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International Review of Mechanical Engineering - January 2012 (Vol. 6 N. 1) - Papers

 

 

 

 

   

 

 


 

 

International Review of Mechanical Engineering - Papers

 

 

go to top   Warpage Analyses on Thin Plate in Three-Plate Mold by Taguchi Method and Analysis of Variance (ANOVA) for PC, ABS and PC/ABS
         by Z. Shayfull, M. Fathullah, S.M. Nasir, N. A. Shuaib, M. S. Abdul Manan

        Vol. 6 n. 1, pp.1-10

 

Abstract -  Warpage is a common issue in plastic injection molding process. It can get worse for thin parts and therefore it is more challenging for product design engineers, mold designers and manufacturing engineer to cope with overwhelming customer demands on small and thin products lately. A lot of research have been done on this topic just to study the most significant factors influencing warpage on plastic parts but lack of study on thin plate parts by using pin point gate which is automatic de-gating gate which have an ability to reduce production cost. In this study, thin plate plastic product is to be the subject of analysis. The part with dimension 120mm x 50mm x 1mm is evaluated using pin point gate in three-plate mold. Three experiments have been done using Autodesk Moldflow Insight (AMI) to simulate warpage resulted on the thin plate parts by using Polycarbonate (PC), Acrylonitrile Butadiene Styrene (ABS) and Polycarbonate/Acrylonitrile Butadiene Styrene (PC/ABS) materials. Taguchi Method is applied in identifying the optimum value of injection molding parameters while Analysis of Variance (ANOVA) is used to get the most significant factor affected warpage. The results show that packing time is the most significant factor affecting warpage on thin plate parts for PC, ABS and PC/ABS materials. This finding is significant in helping industrial practitioners particularly in manufacturing ultra-thin shell parts with high quality in term of warpage issues.
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Keywords: Thin Plate, Plastic Injection molding, Warpage, Taguchi Method, ANOVA.

 


 

go to top   The Influence of Different Mold Temperature on Warpage in a Thin Shallow Injection Molding Process
 
        by N.A. Shuaib, S.M. Nasir, M.Fathullah, Z. Shayfull, M. S. Abdul Manan

         Vol. 6 n. 1, pp. 11-16
 

Abstract – Every injection molding parameter have its own influence towards the quality of an injection-molded part. Temperature, pressure and time are main parameters that typically highlighted in controlling the warpage defect of the part. This study is performed to investigate the influence of mold surface temperature, core and cavity temperature on warpage defect of a thin-shallow part. . The warpage results are obtained using Taguchi Method and optimized using Analysis of Variance (ANOVA) simulated in two experiments using Moldflow software. Confirmation run of best setting for experiment 2 which considers core temperature and cavity temperature resulted to be the more effective than considering only mold surface temperature in experiment 1. It is concluded that by considering core and cavity as the mold temperature, the warpage defect can be minimized up to 79.9%.

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Keywords: Thin Shallow, Mold Temperature, Injection Molding; Warpage, Taguchi Method.

 


 

go to top   Drag Force Reduction Technique for Abrasive Resisting Materials
         by S. V. Gavali, V. B. Tungikar

         Vol. 6 n. 1, pp. 17-21

 

Abstract - In this paper Computer program is developed for estimation of the effect of centrifugal force on the formation of graded distribution of right circular cone particles within the molten aluminum metal. The volume fraction of the heavier Titanium Di-boride particles is controlled by inertial forces upon centrifugal force processing the semisolid composite. Titanium Di-boride particles are modeled as right circular cone particles subject to a drag force in a Stoke flow in the liquid aluminum matrix. The equation of motion for the particles under the applied centrifugal forces is solved mathematically assuming a Gaussian diameter size distribution with a spatial uniform random distribution of particles in the sample. The effect of average particles diameter is also important .Larger the diameter of the particles faster is their motion, however the corresponding drag force increases. Hence the aerodynamic shape (right circular cone) is chosen to reduce the drag force. It is possible to understand and control the experimental conditions to obtain an appropriate functionally-graded aluminum matrix by centrifugal casting for high wear resistance applications.
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Keywords: Centrifugal Casting, Functionally Graded Aluminum Matrix, Titanium Di-Borides.

 


 

go to top   Radiation and Mass Transfer Effects on Flow of Micropolar Fluid Past a Continuously Moving Plate with Suction / Injection
         by P. Loganathan, N. Golden Stepha

         Vol. 6 n. 1, pp. 22-28  

 

Abstract - The present paper deals with the analysis of heat and mass transfer of a micropolar fluid on continuously moving plate with suction or injection. The plate is moving with a constant velocity in the fluid which is considered as gray, absorbing-emitting but non-scattering medium .The radiative heat flux and viscous dissipation are taken into account in the energy equation. The partial differential equations governing the flow have been transformed into system of ordinary differential equation and solved numerically by fourth order Runge-Kutta method with shooting technique. The velocity, microrotation, temperature, concentration, skin-friction, rate of heat and mass transfer are shown graphically.

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Keywords:  Microrotation, Radiation, Mass Transfer, Suction, Injection.

 


 

go to top   Concurrent Simulation of Permeability, Thermal Conductivity and Modulus for Carbon Fibre Reinforcements and Composites
         by Reza Samadi, Francois Robitaille

         Vol. 6 n. 1, pp. 29-38

 

Abstract - The selection of a carbon fibre reinforcement for manufacturing structural polymer composite parts requires good knowledge of numerous material properties at the design stage, for both the various carbon fibre reinforcements that may be selected and the composite parts to be made from these reinforcements. This paper presents predictive meso-scale simulations of i) in-plane permeabilities of unidirectional and bidirectional non-woven carbon fibre textile reinforcements, ii) through-thickness thermal conductivity of composites made from these reinforcements, and iii) in-plane moduli of composites made from these reinforcements. Experimental validation results are presented for all simulated properties. The effect of the reinforcement configuration on these processing (i) and performance (ii, iii) properties is quantified through systematic variation of the geometric parameters that define the configuration, for constant reinforcement surface density (s) and composite fibre volume fraction (vfc). Results are presented for 136 simulations performed using 34 geometric models of reinforcements. The geometric parameters that have the strongest effects on the permeability, conductivity and modulus are identified. Differences in the amplitude of these effects observed from simulation correlate well with the different levels of variability observed experimentally for each property.
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Keywords: Composite Materials, Reinforcement, Resin Flow, Thermal Conductivity, Stiffness.

 


 

go to top   Development of Tooling for Hydraulic Forming of Ceramic Spheroids Using Alumina
         by V. Bristot, V. Bristot, L. Schaeffer, V. Gruber

         Vol. 6 n. 1, pp. 39-43

 

Abstract - In this study, tooling for hydraulic shaping of ceramic spheroids in alumina was developed based on the process for manufacturing alumina bricks and ceramic tiles, since the only known process to shape ceramic spheres in alumina available on the market so far was that known as isostatic shaping. The purpose of these spheres and spheroids is to use as grinding bodies to process raw materials, reducing the solid matter particles. They were initially developed by making a model with a shaping cavity, obtained using a manual hydraulic press. Using the apparent density and wear results that were achieved using the spheroids produced from a cavity model, a prototype of the tooling was constructed with eight shaping cavities, and installed in an automatic hydraulic press to verify its performance in a real life industrial production situation.

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Keywords: Tools, Hydraulic Presses, Manufacturing Process.

 


 

go to top   Experimental Investigation on Hardness, Cutting Force and Roughness in Milling of Hybrid Composites
         by A. Arun Premnath, T. Alwarsamy, T. Rajmohan

         Vol. 6 n. 1, pp. 44-49

 

Abstract - Hybrid metal matrix composites (MMCs) form a new class of engineering materials which finds its application mainly in the aerospace and automobile sectors. In the present study a modest attempt has been made to develop aluminium based alumina and graphite particulate hybrid MMCs with an objective to study the effect of alumina weight fraction on cutting force and surface roughness in face milling of MMCs using tungsten carbide insert. Materials used for the present investigation are Al 6061-aluminum alloy reinforced with alumina (Al2O3) of size 45 microns and graphite (Gr) of an average size 60 microns, which are produced by stir casting route. Experiments were performed under different cutting conditions, such as spindle speed, feed rate and weight fraction of Al2O3 particles. The result indicated that the feed rate is the first predominant factor influencing the cutting force than alumina weight fraction and speed. The test results revealed that surface roughness increased with increasing the feed rate and decreased with increasing the speed and weight fraction of the particles.

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Keywords: Milling; Hybrid composites, Stir casting, Tungsten carbide inserts, Cutting force.

 


 

go to top   Optimization of the Boundary Conditions by Genetic Algorithms
         by J.L. Marcelin

         Vol. 6 n. 1, pp. 50-54

 

Abstract - This work examines the possibility of using a stochastic method, called the genetic algorithm for the optimization of boundary conditions in finite elements calculations. The examples show that using genetic algorithms in order to optimize boundary conditions is an efficient way.
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Keywords: Optimization, Boundary Conditions, Genetic Algorithms.

 


 

go to top   Stress Analysis of FG Thick Pressure Vessels Considering the Effects of Material Gradations and Poisson’s Ratio Using DQ Method
        by A. M. Goudarzi, S. Saadati, A. Paknahad

        Vol. 6 n. 1, pp. 55-60

 

Abstract - A numerical method has been proposed to obtain radial displacements of functionally graded thick-walled cylindrical pressure vessels. Also stress distributions for both plane-stress and plane-strain assumptions are calculated in radial and circumferential directions. The material is assumed to be isotropic where both of the elastic coefficients, i.e. Young’s modulus and Poisson’s ratio, are permitted to vary in the radial direction. Tree types of material gradations are considered for functionally graded material. The effects of spatial variation of Poisson’s ratio and material gradation upon the radial displacements and stress distributions are investigated.

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Keywords: : FGM, Pressure Vessel, Differential Quadrature Method, Poisson’s Ratio.

 


 

go to top   Iterative Algorithm for Active Vibration Control of Flexible Beam
         by Mohd S. Saad, Hishamuddin Jamaluddin, Intan Z. M. Darus

         Vol. 6 n. 1, pp. 61-73

 

Abstract - This paper presents the development of dynamic model of a flexible beam structure using finite difference method. A Simple Proportional (P) control scheme is applied to suppress vibration at the tip of the flexible beam. The performance of P controller is studied by gradually increasing manually the proportional gain until significant attenuation of the vibration is observed. Then the controller is further extended to self-tune the proportional gain by using an intelligent mechanism known as Proportional Iterative Learning Algorithms (P-type ILA). The robustness of both controllers in suppressing the vibration is investigated by changing the beam’s physical parameter, applying disturbance at different segments and amplitudes respectively. The simulation results clearly revealed the effectiveness and robustness of a self-tuning proportional control over conventional P control scheme as active vibration control of a flexible beam.

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Keywords:  Flexible Beam, Finite Difference, Iterative Learning, Vibration Control.

 


 

go to top   Reduced Models Based on Smooth Decomposition for Random Mechanical Systems
         by Sergio Bellizzi, Rubens Sampaio

         Vol. 6 n. 1, pp. 74-85

 

Abstract - In this paper, the smooth decomposition method combined with the Petrov-Galerkin projection for structure-preserving model reduction is used to analyze second-order discrete nonlinear structural systems under random excitation. The smooth decomposition method is a multivariable-data analysis method. It can be viewed as a projection of an ensemble of spatially distributed data such that the vector directions (the smooth modes) of the projection not only keep the maximum possible variance but also the resulting motions along the vector directions are as smooth in time as possible. The efficiency of the approach is analyzed comparing the power spectral density functions of the reduced-order model and of the original system. Nonlinear mechanical systems under random excitation with homogeneous and non-homogeneous mass distribution were considered. It is established here that a smooth-mode basis can be used advantageously instead of the Karhunen-Loève mode basis. In the case of a non-homogeneous mass distribution, the reduced models based on smooth decomposition were found to be the most efficient.

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Keywords:  Karhunen-Loève Modes, Smooth Mode, Model Reduction, Random Vibrations.

 


 

go to top  Hydrodynamics and Mass Transfer Using Three-Phase Fluidized Bed Contactor
         by Abbas H. Sulaymon, Raghad F. Almilly

         Vol. 6 n. 1, pp. 86-96
 

Abstract - This research presents a study of the hydrodynamics and mass transfer of the absorption of CO2 from CO2-air mixture (0.5-1%) by volume using water and NaOH solution. The hydrodynamic and mass transfer parameters are improved in the turbulent bed contactor (TBC) by the imposition of pulsed liquid flow (pulsation 0.01-0.03 m/s)upon a steady operation through this new research. New mathematical models of steady-state forces' balance for wetted-bed particles and single spherical particle were developed in TBC. It was found (by this new approach) that a single spherical mathematical model can well represent the TBC when shallow beds are used. New correlations were obtained to represent the various cases of the absorption processes using dimensional analysis. The constants of these correlations were determined using nonlinear regression technique.
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Keywords: Absorption of CO2 , Dimensional Analysis, Hydrodynamics and Mass Transfer , Pulsation in Liquid Flow , Mathematical Model , Single Sphere , Three-Phase Fluidized Bed Contactor.

 


 

go to top   Experimental Study on the Forced Draft Cooling Tower Using Psychrometric Gun Technique
         by Ramkumar Ramakrishnan, Ragupathy Arumugam

         Vol. 6 n. 1, pp. 97-103

 

Abstract - In this paper an experimental study was carried out on forced draft cooing tower with expanded wire mesh (EWMP) packing. Air quality and performance of the tower was studied over the packing height. Due to complicated configuration of packing surface, it is not possible to measure the air temperature at the intermediate points of the packing height. In the present experimental study a new concept of psychrometric gun technique is used to measure dry/wet bulb temperature of air at intermediate points of tower packing. The paper elaborates the effect of L/G ratio on the thermodynamics properties of moist air inside the cooling tower and performance characteristics over the packing height. It has been concluded from this work that the minimum cold water temperature was attained at lower L/G ratio and the tower performance decreases with an increase in the L/G ratio. Experimental values were compared with the mathematical model.

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Keywords: Cooling tower, Psychrometric gun, Wire Mesh packing, Characteristic, Thermal Performance.

 


 

go to top   Experimental Investigation of Heated Horizontal Rectangular Fin Array under Mixed Convection
         by S.G. Taji, G. V. Parishwad, N. K. Sane

         Vol. 6 n. 1, pp. 104-112

 

Abstract - This work is presented on experimental study of heat transfer by natural and mixed convection from horizontal rectangular fin array with variation in spacing. The purpose of present paper is to investigate the possibility of performance improvement of horizontal rectangular fin array in assisting mode of mixed convection. The performance of horizontal fin array is studied by varying spacing, keeping length and height same for different heater input and flow velocities. At natural convection condition experimental investigation of fin array shows possibility of better performance with optimum fin spacing region which is in between 8-10 mm. The experimental results are validated with the previous investigator’s heat transfer results for natural and assisting mode of mixed convection. Experimental results are in close match with the previous investigators results and lie in between heated horizontal flat plate and vertical plate under natural convection. At all Richardson number (Ri), forced flow assists natural convection and ha values are always higher in assisting mode compared with those under natural convection.
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Keywords: Cooling of Electronic Devices, Natural and Mixed Convection, Horizontal Fin Array.

 


 

go to top   Calculation of Reduction Heat Transfer between Two Finite Concentric Cylinders Using Radiation Shields with Temperature-Dependent Emissivity
         by Seyfolah Saedodin, M.S. Motaghedi Barforoush, Mohsen Torabi

         Vol. 6 n. 1, pp. 113-119

 

Abstract - Radiation is one of the most important modes of heat transfer. The present article is concerned with determination of the effect of the one and two radiation shields between two finite concentric cylinders to reduce net heat transfer. Hence a simplifying approach for calculating the radiant energy is achieved using the concept of net radiation heat transfer and provides an easy way for solving a variety of situations. This method has been applied to calculate the net radiation heat transfer between two finite concentric cylinders. Then this method used to calculate reduction heat transfer when radiation shields with temperature-dependent emissivity applied between these objects. Moreover, using this method the percentage reduction in heat transfer between two surfaces was calculated. The findings reveal that, one tungsten radiation shield which has very low emissivity can reduce the net heat transfer even better than two aluminum oxide radiation shields.
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Keywords: Radiation Shield, Net Radiation Method, Concentric Cylinders with Finite Length, Temperature-Dependent Emissivity.

 


 

go to top   Heat Generation Effects on Unsteady Natural Convective Flow over a Vertical Plate with Variable Viscosity
         by P. Loganathan, D. Iranian, P. Ganesan

         Vol. 6 n. 1, pp. 120-127

 

Abstract - This paper is focused on the study of heat generation on unsteady natural convective flow over a semi infinite vertical isothermal plate with effects of variable viscosity. It is assumed that the viscosity of the fluid to vary as an exponential function of the temperature. The governing equations of continuity, momentum and energy are transformed into non-linear coupled equations and then solved using implicit finite-difference method of Crank -Nicholson type. The fundamental parameter of the problem is variable viscosity parameter. Numerical results are found for different values of heat generation, viscosity variation parameters and Prandtl number (both air and water). The velocity, temperature distributions, local as well as skin friction coefficient and Nusselt number are analyzed numerically and shown graphically. The skin-friction coefficient and heat transfer rate are found to depend strongly on the viscosity parameter. It is noted that the results pertaining to variable fluid properties differ significantly from those of the constant fluid properties.

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Keywords:  Unsteady, Variable Viscosity, Vertical Plate, Heat Generation, Finite Difference.

 


 

go to top   Effect of Cavity Design of Synthetic Jet Actuator to the Heat Transfer Characteristic of an Impinging Flow Configuration
        by Harinaldi, Rikko Defriadi, Damora Rhakasywi

        Vol. 6 n. 1, pp. 128-136

 

Abstract - A Synthetic jet works based on a vibrating membrane inside a cavity and nozzle for the air outlet. The synthetic jet cavity interior has an important role to generate the air at sufficient conditions to do the cooling process. This research investigated the flow and convective heat transfer characteristics on four impinging synthetic jet prototype with different excitation modes of a sinusoidal waveform forcing. The main purpose of this synthetic jet was to create vortices pair to come out from nozzle which will accelerate the heat transfer process occurring at the impinged wall. This heat transfer enhancement principles became the basis to simulate an alternative cooling system to substitute the conventional fan cooling in electronic devices due to its advantage for having a small form factor and low noise. The investigation combined computational and experimental works. In the experiment sinusoidal waveform was used to oscillate the membrane and the wave frequency used were 80 Hz, 120 Hz, 160 Hz and the velocity amplitude was 1 m/s. Some results indicated significant influence of the cavity design, frequency excitation, and waveform to the rate of heat transfer obtained.
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Keywords: Heat Transfer, Impinging Wall, Synthetic Jet, Sinusoidal Wave.

 


 

go to top   Resonant Behavior of a Hydraulic Ram Pump
         by Mario O. M. de Carvalho, Alberto C. G. C. Diniz, Fernando J. R. Neves

         Vol. 6 n. 1, pp. 137-146

 

Abstract - Performance of Hydraulic Ram Pumps is studied in certain operation conditions. Operation near resonant conditions is studied in order to delimit areas of good design and operation. A numerical model previously developed by the authors for simulation of the dynamic behavior of these machines is used. The results identify situations of inadequate operation and reinterpret traditional design and operation criteria for the ram pump, which, to date, have been mainly empirical.

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Keywords:  Hydraulic Ram Pump, Numerical Simulation, Optimization, Resonance.

 


 

go to top   Combustion and Performance Analysis Of DI-Diesel Engine Fuelled with Neat Mahua Methyl Ester along with Oxygenated Fuel (DEE) as an Additive
         by A P. Ramesh Babu, V.J.J. Prasad, N. Hari Babu, B.V.Appa Rao

         Vol. 6 n. 1, pp. 147-152
 

Abstract - IBio-diesels and their blends are proven alternative fuels for petroleum diesel. But still the research work is going, on the bio-diesels application to make it environmental friendly. Particulate matter and oxides of nitrogen are the main pollutants in the tail pipe emissions of bio-diesel fueled engine. In this paper, mahuva methyl ester along with diethyl ether (DEE) used as fuel for the single cylinder DI-Diesel engine, analysis of combustion pressure and heat release rate with respective to the crank angle and performance and emission analysis is presented.. In this experiment DEE mixed with the MME at different proportion such as 3%, 5% 10% and tested at different loads on diesel engine. Smoke levels are decreased substantially with 15% DEE blend with MME at full load. The thermal efficiency rise and SFC are better in the case of 15% additive blend.

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Keywords:  Oxygenated Fuels, Dimethyl Ether, Mahuva Methyl Ester, Diethyl Ether, Combustion Pressure.

 


 

go to top   Real-Time Control of Automotive Engine Fuelled with Malaysian Palm Oil Biodiesel
         by Azuwir Mohdnor., M.Z. Abdulmuin, A.H. Adom

         Vol. 6 n. 1, pp. 153-160

 

Abstract - With the rapid decline in energy resources, the increasing environmental concerns, and the high demand of energy consumption, many countries have been looking for alternative energy to substitute fossil fuel. One of the alternative is to use bio-fuel as renewable energy. This paper describes the real-time control of automotive engine fuelled with palm oil biodiesel (Palm Methyl Esters). A self-tuning control algorithm based on pole assignment method is presented and an on-line model parameters estimation strategy based on the recursive least squares method is developed. Assuming a discrete time form for the system model, an Autoregressive eXogenous (ARX) model structure was selected in this work. The estimation strategy recursively updates the system dynamics of the engine in order for the self-tuning controller to control the engine speed for the best possible transient and steady state response at the speed range from 1800 rpm to 2300 rpm. Real-time results of the on-line parameter estimation and self-tuning speed controller implemented for automotive engine fuelled with palm biodiesel were presented. Finally, the performance of the speed controller error was examined.

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Keywords:  Engine Speed Controller, PID, Self-Tuning, Palm Biodiesel.

 


 

go to top   Reduction of NOx Emission from Diesel Engine using Urea Injection with SCR Technique with Different Catalyst Connected in Series
         by K. Chithamparam Asary, N.V. Mahalakshmi, K. Jeyachandran

         Vol. 6 n. 1, pp. 161-165

 

Abstract - The reduction of oxides of nitrogen emission (NOx) from compression ignition engines is an important objective due to environmental and human health concerns particularly in areas that are ozone non-attainment zones. In addition, NOx emissions from engines and vehicles are legislated and regulated around the world, with the emissions regulations continuously tightening in the upcoming years. Thus, many methods that can reduce these emissions from compression ignition engines and vehicles are being considered as options. The scope of this paper is to explore strategies to reduce NOx emissions from compression ignition engines. This paper uses the injection of aqueous Solution of urea in the Exhaust stream for the reduction of NOx. The test was carried out in a single cylinder light duty water cooled DI Diesel engine which is coupled with an eddy current dynamometer. Initially, the optimum flow rate and the concentration of urea solution for the maximum reduction of NOx were determined for different loading conditions. In the initial experimental work, there were no appreciable changes in CO, CO2 and O2 in the engine exhaust, except some reduction of HC and exhaust gas temperature and increase in smoke density due to injection of urea in the engine exhaust. It had been concluded that 29.3% of NOx reduction was achieved with the flow rate of 0.75 lt/hr with 30% concentration. Also a selective catalytic reduction technique with vanadium and titanium dioxide catalyst connected in series was introduced which showed 89.73% of NOx reduction from the engine exhaust.
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Keywords: Nox Reduction, Selective Catalytic Reduction Technique, Vanadium and Titanium Dioxide Catalyst, Aqueous Solution of Urea.

 


 

go to top   Jordan Transport Energy Demand Forecasting: The Application of Time Series Technique
         by Adnan Mukattash, Ahmed Al-Ghandoor, Ahmad M. Qamar

         Vol. 6 n. 1, pp. 166-169

 

Abstract - This paper illustrates the application of double exponential smoothing technique to forecast Jordan transport energy demand. The model has been developed using past Jordan transport energy demand during years 1985-2009. The results show that energy demand will increase by 5.23/yr during the forecasted period reaching 4,200 thousands ton oil equivalents (toe). It is expected that the results of this study will be helpful in developing highly applicable and productive planning for future transport energy policies.

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Keywords:  Energy, Transportation, Forecasting, Jordan.

 

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