**3.1 Making of the filter moulds**

The mould for the filter press machine was designed and made using aluminium as material, which was shaped using the sand casting method. The processes involved in the making of the filter mould include; generating a CAD drawing (see **Figure 8**), detailing the dimensions of the moulds; and the making of a wooden mould patterns (see **Figures 9** and **10**) from which sand moulds were derived.

The mould design was generated during the course of the study using dimensions which were estimated by the researcher to produce a ceramic water filter that would fit into commonly available wide-rimmed large plastic containers. The size of the container was used as mark up for the determination of the dimensions of the moulds. The core and drag mould components were designed to give a pressed ceramic filter product of 30 mm thickness all round; this is to accommodate the high shrinkage possible in most plastic ball clays available for use in South West Nigeria; as well as to allow for longer contact time with silver for the inactivation of pathogens in water and greater possibility of trapping the pathogens as they travel through the filter walls. With this design sketch, a wooden pattern made of cut out pieces of 2-inch plywood held together with resin bond, was derived. The pattern is highly essential to the process because the sand moulds which was used for casting the metal form is taken from it. So it is important to ensure correctness of dimensions and form in the wooden pattern.

The process of making of the sand moulds included filling up firmly, a squareshaped wooden frame in which the wooden pattern has been placed with fine sand (see **Figure 11**); after which the pattern is taken out and the sand is smoothened out

using a metal spoon (see **Figures 12**–**14**). The metal cast was then taken from the

Pieces of waste aluminium collected from the local scrap market were charged into the rotary furnace and melted (see **Figure 15**) at temperatures between 600 and 700°C. The crucible bearing the molten aluminium was removed from the

prepared sand mould.

*Top view of wooden patterns for the mould.*

**Figure 10.**

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**Figure 9.**

*Wooden patterns for the mould.*

*Manufacturing a Ceramic Water Filter Press for Use in Nigeria*

*DOI: http://dx.doi.org/10.5772/intechopen.91378*

**Figure 8.** *CAD drawing for moulds (material: Aluminium).*

*Manufacturing a Ceramic Water Filter Press for Use in Nigeria DOI: http://dx.doi.org/10.5772/intechopen.91378*

**Figure 9.** *Wooden patterns for the mould.*

All the materials and manpower used in fabricating this press were sourced from within the country. The hydraulic press machine typically consists of two parts; the moulds and the frame which holds the moulds and the hydraulic component. The

The mould for the filter press machine was designed and made using aluminium

The process of making of the sand moulds included filling up firmly, a squareshaped wooden frame in which the wooden pattern has been placed with fine sand (see **Figure 11**); after which the pattern is taken out and the sand is smoothened out

as material, which was shaped using the sand casting method. The processes involved in the making of the filter mould include; generating a CAD drawing (see **Figure 8**), detailing the dimensions of the moulds; and the making of a wooden mould patterns (see **Figures 9** and **10**) from which sand moulds were derived. The mould design was generated during the course of the study using dimensions which were estimated by the researcher to produce a ceramic water filter that would fit into commonly available wide-rimmed large plastic containers. The size of the container was used as mark up for the determination of the dimensions of the moulds. The core and drag mould components were designed to give a pressed ceramic filter product of 30 mm thickness all round; this is to accommodate the high shrinkage possible in most plastic ball clays available for use in South West Nigeria; as well as to allow for longer contact time with silver for the inactivation of pathogens in water and greater possibility of trapping the pathogens as they travel through the filter walls. With this design sketch, a wooden pattern made of cut out pieces of 2-inch plywood held together with resin bond, was derived. The pattern is highly essential to the process because the sand moulds which was used for casting the metal form is taken from it. So it is important to ensure correctness of dimen-

procedures engaged in the making of both parts are discussed further.

**3.1 Making of the filter moulds**

*Design and Manufacturing*

sions and form in the wooden pattern.

*CAD drawing for moulds (material: Aluminium).*

**Figure 8.**

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**Figure 10.** *Top view of wooden patterns for the mould.*

using a metal spoon (see **Figures 12**–**14**). The metal cast was then taken from the prepared sand mould.

Pieces of waste aluminium collected from the local scrap market were charged into the rotary furnace and melted (see **Figure 15**) at temperatures between 600 and 700°C. The crucible bearing the molten aluminium was removed from the

**Figure 11.** *Filling the frame with sand.*

**Figure 14.** *Finished sand mould.*

**Figure 13.**

*Smoothening the sand mould.*

*Manufacturing a Ceramic Water Filter Press for Use in Nigeria*

*DOI: http://dx.doi.org/10.5772/intechopen.91378*

**Figure 15.**

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*Process of melting the scrap aluminium in a rotary furnace.*

**Figure 12.** *Pattern taken out.*

furnace using a pair of furnace tongs (see **Figure 16**) and the crucible holding the molten metal was set in a 2-man carrier rod (see **Figure 17**).

It is important to remove dross and check for unmolten particles of other metals before casting (see **Figure 18**). The molten metal is then poured into the sand moulds by means of crucible tongs and carrier rod (see **Figures 19** and **20**).

In the process of pouring in the molten material, it is important to poke at it using a metal rod to aid the removal of any air bubbles that may have been trapped in while pouring (see **Figure 21**). The metal cast is afterwards left to cool for about 24 hours before it is removed from the mould (see **Figure 22**). The surface finish of the cast aluminium mould is mostly dull, lacks lustre and sometimes presents tiny holes as seen in **Figure 23**. Polishing the metal is therefore important to give a more usable finish to the cast aluminium moulds (see **Figure 24**).

The last phase in the making of the mould was the machining and polishing of the cast. Aluminium was the material used to make the moulds in this study. This is because aluminium is a non-rust metal and it is more affordable than stainless steel and can easily be machined because it is a relatively soft metal. Aluminium is also a very available material in most scrap markets across the country, and hence easy to access for this purpose. The machining or polishing of the moulds was carried out using a horizontal lathe machine in a privately-owned engineering workshop.

*Manufacturing a Ceramic Water Filter Press for Use in Nigeria DOI: http://dx.doi.org/10.5772/intechopen.91378*

**Figure 13.** *Smoothening the sand mould.*

**Figure 14.** *Finished sand mould.*

furnace using a pair of furnace tongs (see **Figure 16**) and the crucible holding the

before casting (see **Figure 18**). The molten metal is then poured into the sand moulds by means of crucible tongs and carrier rod (see **Figures 19** and **20**). In the process of pouring in the molten material, it is important to poke at it using a metal rod to aid the removal of any air bubbles that may have been trapped in while pouring (see **Figure 21**). The metal cast is afterwards left to cool for about 24 hours before it is removed from the mould (see **Figure 22**). The surface finish of the cast aluminium mould is mostly dull, lacks lustre and sometimes presents tiny holes as seen in **Figure 23**. Polishing the metal is therefore important to give a more

It is important to remove dross and check for unmolten particles of other metals

The last phase in the making of the mould was the machining and polishing of the cast. Aluminium was the material used to make the moulds in this study. This is because aluminium is a non-rust metal and it is more affordable than stainless steel and can easily be machined because it is a relatively soft metal. Aluminium is also a very available material in most scrap markets across the country, and hence easy to access for this purpose. The machining or polishing of the moulds was carried out using a horizontal lathe machine in a privately-owned engineering workshop.

molten metal was set in a 2-man carrier rod (see **Figure 17**).

**Figure 11.**

**Figure 12.** *Pattern taken out.*

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*Filling the frame with sand.*

*Design and Manufacturing*

usable finish to the cast aluminium moulds (see **Figure 24**).

**Figure 15.** *Process of melting the scrap aluminium in a rotary furnace.*

**Figure 19.**

**Figure 20.**

**Figure 21.**

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*Casting process using the crucible carrier.*

*Poking the poured-in metal to remove trapped air.*

*Pouring in the molten metal into the sand mould using furnace tongs.*

*Manufacturing a Ceramic Water Filter Press for Use in Nigeria*

*DOI: http://dx.doi.org/10.5772/intechopen.91378*

**Figure 16.** *Removing molten aluminium from the furnace using a pair of tongs.*

**Figure 17.** *Crucible set in the carrier rod in readiness for casting.*

**Figure 18.** *Stoking the molten metal to remove dross and other particles.*

*Manufacturing a Ceramic Water Filter Press for Use in Nigeria DOI: http://dx.doi.org/10.5772/intechopen.91378*

**Figure 19.** *Pouring in the molten metal into the sand mould using furnace tongs.*

**Figure 20.** *Casting process using the crucible carrier.*

**Figure 21.** *Poking the poured-in metal to remove trapped air.*

**Figure 16.**

*Design and Manufacturing*

**Figure 17.**

**Figure 18.**

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*Removing molten aluminium from the furnace using a pair of tongs.*

*Crucible set in the carrier rod in readiness for casting.*

*Stoking the molten metal to remove dross and other particles.*

**3.2 Making of the hydraulic press frame**

*DOI: http://dx.doi.org/10.5772/intechopen.91378*

*Manufacturing a Ceramic Water Filter Press for Use in Nigeria*

enhance consistency in production.

**Figure 25.**

**Figure 26.**

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*Cut out metal parts for the frame.*

*PWB design of press machine [10].*

The frame of the hydraulic press machine was made from cast iron and steel parts. The design for the frame was adapted from the Potters Without borders (PWB) ceramic water filter press design (see **Figure 25**). The PWB filter press design incorporates the use of a removable car jack as its hydraulic mechanism. The design for this study has incorporated a hydraulic controller system which is comprised of a box, an industrial jack to drive the pressing mechanism which is expected to be more durable than the car jack over time and continued use; and a pressure gauge to measure the pressure applied in the pressing of each filter to

The metal parts for the frame were sourced from Akure and Ibadan in Southwest Nigeria. Cast iron was the major material from which the parts of the frame were made. Some parts were also of made of steel. The long metal parts were cut into dimensions (see **Figures 26** and **27**) and holes were drilled through them to enable assembly of the frame using nuts and bolts. Bolting was preferred to welding in the assembly of the machine parts, to allow room for adjustments and for easy movement and transportation of the machine. The cutting and welding of the frame

**Figure 22.** *Cooling.*

**Figure 23.** *Cast aluminium moulds.*

**Figure 24.** *Polished aluminium mould.*
