International Journal of Engineering Trends and Technology (IJETT) – Volume 12 Number 7 - Jun 2014
Design, Fabrication and the Experimental
Performance Evaluation of Flat Plate Solar Water
Heater specifically for Jorhat, Assam (26.750N,
94.220E)
D. Sarma1, R. Gogoi2, B. Nath2, S. Konwar2,
C.L. Meitei2
1
1,2
M.E student, 2BE Student
Mechanical Engineering Department, Jorhat Engineering College
Abstract: Among all the non-conventional energy sources, solar
energy is one of the main alternative source of energy for the
limited fossil fuels. The conversion of solar radiation into heat
energy in an effective and efficient way which can be used in the
domestic as well as small scale industrial heating purposes is now
a challenge for the human race. This study focuses on design and
experimental performance analysis of solar flat plate water
heater under the meteorological condition of Assam using locally
available materials. The solar flat plate water heater is
specifically designed, fabricated and tested at Jorhat, Assam on
latitude 26.750N.Solar energy is absorbed by the flat-plate
collector consisting of a thin aluminium absorber plate integrated
with fluid carrying copper riser and header tubes, and placed in
an insulated casing with a glazing glass cover and also a storage
water tank is integrated with the system. The energy emitted by
the absorber plate cannot escape through the glass, thus
temperature rises. The water gets heated and flows into the
storage tank due to difference in density and is known as
thermosyphon principle.
Keywords: solar water heater, solar energy, solar collector,
thermosyphon principle.
I. INTRODUCTION
Solar energy being abundant and widespread in its
availability, free from environmental pollution makes it one of
the most promising source of alternative energy. The
availability of solar energy in a region depends on the
meteorological condition of the location. Solar thermal energy
has historically been associated with water heating, which is
the second-end-use energy demand in the residential sector
and the sixth largest in the commercial sector[1]. A solar
collector absorbs the incident solar radiation, converts it into
heat and finally transfers this heat to a working fluid. Solar
water heating system receives energy from the sun to directly
or indirectly heat water. The natural or free circulation solar
water heating system is mostly applicable in smaller
installations. The natural circulation of water between the
solar collector and the water store is governed by
thermosyphon action, whereas in the force convection system
an external agent is integrated with the system which
increases the cost, energy consumption as well as the system
ISSN: 2231-5381
becomes complex in design. The technology of solar energy is
well understood and in meeting energy and environmental
goals the role of this technology is crucial. This technology
has the potential to substitute the natural gas and electricity
in all climates. This study is an attempt to design and fabricate
a suitable model to enhance the collector efficiency under
meteorological condition of Jorhat, Assam on latitude
26.750N.
II. LITERATURE REVIEW
In order to design a flat plate solar water heater a
series of studies have been made on natural circulation solar
water heating system and various conclusions have been
drawn to improve the performance of the system. All natural
circulation systems are self-regulating, the greater the energy
received, the more the vigorous circulation[2]. The force that
induces the circulation by overcoming the resistance of the
system components is due to the difference in density of the
hot water in the flow pipe. Higher flow rate leads to higher
collector efficiency factor. However, it leads to higher mixing
in tank and therefore a reduction in the overall solar water
heating system efficiency[3]. The circulation rate increases
when the riser tube of converging cross-sectional area is used.
However, the water content in the converging riser was less
than that in the straight riser; so the temperature increased and
its density was lighter[4]. Various studies reviewed above
have shown the importance of flow rate to the collector
performance of the solar water heating system. In this study,
the fluid flow system of a natural circulation solar water is
designed and constructed with the aim of improving the
collector efficiency and its comparison with the theoretical
model.
III. OBJECTIVE OF PRESENT WORK
In this present work, it has been proposed to design
and fabricate a flat plate solar water heating system for
determining the performance specifically for Jorhat, Assam on
latitude 26.75N where the intensity of solar radiation is
4.47KWh/m2/day, which is quite low as compared to the other
part of the country. The capacity of the SWHS is 50 litres of
water for domestic purpose. In this study, the fluid flow
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International Journal of Engineering Trends and Technology (IJETT) – Volume 12 Number 7 - Jun 2014
system of a natural circulation solar water is designed and
constructed with the aim of improving the collector efficiency.
IV. MATERIALS AND METHODS
Solar water heater is getting popularity in use since
they are relatively inexpensive, easy to fabricate and
maintain.[5]. A careful study of the existing solar water
heating systems was done and a choice was made on the
system to be designed with focus on simplicity, installation
and maintenance cost as well as durability [6]-[10]. Use of
locally available materials was made a matter of priority. A
flat plate collector is used as the absorber plate and is
integrated with the riser pipes and header pipes and is placed
in an insulated casing with a glass cover. A water storage tank
is integrated in the system. The water gets heated up and flows
into the storage water tank through thermosyphon principle.
The performance of thermosyphon depends upon the size and
capacity of the storage tank, the thermal capacity of the
collector and the connecting pipes including fluid flow[6]. All
components have been designed for and constructed in line
with the design values obtained. The system was tested for
several months and results were tabulated.
Working principle of a flat-plate solar water heater
Under gravity, cold water from the tank enters the
collector through the bottom header pipes and into the riser
tubes until all the absorber tubes and the header at the top of
the absorber sheet are filled with water. When the sun rises to
a certain level, the radiant energy which falls on the absorber
tubes and plate after passing through the glass glazing begins
to heat the water therein. The heated water, being less dense
and lighter than the cold water, rises and via the top header
pipe flows into the top of the insulated tank. This process
continues as more cold water from the tank flows into the
collector. This process is called “Thermosyphon process” and
this thermosyphon process continues until the temperature of
water in the tank and the absorber tubes equalizes. Further,
when the hot water from the tank is drawn out till the point of
utilization, cold water enters the tank. Thus towering the
overall temperature between the water in the tank and
absorber tubes, and thus the thermo-syphon process starts
once again as explained earlier. Solar water heaters based on
thermosyphon principle have the following advantages:
simplicity and low cost requires no electrical supply, need no
external agents to control, easy to install, is reliable and longlasting since there are no moving parts, several collectors can
be connected in parallel to increase hot water supply, is easy
to build and operate, no fuel cost, provides heated water of
about 80 °C or within the range, and is portable. They,
however, highly depend on weather conditions, very useful
and effective only during the dry season, and can be more
practicable and useful in regions with high solar intensity.
ISSN: 2231-5381
V. DESIGN ANALYSIS
The solar flat plate water heater has been divided into
the following components namely: absorber plate, storage
tank and fluid passage pipes. The design of the present model
has been made considering the meteorological conditions of
Jorhat, Assam, where the received intensity of solar radiation
is about 4.47Kwh/m2/day obtained from Atmospheric Science
Data Center,NASA[14], which is reasonably low compared to
the national standard intensity. Therefore, the design has been
made to eliminate all these factors to improve collector
efficiency for this region modifying the recommended Indian
standard(IS:12933; part 1) in particular cases. The complete
view of the designed prototype is shown in fig:1 and fig:2.
a) Calculation of designed efficiency of the system ( ηo)
Overall efficiency of the system, ηo=
heat removed by water per second
Energy collected by water per second
=54.6%
b) Calculation of collector efficiency
Amount of radiant energy removed by water in the collector
per second, Q= mCpΔT
where, m= mass flow rate of water
Cp= Specific heat of water
ΔT= maximum change in the temperature of water
Total amount of radiant energy incident upon the collector
plate= IAc
Where, I= monthly solar intensity,Ac= area of the collector
plate
Efficiency of the collector plate is given as,
radiant energy removed by water in thecollector for 6 hours
η= total amount of radiant energy incident upon the plate for6 hours
η=
=
%
The average overall efficiency of the system obtained,
ηavg = 54.32%
Selection of storage tank
Selection of the shape of the storage tank is a
significant factor in the design of the flat plate solar water
heater. Three basic geometrical shapes as cubical, cylindrical
and spherical shapes have been taken into consideration and
the Area/Volume ratio for each shape calculated. The
Area/Volume ratio for spherical shape is observed to be the
least of the three shapes. Since heat loss is directly
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International Journal of Engineering Trends and Technology (IJETT) – Volume 12 Number 7 - Jun 2014
proportional to the surface area of a body, the least amount of
heat loss is observed in case of the spherical shaped tank its
least surface area, the volume of all the tanks being constant.
But the construction of such a spherical tank is difficult as
well as expensive. Taking all the factors into account,
cylindrical shaped storage tank is preferred; its Area/volume
ratio value lying between that of the other two shapes.
Heat loss through the top and bottom of the tank=
=2.36W/m2
=2.36 0.3280
=0.774W
Total heat loss through the tank = 2.144 W
Pipe sizing
Diameter of riser pipe= 0.009m
Diameter of header pipe= 0.0127m
Tank specification
Material used: Galvanized iron sheet
Diameter of the tank, d= 0.457m
Height of the tank, h = 0.304m
Side area of the tank = 0.4374m2
Base and top area
= 0.3280m2
Total surface area = side area+ base and top area
=0.7655m2
Thickness of the tank = 0.2 cm
=0.002m
Thermal resistance of the GI sheet
=
=
=0.00003m2-K/W
Fig:1. Complete design of the prototype
Tank insulation
The tank is insulated on the sides with a thermocol layer of
3cm and glass wool layer of 13.6 cm; the top and bottom of
the tank is insulated with thermocol layer of thickness 9.5cm
and 8.1cm respectively.
Thermal resistance of glass-wool on the sides of the tank=
3.4m2K/W
Thermal resistance of thermocol on the sides of the tank=
1m2k/W
Total resistance on the sides of the tank
Rs=4.4m2k/W
Heat loss calculated through the sides of the tank is found to
be
= 1.52W
Heat loss through the sides of the tank,
Fig: 2. Exploded view of the collector plate
VI. SELECTION OF MATERIALS
=
=
W/m2 =3.14W/m2
= 3.14 0.4374 W
=1.37W
Thermal resistance of the top and bottom of the tank=
5.86m2K/W
ISSN: 2231-5381
Diathermanous materials (glazing): In order to
provide the necessary “Green house” effect to heat up the
water, a transparent cover is required. The purpose of glazing
is to admit maximum possible heat radiation and to reduce the
loss of heat from the top of the collector to the lowest
attainable value. Glass, having low iron content is used as the
principal material to glaze the solar collectors since it has a
relatively high thermal transmittance to visible light (0.8520.9 at normal incidence) and low thermal transmittance to
infrared radiation. A clear window glass panel of length 2.05m
and breadth 1.035m and thickness 4mm has been provided as
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International Journal of Engineering Trends and Technology (IJETT) – Volume 12 Number 7 - Jun 2014
glazing. The outer portion is framed with plywood of
thickness 10.2mm.
Absorber plate: The absorber is usually made of copper,
aluminium or steel. Factors that determine the choice of
absorber material are its thermal conductivity, its durability
and ease in handling its availability and cost and the energy
required to produce it. Copper is best suited as the material for
the absorber plate but due to its high thermal conductivity but
it is very expensive. Thus we have opted for aluminum sheet
as the absorber plate, taking into account its cheapness
compared to copper, its good means of attachment to other
materials despite the low welding properties and most
importantly its good thermal conductivity. The length and
breadth of the absorber plate are 2m and 1m respectively. To
increase the absorptivity a coating of black paint is applied
over it.
Collector casing: Casing is an important part of a flat plate
solar water which surrounds the inner components like the
absorber plate, tubes and keep them free from dust, moisture
etc. in absence of proper casing heat is lost from the absorber
as a result of not only forced convection caused by the local
wind but also the natural convective air currents created
because the absorber is hotter than ambient air. The casing
forms a trapped air spaced thereby reducing these losses. The
casing has been constructed from plywood of length 2.035m,
breadth 1.4m and thickness 0.17m. The inner part of the
casing has been kept vacant for the insulation set up and
supports have been provided to support the sheet.
Collector insulation: Flat plate collectors must be insulated to
reduce the conduction and convection losses through the
backside and the sides of the collector box. The insulation
material should be dimensionally and chemically stable at
high temperatures and resistant to weathering and dampness
from condensation. The insulating material materials used in
the project are glass-wool. The inner part of the casing has
been lined with a layer of thermocol. Sections of thermocol
have been placed in parallel to form air-pockets at regular
intervals to minimize the convective heat loss and reduce the
bottom surface area of insulation. The sections have been
covered with thin sheets of chart paper and then covered with
glass wool. Also a thin layer of thermocol layer of thickness
6cm is lined in the side of the casing to reduce heat loss
through the side wall. Glass wool of thickness 5cm has been
placed above the chart paper.
Pipes: Copper pipes of diameter 9mm have been used as riser
tubes. Copper pipes are first straightened and then welded to
the header pipes and the whole arrangement is connected to
the aluminum absorber plate. Two copper pipes of diameter
1.27 cm have been used as header pipes. The header pipes and
riser pipes are joined by arc welding process.
Fig 3. Image of the prototype
VII. RESULTS AND DISCUSSION
This study dealt with the design, fabrication and
performance analysis of the flat plate solar water heater. From
the experimental study of the designed prototype as shown in
fig:3 it is observed that the theoretical efficiency as well as the
experimental efficiency are almost equal. This can be
explained with the help of Fourier's law which states more the
temperature rise greater will be heat loss. The modification
done in the part of insulation in comparison with the IS:
12933 part 1 recommended standard reduces the heat loss.
The maximum temperature obtained from the prototype is
75.70C while the ambient temperature was 26.80C. It shows
that the outlet temperature of the water is 48.90C higher than
the ambient temperature. The average efficiency of the system
is 54.3% which is quite reasonable under the meteorological
condition of Jorhat on latitude 26.750C.
Wooden Frames: Two wooden frames have been fabricated for
storage tank as well as for the plywood casing. In the casing
stand proper provisions are made with tilt angle mechanism
for better interception of the incident solar radiation on the
absorber plate. Also a screw adjustment of the angular
inclination has been installed for fine adjustment of the
angular inclination. The height of the storage tank stand is
around 6ft which is equal to height of the casing at maximum
inclination.
ISSN: 2231-5381
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(a) January' 2014
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International Journal of Engineering Trends and Technology (IJETT) – Volume 12 Number 7 - Jun 2014
(b) February' 2014
(b) 3rd February 2014
(c) March' 2014
Fig: 4 (a,b & c). The average variation of the temperatures with time in three
months.
(c) 12th March 2014
Fig:5 (a,b&c). The variation of temperatures with time in particular dates.
(a) 23rd January,2014
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In the fig:4(a, b & c) the typical average daily
variation of the ambient temperature, storage water
temperature and the outlet water temperature of the system for
every months are depicted. In the fig:5(a,b,& c), the variations
of the ambient, storage water and outlet water temperatures
have been shown on three particular dates in three respective
months. It can be concluded from the above figures that the
temperature of the system gradually rises and reaches peak
value around the middle of the day where the peak solar
insolation occurs. It has been observed that the rise of
temperature difference between the ambient and the plate
outlet temperature gradually increases from the month of
January to February and relatively low in March.
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International Journal of Engineering Trends and Technology (IJETT) – Volume 12 Number 7 - Jun 2014
[11] D. A. G. Redpath, 'Thermosyphon heat-pipe evacuated tube solar water
heaters for northern maritime climates, Solar Energy', 86 (2012), 705–715.
VIII. CONCLUSIONS
From the experimental study of the designed and
constructed flat plate solar water heater specifically for the
region of Jorhat, Assam on latitude 26.750N where the average
solar insolation is quite low compared to the other region of
the nation, the following conclusions can be drawn: The
efficiency of the system drops during the month of February
due to the weather status of the region. From the daily analysis
of the system it shows that the temperature varies and reach
maximum around the mid-day when the collector plate
receives maximum energy and is relatively low in the
morning. It shows that the temperature of the water in the
system depends upon the solar radiation incident on the plate
and on the weather condition of the location. The efficiency of
the system can be improved by using proper coatings to
increase the absorptivity and also by reducing heat loss
through the various surfaces of the system. Provisions for
angular installation can be integrated with the system for
receiving maximum solar radiation and thus will increase the
efficiency of the system.
[12] Nosa Andrew Ogie, Ikponmwosa Oghogho and Julius Jesumirew,
“Design and Construction of a Solar Water Heater Based on the
Thermosyphon Principle”, Ashdin Publishing, Journal of Fundamentals of
Renewable Energy and Applications, Vol. 3 (2013), Article ID 235592, 8
pages, doi:10.4303/jfrea/235592.
[13] Solar Flat Plate Collector-Specification, Indian Standard (IS), IS
12933(Part 1-5): 2003.
[14]
NASA,
Atmospheric
Data
Center.
https://eosweb.larc.nasa.gov/cgi-bin/sse/grid.cgi
REFERENCES
[1] K. Hudon, T. Merrigan, J. Burch and J. Maguire, “Low-Cost Solar Water
Heating Research and Development Roadmap”,National Renewable Energy
Laboratory(NREL),Technical report, NREL/TP-5500-54793, August 2012.
[2] Adegoke, C.O and B.O Bolaji, 2000, “Performance evaluation of solaroperated thermosyphon hot water system in Akure”, Intl. J. Eng. Eng.
Technology, FUTAJEET, 2:35-40.
[3] Duffie, J.A and W.A. Beckman, 1991, Solar Engineering of Thermal
Process, 2nd(Edition), John Wiley and Sons, New York.
[4] KE Amori and NS Jabouri, “ Thermal performance of solar hot water
systems using a flat plate collector of accelerated risers”, TJER 2012, Vol. 9,
No. 1, 1-10.
[5] S. J. Richards, D. N. W. Chinnery, “A solar water heater for low cost
housing”, 41, CSIR Research Report 237, South Africa (1967).
[6] R. Abdollah and T. Hessam, Experimental investigation on the
performance of thermosyphon solar water heater in the South Caspian Sea,
Thermal Science, 15 (2011), 447–456.
[7] K. Chuawittayawuth and S. Kumar, “Experimental investigation of
temperature and flow distribution in a thermosyphon solar water heating
system, Renewable Energy”, 26 (2002), 431–448.
[8] O. V. Ekechukwu and B. Norton, “Review of solar-energy dryin systems
III: low temperature air-heating solar collectors for crop drying applications,
Energy Conversion and Management”, 40 (1999), 657–667.
[9] P. Gbaha, T. R. Ori, H. Y. Andoh, P. M. E. Koffi, K. Konan, and J. K.
Saraka, “Thermal and economical study of two solar water heaters: the one
using glass wool and the other vegetable fibe as thermal insulator”, Indian
Journal of Science and Technology, 4 (2011),
809–814.
[10] O. C. Iloeje, O. V. Ekechukwu, and G. O. I. Ezeike, “Design, construction
and test run of a two-tonne capacity solar rice dryer with rice-husk-fired
auxiliary heater”, in Proceedings of ISES Solar World Congress, L. Imre and
A. Bitai, eds., Hungarian Energy society, Budapest, Hungary, 1993, 83–85.
ISSN: 2231-5381
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Available:
International Journal of Engineering Trends and Technology (IJETT) – Volume 12 Number 7 - Jun 2014
ANNEXURE
Table :1. Experimental data collected from the designed model.
Date
Time
Ambient
Temperature
Tank water temp.
Plate outlet water
temp.
Remarks
02-01-2014
09:00
12:00
15:00
09:00
12:00
15:00
08:45
11:30
15:20
16:40
09:10
12:00
15:15
16:35
09:00
11:50
15:10
16:30
08:40
12:15
15:30
16:04
09:19
12:49
15:30
16:21
10:40
12:50
16:52
09:20
12:21
15:40
09:50
17
19
20
17
19
20
16
18
19
17
17
19
16
14
15
17
17
16
16
19
19
17
14
19.5
16
14
19
22
15
20
21
17
17
35
45
48
36
46
49
33
49
46
40
33
49
45
39
32
49
46
41
31
49
46
41
30
48
43
40
42
57
54
34
51
46
32
50
61
55
63
62
56
46
58
55
48
45
62
54
50
41
57
54
50
40
60
57
52
38
60
56
52
53
67
60
50
63
56
35
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03-01-2014
04-01-2014
05-01-2014
06-01-2014
08-01-2014
09-01-2014
10-01-2014
11-01-2014
12-01-2014
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International Journal of Engineering Trends and Technology (IJETT) – Volume 12 Number 7 - Jun 2014
14-01-2014
16-01-2014
19-01-2014
22-01-2014
23-01-2014
24-01-2014
25-01-2014
27-01-2014
28-01-2014
11:10
13:00
15:00
16:04
17:15
09:20
11:30
14:40
15:57
09:30
11:20
14:41
15:45
16:41
09:00
11:15
13:00
15:45
10:04
12:10
14:40
16:38
09:36
11:56
13:54
16:21
19:54
21:54
19:00
22:09
10:06
12:29
14:59
16:02
09:55
13:25
15:34
17:06
09:00
10:15
13:05
15:06
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18
22
20
19
15
18
20
19
17
18
20
20
19
18
19
20
20
18
20
22
22
21
19
22
24
18
15.4
15
16
15
16
24
24
22
20
24
23
18
19
21
24
22
37
52
50
47
45
33
42
53
47
35
45
57
53
50
36
46
58
52
34
43
57
49
33
49
55
49
50
47
49
53
46
60
60
58
39
58
55
52
40
47
56
54
42
56
53
45
39
44
55
62
53
43
55
63
59
46
40
60
62
57
40
56
60
42
52
64
68
53
26
19.5
29
20
56
60
59
54
61
75
56
40
53
59
67
62
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International Journal of Engineering Trends and Technology (IJETT) – Volume 12 Number 7 - Jun 2014
31-01-2014
01-02-2014
03-02-2014
04-02-2014
05-02-2014
06-02-2014
08-02-2014
09:00
10:09
12:45
15:30
09:30
11:34
13:25
16:10
17:14
08:30
09:30
11:40
12:45
13:50
14:50
15:30
16:10
17:05
08:30
09:40
11:10
13:20
15:10
08:25
09:50
10:56
12:07
14:03
15:09
16:06
08:17
09:50
10:50
11:51
13:52
16:15
08:31
09:20
10:50
12:15
14:30
15:30
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20
21
20
19
20
23
26.7
22
18
18.6
21.4
24.4
25.1
26.8
26.5
24.8
21.2
19.2
18.6
20.1
22.7
25.4
20
16.9
19.3
21.7
24
26.7
23
20
17.9
19.2
21.1
24.7
26.8
20.4
18.1
19.8
22.3
24.6
26
23.2
38
42.5
59
53
39
50
65.8
59
55
48.4
49.8
60
66.7
69.4
67.2
67
66.9
62.9
40
47.2
58.5
65.7
55.3
40
45
50.4
56.2
63.2
59
56
29.5
40.7
43.6
47.2
50.5
48.6
30.1
42.5
46.2
56.7
59.4
52
46
56.5
67
62
59
62
74.3
63
46.4
50.7
60
70.6
74.9
75.7
69.5
65.4
62.5
56.9
38.5
56.7
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60.7
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53.8
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72.1
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56.5
62.2
64.2
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57.7
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International Journal of Engineering Trends and Technology (IJETT) – Volume 12 Number 7 - Jun 2014
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48.5
54.2
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70.2
70.8
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International Journal of Engineering Trends and Technology (IJETT) – Volume 12 Number 7 - Jun 2014
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International Journal of Engineering Trends and Technology (IJETT) – Volume 12 Number 7 - Jun 2014
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