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Experimental, Computational and Numerical Analysis of
Oxygen Enrichment Process in Energy Conservation in
Rotary Furnace Foundry Operation
Dr. R.K. Jain Professor & Head, Department of Mechanical Engineering, ITM University, Gwalior, India
ABSTRACT
This paper deals with Experimental Investigations computational and numerical analysis of oxygen
enrichment of combustion volume in LDO-fired rotary furnace, for specific fuel and energy conservation.
Energy consumption is major problem being faced by the Indian ferrous foundries. “Bureau of Energy
Efficiency, “The Energy and resources Institute,” Govt. of India New Delhi & other International agencies
has reported that energy consumption in Indian ferrous foundries is much more above the required limits
and has to be drastically reduced.
The author conducted experimental investigation on oxygen enrichment of preheated air in a self
designed and developed 200 kg rotary furnace in an industry The specific fuel and energy consumption of
furnace, (when operated under existing conditions, without oxygen enrichment of preheated air,) in
melting only was 0.460liter/kg or 4110.45 Kwh/tone and total 4172.00 Kwh/tone. When operated with
oxygen enrichment of preheated air, the specific fuel and energy consumption in melting only reduced to
0.260 liter/kg or 2667.00 Kwh/tone and in total to2711.00 Kwh/tone. The energy consumption in melting
only is reduced by 35.12% and in total by 35.01%.
The L.M. modeling method of artificial neural networks contained in Mat Lab software is used for
modeling and optimization. The average percentage variation between actual experimental and modeled
results is +8.905% which is within acceptable limits of±10%. The numerical techniques of initially
developing equations and then solving them has been applied. The result so obtained is compared with
Experimental, and computational results. The variation is -3.5678% which is well within the acceptable
limits.
Keywords: Rotary Furnace, Specific Fuel, Oxygen Enrichment, Energy Consumption.
1. INTRODUCTION
The rotary furnace is very simple melting unit consisting mainly of a drum of required size having a cone
on each side lined with refractory, fire bricks or ramming mortar generally having alumina as a
constituent. This drum is placed on rollers so that they may be either locked or slowly rotated about their
central axis. The rollers are driven by a small electric motor. At one end of the drum, a suitable burner is
placed with appropriate blower system and combustion gases exit from other end. This drum or horizontal
cylinder is flanked by two conical portions on both sides. One of the cones accommodates the burner
whereas from the other cone, hot flue gases exit. Charging of the iron for melting is also done from this
side. The cone on one side can accommodate different types of burners using the light diesel oil (LDO).
The tap hole is located in the cylindrical wall halfway between the ends. This tap hole is used to take out
the molten metal, but it is kept closed during the melting of metal. Figure-1 shows the layout and
accessories of a rotary furnace.
International Journal of Research in Mechanical Engineering
Volume-2, Issue-2, March-April, 2014, pp. 01-12, © IASTER 2014
www.iaster.com, ISSN Online:2347-5188 Print: 2347-8772
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Fig 1. Layout of a Rotary Furnace Plant
2. LITERATURE REVIEW
A number of investigations had been conducted in the past on a rotary furnace. Baker EHW [1] explained
the working of Rotary furnace. Jain R.K, Singh R,[2].applied regression modeling and excel solver
technique for mathematical modeling and optimization of critical parameters of rotary furnace viz. rpm,
melting rate, specific fuel consumption etc. Jain RK, Singh R, Gupta B.D. [3] presented an overview of
energy consumption in ferrous foundry and stressed upon the need of an energy efficient furnace for
foundries. Baijayanath, Pal Prosanto Panigrahy K.C. [4] explained that most of the units are crippled with
usage of rudimentary techniques. The Indian foundry industry needs optimization of energy consumption.
Singh Kamlesh Kumar [5] advocates the use of newer and cleaner technology for energy conservation.
Arjunwadkar S.H, Pal Prosanto [6] stressed upon to use energy efficient melting techniques. Pandey
G.N., Singh Rajesh, Sinha A.K [7] emphasized upon to supply oxygen at 8kg/cm2 pressure as it reduces
melting time and emission levels.
W.W.Levi [8] was the first person to develop a mathematical model between carbon content in the charge
and that of tapped metal. Pehlke [9] developed the first thermo chemical model for predicting cupola
performance under various operating conditions. Landefeld and Katz [10] developed a kinetic model for
carbon pick up in cupola based on carbon activity .Sahajwala[11] et al have estimated the extend of
carburization and re carburization of the solid charge in stack of cupola and found it to be negligible.
Sahajwala and Pehlke[12] pointed out accurate control of carbon content depend upon identifying the
phenomena which controls it. Stanik et al [13] has developed similar mathematical models .Karunakar
and Datta[14] has successfully applied artificial neural networks in the control of cupola furnace. Bishop
Christopher M.[15] explained the working and importance of neural networks in modeling and
optimization .Haykins Symon [16] successfully applied the single layer and multilayer network
architecture for neural networks in modeling and optimization.
Grewal B.S [17]. explained numerical methods to solve the linear, transcendental and polynomial
equations. Rao S.S [18] described the procedures of optimization using mathematical techniques. Shastri
S.S.[19] applied numerical techniques to solve the engineering problems. Das H.K and Verma Rama [20]
used statistical techniques for optimization of objectives.
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2. MATERIALS AND METHODS
2.1Melting Operation-The process of melting the charge in rotary furnace is carried out in the
following steps:
(I) Preheating of oil and furnace
(II) Charging– After pre heating, the furnace is charged.
(III) Rotation-After sufficient pre heating and charging, the furnace is rotated at desired speed.
(IV) Melting- The flame starts coming out of the exit end, which is initially yellowish in color. After
approximately 1 hour, the colour of flame changes to white indicating that metal has been
thoroughly melted. The temperature of the molten metal is measured using pyrometer. If it is
approximately 1250 to 1300ºC, the rotation of furnace is stopped.
(V) Tapping-The tape hole is slightly lowered and opened and metal is transferred into ladles, which
are pre heated prior to the transfer of molten metal to avoid heat losses.
(VI) Inoculation-The Ferro silicon and Ferro manganese approx. 600 grams per heat are added in
molten metal contained in the ladles.
(VII) Pouring –The ladles are then carried to moulds and pouring is completed. The furnace is shown in
fig 1.
3. EXPERIMENTAL INVESTIGATIONS
3.1 Operating Furnace Under Existing Conditions of Operation without Oxygen Enrichment —
Specific Fuel and Energy Consumption
The furnace was operated under existing conditions of operation without oxygen enrichment. The charge
per heat is 200.0 kg. In first heat, as furnace was started from room temperature, the melting time, fuel
and energy consumption were more. In subsequent heats, the melting time, fuel and energy consumption
were reduced. 1liter of LDO is equivalent to 9.9047kwh/kg of energy. Observations are given in table 1.
Table1- Performance and Specific Fuel Consumption of Furnace under Existing Conditions
of Operations without Oxygen Enrichment
(I) The graphical representation the graphical representation of energy consumption under existing
conditions of operation is shown in fig 2.
S
N
He
at
no
Rp
m
Time
min
Fuel
liters
Specific
Fuel
(lit/kg)
Melting
Rate
(kg/hr)
Flame
temp.0C
Preheated
air cons.
m3
Energy
consumption
oxygen enrich.
kwh/kg
1 1 2.0 50.0 92.0 0.460 240.0 1310.0 1320.0 4.556
2 2 2.0 47.0 90.0 0.450 255.3 1314.0 1290.0 4.457
3 3 2.0 46.0 87.0 0.435 260.8 1325.0 1240.0 4.308
4 4 2.0 46.0 86.0 0.430 266.0 1334.0 1220.0 4.259
5 5 2.0 45.0 83.0 0.415 266.0 1350.0 1175.0 4.110
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Fig 2- Energy Consumption under Existing Conditions of Operation
3.2 Operating Furnace with Oxygen Enrichment of Preheated Air- Specific Fuel and Energy
Consumption
It is thought to optimize the energy consumption by reducing the amount of air and supplying oxygen
externally, required for combustion. Several experiments were conducted, gradually reducing air to its
theoretical requirement and even lesser in steps of 5.0 to 10.0% and supplying oxygen externally in steps
of 1.0 to 2.0 %, and its effect on flame temperature, time, fuel, melting rate, and fuel consumption was
studied. The effect was significant only when air was reduced to 75.0% of its theoretical requirement and
approx 7.0% oxygen was supplied externally. The experimental investigations conducted are given in
following sections.
(I) Effect of 6.9%oxygen enrichment of 75.3-75.4 % of theoretically required air on flame
temperature, time, fuel, melting rate, specific fuel and energy consumption-Numbers of experiments
are conducted, rotating furnace at optimal rotational speed 1.0 rpm, with 6.9% oxygen enrichment of
75.3-75.4% of theoretically required air, preheating LDO to 700C. The effect of above on flame
temperature, time, fuel, melting rate, and specific fuel consumption are given in table 3.
Table 2- Effect of 6.9% oxygen enrichment of 75.3-75.4% of theoretically required air on performance
(flame temperature, time, fuel, melting rate), and specific fuel consumption.
The above experimental investigations reveal that by 6.9% oxygen enrichment of 75.3-75.4% of
theoretically required preheated air, the specific fuel and energy consumption are significantly reduced.
He
at
no
Rp
m
Preh
eated
air
temp 0C
Flame
temp0
C
Time
min
Fuel
liter
Melting
rate
kg/hr
Specific
fuel
cons
lit/kg
Oxy
gen
cons
m3
Oxy
gen
cons
%
Preheated
air
cons.
m3
Preheated
air
cons %
Energy
consumpti
on oxygen
enrich
kwh/kg
1 1.0 410.0 1710.0 33.0 56.0 363.0 0.280 39.0 6.9 459.0 75.3 2.773
2 1.0 418.0 1722.0 32.0 56.0 375.0 0.280 39.0 6.9 459.0 75.3 2.773
3 1.0 428.0 1730.0 32.0 55.0 375.0 0.280 38.5 6.9 451.0 75.4 2.773
4 1.0 449.0 1746.0 31.5 54.0 385.0 0.270 38.0 6.9 443.0 75.4 2.674
5 1.0 454.0 1752.0 31.0 53.0 387.0 0.265 37.0 6.9 434.5 75.3 2.624
6 1.0 458.0 1754.0 30.5 52.0 393.0 0.260 36.6 6.9 426.7 75.4 2.575
7 1.0 460.0 1755.0 30.5 52.0 393.4 0.260 36.5 6.9 426.5 75.4 2.575
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(II) The Graphical Presentations
(a) Effect of 6.9% oxygen enrichment of 75.3-75.4% of theoretically required air on specific energy
consumption- are presented graphically in figs 2.
Fig 3-Effect of 6.9% oxygen enrichment of 75.3-75.4% of theoretically required air
on specific energy consumption
4. RESULTS
The results of above experimental investigations are summarized in table 5.
4.1 Performance of furnace- The performance of furnace is compared in table 5
Table 3- Comparison of Performance of Furnace
(III) The Graphical Presentations
Comparison of flame temperature, time, fuel, melting rate, and specific fuel consumption, and specific
energy consumption under existing conditions and with 6.9% oxygen enrichment - are presented
graphically in figs 2.
Parameters
Operating furnace
without oxygen
enrichment of preheated
air
Operating furnace with 6.9%
oxygen enrichment of 75.3%-
75.4% of theoretically required
preheated air
Time minutes 45.0 30.5
Flame temperature0C 1350.0 1755.0
Melting rate kg/hr 266.0 393.4
Fuel liters 83.0 52.0
Specific fuel cons.lit/kg 0.415 0.260
Specific energy cons. kwh/kg 4.110 2.575
Preheated Air consumption m3 1175.0 426.5
Oxygen consumption ------- 182.5 m3/tone
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Fig 4- Comparison of flame temperature, time, fuel, melting rate, and specific fuel consumption, and specific
energy consumption under existing conditions and with 6.9% oxygen enrichment
5. COMPUTATIONAL TECHNIQUES
Statistical methods such as cluster analysis, pattern recognition and design of experiments, factorial analysis
and regression analysis are some of the statistical techniques which enable one to analyze the experimental
data and build empirical models to obtain the most accurate representation of physical situations. The data on
preheated air temperature, flame temperature time of heat fuel consumption/heat, oxygen.
The furnace was run with a maximum preheated air temperature of 4600C, flame temperature 1750C,
Time / heat 30.5 minutes, fuel/heat 52 liters, melting rate 393.44 kg/hr, oxygen Consumption/heat
36.5m3, and air consumption/heat 426.5m3. The specific fuel consumption was 0.260 liters/kg. The
specific fuel consumption has been taken as output parameter Y and all other parameters viz. preheated
air temperature, flame temp. fuel, oxygen & air consumption /heat, melting rate etc. has been taken as
input parameters X [x1, x2, x3, x4, x5, x6, x7 etc].
5.1 Modeling of specific fuel consumption ---- Table 2 is being reproduced with specific fuel
consumption as output for mathematical modeling.
Table 4- Table 2 Reproduced with Specific Fuel Consumption as Output and all other
Parameters as Input for Mathematical Modeling
OUTPUT <--------------- INPUT X -----------------------------------------------------
Sn
Specific
fuel
consump
Lit/kg.
Preheat
Air
temp 0c
Flame
temp
0c
Time
/heat
Min.
Fuel
/heat
Lit.
Oxygen
Consum.
/heat
M3
Air
Consump
/heat
M3
Melting
Rate kg/hr
1 0.280 410 1710 33 56 39 459 363
2 0.280 418 1722 32 56 39 459 375
3 0.280 428 1730 32 55 38.5 451 375
4 0.270 449 1746 31.5 54 38 443 385
5 0.265 454 1752 31 53 37 434.5 387
6 0.260 458 1754 30.5 52 36.60 426.7 393.44
7 0.260 460 1755 30.5 52 36.50 426.5 393.44
The specific fuel consumption has been taken as output parameter Y and all other parameters viz
preheated air temperature, flame temperature. fuel ,oxygen &air consumption/heat, melting rate etc has
been taken as input parameters X [xi x2 x3 x4 x5 x6 x7] etc.
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Regression modeling is used as given in matrices of MAT LAB 7.0.The steps followed are same as
mentioned in model 1.
The specific fuel consumption (lit/kg) is function of
= ƒ [(PA)(FT)(TIME)(FUEL)(OXYGEN)(AIR)(MELTING RATE)]
and is given by following equation
SFC=C0(PA)C1
(FT)C2
(TIME)C3
(FUEL)C4
(OXYGEN)C5
(AIR)C6
(MELTING RATE)C7
-- (1)
Where C0 C1C2C3C4C5C6C7 are constants to be evaluated using mat lab. The programme run is shown
below clc;
clear all;
close all;
y=[-1.27296;-1.27296;-1.27296;-1.30933;-1.32802;-
1.34707;-1.34707];
x1=[1 1 1 1 1 1 1];
x2=[6.01615 6.03548 6.05912 6.10031 6.11809 6.12686
6.13122];
x3=[7.44424 7.45124 7.45587 7.46508 7.46851 7.46965
7.47022];
x4=[3.49650 3.46573 3.46573 3.44998 3.43398 3.41772
3.41772];
x5=[4.02535 4.02535 4.00733 3.98898 3.97029 3.95124
3.95124];
x6=[3.66356 3.66356 3.65065 3.63758 3.61091 3.60004
3.59731];
x7=[6.12905 6.12905 6.11146 6.09356 6.07419 6.05608
6.05561];
x8=[5.89440 5.92692 5.92692 5.95324 5.95842 5.98492
5.97492];
x=[x1;x2;x3;x4;x5;x6;x7;x8]';
xt=x';
st3=xt*x;
st4=inv(st3);
st5=xt*y;
st6=st4*st5
v=st6(1)
c0=exp(v)
c1=st6(2)
c2=st6(3)
c3=st6(4)
c4=st6(5)
c5=st6(6)
c6=st6(7)
c7=st6(8)
pa=input('\n enter value of pre-heated air:= ');
ft=input('\n enter flame temperature:= ');
time=input('\n enter time:= ');
fc=input('\n enter fuel consumption:= ');
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oe=input('\n enter oxygen enrichment:= ');
as=input('\n enter air supplied:= ');
mr=input('\n enter melting rate:= ');
logsfc1=log(c0)+c1*log(pa)+c2*log(ft)+c3*log(time)+c4*log(fc)+c5*log(oe)+c6*log(as)+c7*log(mr)
sfc=exp(sfc1)
RESULT
c0 = 6.5300* 10-056
c1 = -4.4722
c2 = 17.3755
c3 = -1.0635
c4 = -21.6445
c5 = 0.6346
c6 = 20.2754
c7 = -2.0810
The equation 1 becomes
logsfc1=log(6.5300*1056
)-4.4722log(pa)+17.3755*log(ft)-1.0635*log(time)-21.6445*log(fuel)
+0.6346*log(oxygen)+20.2754log(air)-2.0810*log(mr)
Or SFC = (6.5300* 10
-056) (PA)
-4.4722 (FT)
17.3755 (TIME)
-1.0635 (FUEL)
-21.6445 (OXYGEN)
0.6346 (AIR)
20.2754
(MELTING RATE) -2.0810
------------------------- ()
5.2 Calculation of modeled specific fuel consumption
1: sfc1= -1.1440, sfc =0.3185. 2: sfc1 =-1.1439, sfc =0.3186 3: sfc1 = -1.1438 sfc = 0.3186
4: sfc1 = -1.1801 sfc = 0.3072, 5: sfc = -1.1989, sfc = 0.3015, 6: sfc1 =-1.1973, sfc = 0.3020
7: sfc1 = -1.2181, sfc = 0.2958
5.3 Comparison of modeled and actual specific fuel consumption----The comparison of modeled and
actual specific fuel consumptions is shown in following table5
Table5 -The Comparison of Modeled and Actual Specific Fuel Consumptions
(I) The Graphical Representation -
The comparison of modeled and
actual specific fuel consumptions is
shown in fig 5.
Fig 5 -The Comparison of Modeled and
Actual Specific Fuel Consumptions.
S.No. Modeled
output
Experimental
output
Absolute
variation
% Absolute
variation
Mean average
%variation
1 0.3185 0.280 +0.0385 +12.087 +8.905%
2 0.3186 0.280 +0.0386 +12.115
3 0.3186 0.280 +0.0386 +12.115
4 0.3072 0.270 +0.0372 +12.109
5 0.3015 0.265 +0.0365 +12.106
6 0.3020 0.260 +0.042 +13.907
7 0.2958 0.260 -0.0358 -12.102
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6. Mathematical Techniques
(I) Formation and Development of Equation
As per mathematical analysis the equation has been considered as
Y=a0x4+a1x
3+a2x
2+a3x+a4,
Where a0-----a4 are constants and x is variable= oxygen consumption/heat.
The mathematical equations are of polynomial curve and given in table 6.
Table 6- The Mathematical Equations
(IV) Evaluation of Constants -Mat lab
The values of constants a1-----a5 are evaluated using Mat lab. The programme run is shown below and
values are given in table 7.
M-file script
A= [(39.0)4 (39.0)
3 (39.0)
2 (39.0) 1; (38.5)
4 (38.5)
3 (38.5)
2 (38.5) 1; (38.0)
4 (38.0)
3 (38.0)
2 (38.0) 1;
(37.0)4 (37.0)
3 (37.0)
2 (37.0) 1; (36.5)
4 (36.5)
3 (36.5)
2 (36.5) 1];
b= [56.0; 55.0; 54.0; 53.0; 52.0];
X=A\b
Solution:
X = -0.4
60.667
-3449.5
87150.83
-825446.6
Where, X= [a0; a1; a2; a3; a4] Table 7 -The Values of Constants A0-----A4 Using Mat Lab
(V) Comparison of Calculated and Experimental Outputs
Putting values of constants as per table 7 in equations 1 to 5, (table 6) and comparison of calculated and
experimental outputs is given in table 8.
Table 8- Comparison of Calculated and Experimental Outputs
S
No Equation
Calcula
ted
output
Experi
mental
output
Absolute
variation
%
Absolute
variation
Mean
average
%
variation
1 a0(39.0)4+a1(39.0)
3 +a2(39.0)
2 +a3(39.0)+a4= 55.843 56.00 -0.157 -0.280%- -3.5678%
2 a0(38.5)4+a1(38.5)
3+a2(38.5)
2+a3(38.5)+a4 54.093 55.00 -0.907 -1.649%
3 a0(38.0)4+a1(38.0)
3+a2(38.0)
2+a3(38.0)+a4 52.364 54.00 -1.636 -3.029%
4 a0(37.0)4+a1(37.0)
3+a2(37.0)
2+a3(37.0)+a4 49.961 53.00 -3.039 -5.733
5 a0(36.5.0)4+a1(36.5.0)
3+a2(36.5)
2+a3(36.5)+a4 48.283 52.00 -3.717 -7.148%
S.No. Equations
1 a0(39.0)4+a1(39.0)
3 +a2(39.0)
2 +a3(39.0)+a4= 56.0
2 a0(38.5)4+a1(38.5)
3+a2(38.5)
2+a3(38.5)+a4= 55.0
3 a0(38.0)4+a1(38.0)
3+a2(38.0)
2+a3(38.0)+a4=54.0
4 a0(37.0)4+a1(37.0)
3+a2(37.0)
2+a3(37.0)+a4= 53.0
5 a0(36.5.0)4+a1(36.5.0)
3+a2(36.5)
2+a3(36.5)+a4=52.0
SN Constants Value
1 a0 -0.4
2 a1 60.667
3 a2 -3449.5
4 a3 87150.83
5 a4 -825446.6
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(VI) Presentation of variations
The variations between experimental and calculated output y (specific fuel consumption) is presented
graphically in fig 4.
Fig 6 -The Variations between Experimental and Calculated Output Y (Specific Fuel Consumption)
6. RESULTS (I) Experimental Analysis The percentage reductions in operating parameters under two different conditions (under existing
conditions of operation and with oxygen enrichment process) are given in table 9.
Table 9- The Comparison of Energy Consumptions under Existing Conditions of Operation
and with 6.9% Oxygen Enrichment
The comparison of energy consumptions based on Experimental analysis is also presented graphically in
figure 5.
Fig 7- The Comparison of Energy Consumptions Based on Experimental Analysis
Parameters Percentage reductions/increments
Time minutes -32.22%
Flame temperature0C +30%
Melting rate kg/hr +47.89%
Fuel liters -37.34%
Specific fuel cons.lit/kg -37.34%
Specific energy cons.kwh/kg 37.34
Preheated Air consumption m3 -63.70%
Oxygen consumption -
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(II) Computational Analysis - The mean average percentage variations is+8.905%, it lies within the
acceptable limits of ± 10%.
(III) Numerical Analysis - The variations between actual and modeled specific fuel consumption is from
-0.280% to-7.148%.The mean average percentage variations is -3.5678% It lies within the acceptable
limits of ±10%.
7. CONCLUSIONS
The above experimental investigations reveal that by 6.9% oxygen enrichment of 75.3-75.4% of
theoretically required preheated air, not only the specific fuel and energy consumption are significantly
reduced but performance of furnace is also significantly improved.
The computational analysis reveals that mean average percentage variation between modeled and
experimental specific fuel consumption is+8.905%.it is acceptable.
The numerical analysis reveals that mean average percentage variation between calculated and
experimental fuel consumption is-3.5678 % It lies within the acceptable limits of ±10%.
It is concluded that computational analysis and numerical analysis both are capable of analyzing the
experimentally investigated results of specific fuel/energy consumption with sufficient accuracy and
further can be utilized for analysis of energy conservation analysis in any sector.
REFERENCES
[1] Baker EHW 1976–“Rotary furnace” Modern Workshop Technology, part -1, Clever Hummer Press
Ltd., London- 2nd
Edition. Chap 4.
[2] Jain R.K., Singh R, 2008- “Modeling and Optimization of Rotary Furnace Parameters using
Regression & Numerical Techniques” proc. 68th World Foundry Congress, Feb7-10, 2008,
Chennai. Pp 178-185.
[3] Jain R.K., Singh R., Gupta B.D2008.- “Energy Considerations in Indian Ferrous Foundries’”.
Indian Foundry Journal, 54(8), p.p. 32-34.
[4] Baijya Nath, Pal Prosanto, Panigrahi K. C. 2007 “Energy Conservation Options among Indian
Foundries-A Broad Overview” . Indian Foundry Journal 53(8) pp. 27-30.
[5] Singh Kamlesh Kumar, 2007 - “Energy Efficiency in Foundry Process and Casting Rejection
Control” Indian Foundry Journal 53(11) pp. 43-48.
[6] Arjunwadkar S.H. Pal Prosanto, et al 2008 -“Energy Savings and Carbon Credits- Opportunities’
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