
KOGI STATE POLYTECHNIC, LOKOJA
sasajohn06@gmail.com
08054514004
Abstract
The easiest medium for diseases outbreak in any community is by air, land or water but water
seems vulnerable than the former. If the water the people drinks in a community is contaminated,
there could be serious epidermis outbreak of diseases like diarrheal and cholera. These diseases
are deadly but avoidable. The only solution is getting clean water for drinking, this can be achieved
by purifying water either through the methods of sedimentation, chlorination or filtration using
ceramic water filter. The formers except ceramic water filters are capital intensive which only
government or big organizations can embark on to save the general populace from bad water,
but the use ceramic water filter by individuals is get clean water. Ceramic water filter is produced
from mixture of the following materials refined clay powder dust, saw dust, grog well mixed with
water at adequate proportion through a water filter press machine which was made from
indigenous materials. The cost of getting an imported one is so expensive which of course
necessitated the desire to fabricate a low cost press machine using materials like used iron and
angle bars to construct it coupled with a motor jack and some non-metal materials to create the
mould. This will become cheap to assess by all classes of people in any society for health safety
and hygiene.
Keyword: Ceramics water filter, filter press, clay, sawdust.
INTRODUCTION:
Water occupies two-third of the earth and despite that, about 60% of the human population on
the earth surface especially people in the developing countries find it difficult to access pure or
portable drinking water. According to Late Fela Anikulapo, a Nigeria musician in one of his
songs said "soso water for African water everywhere for African, but ordinary water to drink nko
he know dey”. Meaning there are many water everywhere in Africa but there is no ordinary water
(good water) to drink. Getting drinkable water has been a challenge in the developing countries
of the world leading to a crisis situation in some areas in Nigeria. Michaelet. al (2013) opined
that ”the water crisis affects million worldwide and it is expected to worsen over coming years
and decades .It was estimated that in 2010, 1.8 billion people consumed water deemed unsafe
and 783 million regularly used water sources unprotected from contamination”.
The resulting effect of children using or drinking contaminated wearer is damaging to health
causing untimely death, blindness and other infections to children under age five and even adults
which were linked to cases of diarrhea and other diseases (World Health Organization [WHO], (
2014). The contaminations in water are caused by different factors such as poor infrastructure,
indiscriminate discharge of industrial waste, illegal mineral exploitation sand climate change.
The target set by WHO was that by 2030, there should be drinkable water in the world, readily
and easily accessible to all. However, with the high technological developments coupled with the
rapid geometric progression in population, the WHO goal looks like a mirage although, efforts
and machineries are geared up toward achieving the set goals through the collaboration with
World Bank, Non-Governmental Organizations’, governments to carry out projects like sinking
borehole in communities around the world and constructing water purification plant like the one
in Lokoja township which was a joint work between Kogi State Government and World Bank.
Yet, it could not still meet the demand of the people in Lokoja and same is applicable to some
towns and villages in Nigeria and other developing countries. These have caused hazards to
health and many avoidable deaths because of non-availability of drinkable water in most of the
developing countries of the world.
It is a challenge to know that the WHO set target goals to provide water for all by 2030 is like a
mirage having about eleven years away to the set period. Meanwhile, deaths have occurred by
lead poisoning, cholera outbreak, water blindness, typhoid and diarrhea. Nevertheless, to solve
the drinkable water problem suitable and affordable for all, the paper focuses on the development
and fabrication of a press machine to produce ceramics water filter using clay, grog and waste
(sawdust) mixed together and fired to 1000°C.
Water is one of the five elements of life. It is life itself because two-third of the weight of human
body is occupied by water. This suggests why human being is weakened with no strength or power
when one is hit with water borne or related diseases. Death may equally occur when there is no
immediate medical assistance. Drinking water is important for healthy living of man according to
Michael. et. al. (2013) W.H.O, says'95% of water borne diseases are gotten from drinking water'.
There are different methods of purifying water, the filtration method could not be 100% safe and
regarded as pure or drinkable water but water filtered through ceramics water filter is 99.99% safe
of drinking. The table below shows the various methods and the level of safety’s
TABLE 1
METHODS OF OBTAINING CLEAN DRINKING WATER IN
DEVELOPING COUNTRIES
Harmful Items Removed
Method
Cloth filtration
Particulates
x
Boiling
Bacteria
Protozoa
Viruses
x
x
x
x
x
x
x
x
inexpensive
x
Bore wells
x
Chlorination
x
Bottled Water
x
x
x
x
Ceramic filters
x
x
x
x
x
\ Source: International Journal for Service Learning in Engineering Vol. 8, spring 2013
x
The Nicaragua experience was a good example of a solution of getting clean
drinking water. According to Potters for Peace; locally manufactured ceramic
filters have traditionally been used throughout the world to treat drinking water.
Currently the most widely implemented ceramic filter is the Potters for Peace,
Filtron (Nicaragua), the TERAFIL terracotta filter (India), and the candle filter
(India, Nepal, Bangladesh, Brazil, design etc). The filter is flowerpot shaped.
Potter for peace. (1998).
Water filtering did not just come into being it’s a practiced that exited in past generations and
evolved in technique in the way different civilization have practiced it with their culture.
“The idea began over a thousand years ago, when porous clay and
sandstone were used to filter water in Sri Lanka. The pores are large
enough to allow the passage of water but not the microbes that cause
water-borne disease.20 Modern filters are made by mixing clay with
sawdust, rice husks, or other flammable organic materials. After being
shaped into a filter with a press, they are fired in a kiln. The organic
material burns out, leaving small pores of about one micron in size,
which can filter out the majority of harmful microbes.17 These simple
clay filters can remove between 97.86% and 99.97% of E. coli, an
important indicator of the amount of contamination present in a sample
of water. The filters also remove particulates and protozoan (which are
larger than bacteria). Further, with the addition of colloidal silver (a
broad-spectrum antimicrobial) the filters have 100% effectiveness in tests
for removal of E. coli.21 Studies have also shown that silver is a
potentially strong anti-viral compound.22,23,24.”
Robert. W, (2003)
The Makeup of the Modern Ceramic Water Filter Press Machine
Taking good look at the modern (foreign) Ceramic water filter machine, it appears heavy,
compact and expensive to procure. See Figure 1 as a good example;
Plate 1:A Foreign Ceramic press Machine for Water Filter
Picture source: Potters for Peace website (http://ww.potpaz.org)
The ceramic water filter machine consists of the main frame, the lifter which carries the jack
situated above the legs, both attached to the main frame. The head stock is attached to the top of
the main frame which holds the male mold, a cross bar which is attached to the main frame
called the H- Slid this lift the female mold below H- Slid is the hydraulic jack. This is placed on
two cross bar attached to the main frame just above the legs. The average price for one ceramics
water filter press machine cost about 3000 thousand dollars excluding other charges like taxes,
agent commission, and transportation etcetera. With this price, it will be difficult to procure the
press machine in other to solve the water challenge in third world countries. It is therefore
expedient to think inwards, design and fabricate a workable and functional ceramic water press
machine.
Due to the high cost of ceramics water filter press machine and having good understanding of
simple machine design and fabrication in engineering. it was necessary to look for cheaper means
to fabricating a simple press machine that could serve the same purpose with less cost. Ebeigbe
and Omem (2010) states that:
“Not only is it possible to fabricate ceramic equipment locally, but, that their
production will greatly alleviate the problem of non-availability and nonaccessibility of the basic equipment necessary for the smooth running of
ceramics studios and workshops.”
Due to the high cost of ceramics water filter press machine, having good understanding of simple
machine in engineering, it was necessary to look for cheaper means of fabricating a simple press
machine that could serve the same purpose at a less cost.
FIGURE 1: Sketch reference by DR.Robert.W.Dies (2013)
METHODOLOGY
Having conceptualized an idea of an intended technology gives a direction and guide to designing
a machine to achieve the set goal. Obasuyi (2004), opined that design is the process of translating
concepts, ideas, innovation into results or physical products. Longe .B ( 2014), states that design
is an action taken geared toward the elimination/eradication of an existing fault, defect or in some
cases, resulting in a total change of the product in a whole new concept, improved and enhanced.
The study of the model reveals that the male and female moulds in the ceramics water filter press
machine were made of steel plates instead a polyester resin which was used in making these
research male and female moulds. See Plates: below
Shows the process of the fabrication.
Plate 1 and 2: materials Angle iron and iron rod
Source: photograph by Dosunmu Aduragbemi Samuel (2018)
Plate 3 And 4: Measuring the angle iron
Source: Photograph by George Paul Efe (2018)
Plate 5: Welding the angles together
Source: photograph by George Paul Efe (2018)
Plate 7: Welding of the jack
Source: photograph by Dosunmu Aduragbemi (2018)
Plate 9: Mixing of Polyester, Accelerator and Catalyst
Source: Photograph by Dosunmu Aduragbemi (2018)
Plate 6: Inserting the rod for Roller.
Source: photograph by George Paul Efe (2018)
Plate 8: Modeling of the mould (clay)
Source: Photograph by Adams Adetoun Balikis (2018)
Plate 10: Application of the Mixed Polyester, Accelerator and
Catalyst on the surface of the male Mould.
Source: Photograph by Dosunmu Aduragbemi (2018)
Plate 11: Separation of the male mould (Pop)
Source: Photograph by Dosunmu Aduragbemi (2018)
Plate 12: Application of the Janlcole on male mould
Source: Photograph by Dosunmu Aduragbemi (2018)
Plate 13: The Assembled two piece mould
Source: Photograph by George Paul Efe (2018)
Plate 14: The casted copy of the model of water filter from the male mould)
Source: Photograph by George Paul Efe (2018)
Plate 15: Finishing of the male mould
Source: Photograph by Dosunmu Aduragbemi (2018
Plate 17: Separation of the female mould (pop) Source:
Photograph by George Paul Efe (2018)
Plate 16: Taking female mould using P.O.P
Source: Photograph by Dosunmu Aduragbemi (2018)
Plate 18: laying chemicals mixed with grog on mould
Source: Photograph by George Paul Efe (2018)
Plate 19: After joining the two piece of model from Female mold
Source: Photograph by Dosunmu Aduragbemi (2018
Plate 21: Fixing bolt to the Female mould connecting to Water Filter
Press Machine
Source: Photograph by Gorge Paul Efe (2018)
Plate 20: Finished Female mould
Source: Photograph by Adams Adetoun (2018)
Plate 22: finishing of the female and male mould installed to the Water Filter Press
Machine
Source: Photograph by Babatunde Damilola(2018)
Plate 23: welding bearing to the machine Source:
Photograph by Dosunmu Aduragbemi (2018)
Plate 25: pressing clay on mould with the machine
Source: Photograph by George Paul Efe (2018)
Plate 24: Testing the machine with the mould
Source: Photograph by Dosunmu Aduragbemi (2018)
Plate 26: taking out the press cast together with the male mould
Source: Photograph by George Paul Efe (2018)
Plate 28: fired Water Filter
Plate 27: Finished press cast Water Filter
Source: Photograph by George Paul Efe
(2018)
Source: Photograph by George Paul Efe
(2018)
Plate 29: Testing the filter after being fired
Source: Photograph by Afam. A. Okuwudili (2018)
The firing process of the ceramics water filter was like any other ceramics been fired to
bisque level of 1000c0 due to the makeup of constitute of the ceramics water filter 90% earthen
materials it underwent the normally process of firing the preheating for period of 2 hours,
another period of 3 hours of every 30 minutes increase in the fire level and 1 hour of full blast
firing for the ceramics water filter to get vitrifying temperature of 1000c0 plate 27 and 28 show
the ceramics water filter when it was bone dry and after going through the firing process.
COST OF FABRICATION OF CERAMIC WATER FILTER PRESS MACHINE
N/S
ITEMS
QUANTITY
AMOUNT
1
U Channel
10,000
2
Angle Iron
3,000
Angle Iron
4,000
Roller and 3mm
plate
23mm Rod for roller
4,500
Electrode
1,000
Cutting and grinding
disc
Bearing Roller
500
4 Pieces
2,000
Car Jack
1
3,000
3
4
5
6
7
8
1,500
9
Bolt and Nut
200
Paint
800
10
11
12
Red Oxide
300
13
Petrol
100
14
Brush
15
Welder
Transportation
3,500
3,500
Resin
Catalyst
6,000
1,000
20
Accelerator
P.O.P
1,000
1,800
21
22
Fiber Mat
Separator
1,500
200
23
Brush
24
Sand Paper
500
25
Transportation
1,500
26
Soap
200
TOTAL
51,900
16
17
18
19
2
1
200
100
Two test were carried out in line with the research they are workability of the press
machine and porosity of the ceramics water filter
Test for workability of the water filter press machine after the preparation of the clay body
for the ceramics water before it was laid on the male mould the male mould was covered
with cellophane which act as lubricate (easy separating) after which the female mould will
be pressed to together male mould already laid with the clay body, this process were
repeated on three occasions with the three different clay body. The following plate: 25
and 26 above will show the processes.
Test for porosity this was carried out to know the best clay body that will be suitable for
the ceramics water filter three different clay body composite were created in the following
orders the 4 Liters paint bucket served as measuring of raw materials the clay bodies.
Clay body 1
3 batches dry earthenware clay powder
2 batches saw dust
1 batch Grog
6 liters of Water
Clay body 2
3 batches dry earthenware clay powder
1 batches saw dust
1 batch Grog
6 liters of Water
Clay body 3
3 batches dry earthenware clay powder
1
/2 batches saw dust
1
/2 batch Grog
6 liters of Water
The above clay bodies were all fired in the same kiln at the same time to a temperature of
1000c0 the three clay bodies were removed from the kiln and placed inside a three buckets
and filled with water allow to drain out of them into the bucket for a period time of 30
minutes. It was observed that clay body 1 drained the fastest within 15 minutes and clay
body 2 took 30 minutes to drain out water while clay body 3 still had 80% of the water
inside. Clay body 1 and 2 are suitable for the production of the water filter but clay body
1 was chosen see Plate: 29.
FINDINGS
1. It was observed that after the first use the water filter need to remove from the bucket
and turned upside down in hot sun, because the water filter was not sterilized with
Colloidal silver, according to Robert, W. (2003) “ Colloidal silver it is use for the
control of bacterial growth or regrowth within the or on water filter elements also act
as a bactericide to chemically or biologically inactivate microorganisms” because the
substance was not used on the body of the produced water filter after some long use it
effected the water as a result of bacterial growth on the body of the water filter.
2. The water filter press machine could be made less heaver with much improvements
for it easy movability.
RECOMMENDATION
The Design of the Ceramic Water filter press Machine shows that with locally sourced
materials, the challenges of getting drinkable water could be solved.
i.
ii.
iii.
iv.
It will open up more challenges in research area relevant to equipment’s and machinery
development.
A further chemical analysis can be made on the local ceramic water filter to test the
water purity before and after filtration
The design of the Ceramic Water Filter Press Machine will increase the income level
of local potters in Nigeria
Source of revenue to both the government and the potters
CONCLUSION
The Ceramic Water Filter Press Machine can be fabricated at a low cost using the indigenous
materials. This indigenous ceramic water press machine and the products produced will have
multiple effect on the community in solving the drinkable water challenges, thereby reducing the
level of water borne diseases and also, making the press machine easily available in the local
market and as well, creating market for the local potters for the production of Ceramics Water
filter and the machine thereby increasing the potters’ income.
REFERENCES
Ebeigbe S.U. and Omem V. (2010). “The Fabrication of a Manually
Operated Clay Extruder for Ceramic Studio and workshops.” Design Review Journal of
Industrial Design 1:1-9.
Michael. H, Siri. M, Khanjan. M (2013) Designing a Low-Cost Ceramic Water Filter Press
“Published International Journal for Service Learning in Engineering”. Vol.8, No 1,
pp. 62-77.
Michael S. H. Boutilier, Jongho Lee, Valerie Chambers, Varsha Venkatesh,Rohit Karnik.
(2014) “Water Filtration Using Plant Xylem”. www.plosone.org Retrived 12th August
2018.
Longe . B. (2014) Design and Fabrication of a Multi-Purpose Hydraulic press for ceramic
Production Using Local Materials, Unpublished Master Thesis, University of Benin,
Benin City, Edo State, Nigeria.
Obasuyi. F (2004) Concept of Industrial Design (Issues and Problem of Delineation) Emotan
Journal of art Vol. 2.
Robert. W. D (2003) “Development of Water Filter Press Machine for Nepel” unpublished.
http//www.mit.edu Retrieved August 5th 2018.
http//:www.potterforpeace.org/ceramic water filter project. Retrieved 12th August 2018.
World
Health
Organization.
Available:
http://www.who.int/water_sanitation
health/mclg/en/. Retrieved 12th August 2018