Experimental, Computational and Numerical Analysis

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
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 of10%. 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.

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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
following steps:
(I)
(II)
(III)
(IV)
(V)
(VI)
(VII)
the
Preheating of oil and furnace

Charging After pre heating, the furnace is charged.
Rotation-After sufficient pre heating and charging, the furnace is rotated at desired speed.
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 1300C, the rotation of furnace is stopped.
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.
Inoculation-The Ferro silicon and Ferro manganese approx. 600 grams per heat are added in
molten metal contained in the ladles.
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
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
1
2
3
4
5
1
2
3
4
5
2.0
2.0
2.0
2.0
2.0
50.0
47.0
46.0
46.0
45.0
92.0
90.0
87.0
86.0
83.0
0.460
0.450
0.435
0.430
0.415
240.0
255.3
260.8
266.0
266.0
1310.0
1314.0
1325.0
1334.0
1350.0
1320.0
1290.0
1240.0
1220.0
1175.0
Energy
consumption
oxygen enrich.
kwh/kg
4.556
4.457
4.308
4.259
4.110
(I) The graphical representation the graphical representation of energy consumption under existing
conditions of operation is shown in fig 2.

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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.
no
Rp
m
1
2
1.0
1.0
Preh
eated
air
temp
0
C
410.0
418.0
3
4
5
1.0
1.0
1.0
428.0
449.0
454.0
1730.0
1746.0
1752.0
6
7
1.0
1.0
458.0
460.0
1754.0
1755.0
He
at
rate
kg/hr
fuel
cons
lit/kg
56.0
56.0
363.0
375.0
0.280
0.280
39.0
39.0
6.9
6.9
459.0
459.0
75.3
75.3
2.773
2.773
32.0
31.5
31.0
55.0
54.0
53.0
375.0
385.0
387.0
0.280
0.270
0.265
38.5
38.0
37.0
6.9
6.9
6.9
451.0
443.0
434.5
75.4
75.4
75.3
2.773
2.674
2.624
30.5
30.5
52.0
52.0
393.0
393.4
0.260
0.260
36.6
36.5
6.9
6.9
426.7
426.5
75.4
75.4
2.575
2.575
Time
min
Fuel
liter
1710.0
1722.0
33.0
32.0
Melting
Specific
Oxy
gen
cons
%
Preheated
Energy
consumpti
on oxygen
enrich
kwh/kg
Oxy
gen
cons
m3
Flame
temp0
C
air
cons.
m3
Preheated
air
cons %
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.

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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
Parameters
Time minutes
Flame temperature0C
Melting rate kg/hr
Fuel liters
Specific fuel cons.lit/kg
Specific energy cons. kwh/kg
Preheated Air consumption m3
Oxygen consumption
Operating furnace
without oxygen
enrichment of preheated
air
45.0
1350.0
266.0
83.0
0.415
4.110
1175.0
-------
Operating furnace with 6.9%

oxygen enrichment of 75.3%75.4% of theoretically required
preheated air
30.5
1755.0
393.4
52.0
0.260
2.575
426.5
182.5 m3/tone
(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.

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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
Sn
1
2
3
4
5
6
7
<--------------- INPUT X -----------------------------------------------------
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
0.280
0.280
0.280
0.270
0.265
0.260
0.260
410
418
428
449
454
458
460
1710
1722
1730
1746
1752
1754
1755
33
32
32
31.5
31
30.5
30.5
56
56
55
54
53
52
52
39
39
38.5
38
37
36.60
36.50
459
459
451
443
434.5
426.7
426.5
363
375
375
385
387
393.44
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
= [(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
close
all;
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
S.No.
1
2
3
4
5
6
7
Modeled
output
0.3185
0.3186
0.3186
0.3072
0.3015
0.3020
0.2958
Experimental
output
0.280
0.280
0.280
0.270
0.265
0.260
0.260
Absolute
variation
+0.0385
+0.0386
+0.0386
+0.0372
+0.0365
+0.042
-0.0358
(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.
% Absolute
variation
+12.087
+12.115
+12.115
+12.109
+12.106
+13.907
-12.102
Mean average
%variation
+8.905%

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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+a1x3+a2x2+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
S.No.
1
2
3
4
5
Equations
a 0 (39.0) 4 +a 1 (39.0) 3 +a 2 (39.0) 2 +a 3 (39.0)+a 4 = 56.0
a 0 (38.5) 4 +a 1 (38.5) 3 +a 2 (38.5) 2 +a 3 (38.5)+a 4 = 55.0
a 0 (38.0) 4 +a 1 (38.0) 3 +a 2 (38.0) 2 +a 3 (38.0)+a 4 =54.0
a 0 (37.0) 4 +a 1 (37.0) 3 +a 2 (37.0) 2 +a 3 (37.0)+a 4 = 53.0
a 0 (36.5.0) 4 +a 1 (36.5.0) 3 +a 2 (36.5) 2 +a 3 (36.5)+a 4 =52.0
(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:
SN Constants Value
X = -0.4
1
a0
-0.4
60.667
2
a1
60.667
-3449.5
3
a2
-3449.5
87150.83
4
a
87150.83
3
-825446.6
5
a
-825446.6
4
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
Equation
Calcula
ted
output
Experi
mental
output
Absolute
variation
%
Absolute
variation
1
2
a0(39.0)4+a1(39.0)3 +a2(39.0)2 +a3(39.0)+a4=

a 0 (38.5) 4 +a 1 (38.5) 3 +a 2 (38.5) 2 +a 3 (38.5)+a 4
55.843
54.093
56.00
55.00
-0.157
-0.907
-0.280%-1.649%
3
4
5
a0(38.0)4+a1(38.0)3+a2(38.0)2+a3(38.0)+a4
a0(37.0)4+a1(37.0)3+a2(37.0)2+a3(37.0)+a4
a0(36.5.0)4+a1(36.5.0)3+a2(36.5)2+a3(36.5)+a4
52.364
49.961
48.283
54.00
53.00
52.00
-1.636
-3.039
-3.717
-3.029%
-5.733
-7.148%
S
No
Mean
average
%
variation
-3.5678%

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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
Parameters
Time minutes
Flame temperature0C
Melting rate kg/hr
Fuel liters
Specific fuel cons.lit/kg
Specific energy cons.kwh/kg
Preheated Air consumption m3
Oxygen consumption
Percentage reductions/increments
-32.22%
+30%
+47.89%
-37.34%
-37.34%
37.34
-63.70%
-
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
10

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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 1976Rotary 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]
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ISSN
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(P) 2347-8772
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12

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International Journal of Research in Mechanical Engineering

Volume-2, Issue-2, March-April, 2014, pp. 01-12, IASTER 2014