| Abstract: |
The global cast iron foundry sector is one of the most energy-intensive manufacturing industries, contributing substantially to greenhouse gas emissions and resource depletion. India, currently ranked as the second-largest casting producer in the world with approximately 14.16 million metric tonnes of output in 2022–23, faces mounting challenges from conventional furnace technologies characterized by high coke consumption, elevated CO2 emissions, and low thermal efficiency. This paper presents an innovative approach to the design of a low-cost green cupola furnace for cast iron production, integrating biomass-charcoal fuel substitution, divided-blast optimization, preheated air supply, and post-combustion heat recovery systems. Drawing on verified global and Indian foundry data, the study evaluates thermal performance, energy consumption, and carbon emission reduction potential of the proposed green furnace in comparison to conventional coke-fired alternatives. The central hypothesis posits that a low-cost green cupola furnace employing optimized biomass blending and divided-blast technology can achieve CO2 emission reductions of 20–40% and energy savings of 15–25% without compromising cast iron metallurgical quality, offering a cost-effective decarbonization pathway for Indian small and medium foundries. |
