International Journal of Scientific and Research Publications 1 ISSN 2250-3153 www.ijsrp.org Cost Reduction Using Alternative Fuel in a Forging Industry Binoy C N * , Joseph George ** , Sijo M T *** * Mechanical Department, SCMS School of Engineering & Technology ** Mechanical Department, SCMS School of Engineering & Technology *** Assistant Professor, Mechanical Department, SCMS School of Engineering & Technology Abstract-Environmental concern and availability of petroleum fuels have caused interests in the search for alternate fuels for internal combustion engines. Conversion of waste to energy is one of the recent trends in minimizing not only the waste disposal but also could be used as an alternate fuel for Industries. Waste plastics are indispensable materials in the modern world and application in the industrial field is continually increasing. In this context, waste plastics are currently receiving renewed interest. As an alternative, non biodegradable, and renewable fuel, waste plastic oil is receiving increasing attention. In the present paper waste plastic pyrolysis oil, waste plastic pyrolysis oil and its blend as an alternative fuel for a forging industry has been introduced. In this study, Applicability of waste tyre pyrolysis oil was studied basis on a forging industry. Pyrolysis oil which is derived from waste rubber tyres was analyzed as an alternative fuel in forging industry. Pyrolysis oil was tested for the required specifications and compared with existing fuel. As because of its low flash point an attempt was done to blend pyrolysis oil and furnace oil to get the required flash point. Satisfactory result was got & Cost analysis on the basis of results was made. Cost analysis proves that using of pyrolysis tyre oil instead of current furnace oil will be beneficial for the forging industry Index Terms- Alternative Fuel, Tyre Pyrolysis Oil, Forging Industry, Cost Analysis I. INTRODUCTION lternative fuels are a material that can be used for fuel other than conventional fuels which are typically petroleum based. Usually alternative fuels are better for the environment. As the conventional fuels are depleting special attentions are now given for alternative fuels and they are gaining universal interest. Unlike rest of the world, India’s demand for diesel fuels is roughly six times that of gasoline hence seeking alternative to mineral diesel is a natural choice [1] . Industrial sector in India is developing and the need for fuels are also increasing as the industry is mainly depended on fossil fuels, the price fluctuation make their planning difficult and their cost of production will also increase. As this difficulty exists, they are searching for alternative fuels which can be a substitute for the present fuel with an economical benefit too. Waste to energy is the recent trend in the selection of alternate fuels [2] . Studies are made before on the subject Tyre pyrolysis oil as an alternative fuel. Disposal of waste rubber products is becoming an environmental challenge in many developing countries due to their non- biodegradability characteristic. Majority of waste rubber products are generated from worn or damaged automotive tyres and industrial conveyor belts [3] . Scrap tyre disposal is also a major environmental hazard. Waste plastics do not biodegrade in landfills, are not easily recycled, and degrade in quality during the recycling process [4] . Pyrolysis of scrap tyres will produce tyre Pyrolysis Oil (TPO), which has volatile capability. Tyres are bulky, designed to be tough and durable and once they are no good as tyres, they are difficult to cut up, hard to store or transport, thus making them very difficult to recycle in an economically viable manner [5]. According to Mr. Hirenkumar M Patel there are around billions tires which are thrown away every year in India. The numbers are expected to increase due to increasing numbers of vehicles. If the scrap tires are not managed well, the scrap tire can give bad effects to the environment and people’s health. One of the solutions is pyrolysis process. Pyrolysis oil is made by this process [6]. Most of the studies find the feasibility of using pyrolysis oil as an alternative fuel for diesel engines. Pyrolysis of waste vehicle tires with the purpose of fuel production for the usage as a fuel in internal combustion engine can be Seen as a hygienic, environmentally acceptable and efficient way of disposing them [6]. As waste disposal is also a major problem tyre pyrolysis can be adopted as a method through which fuel which has comparable features with diesel. Pyrolysis is the chemical decomposition of organic substances by heating the word is originally coined from the Greek-derived elements pyro "fire" and lysys "decomposition". Pyrolysis is usually the first chemical reaction that occurs in the burning of many solid organic fuels, cloth, like wood, and paper, and also of some kinds of plastic. In this study the feasibility and cost analysis of pyrolysis oil in a forging industry is studied. Cost reduction can also achieved by using pyrolysis oil, as it is cheaper than diesel and has almost same properties of diesel. A. The present study The study was conducted in a forging industry in Kerala, India. It is evident from previous research that no such work was carried out in forging industry where the tyre pyrolysis oil used as an alternative fuel for oil fired furnace. The objectives of the study are:  To test the alternative fuel and its required specifications.  To compare the result with the company requirements.  To do cost analysis of using pyrolysis oil against present fuel. A