Working Group 1 Report

ENERGY AND ENVIRONMENT COMMITTEE REPORT

MEETING ON 17-6-2015 AT DUSSELDORF

The Energy and Environment saving working group actively participated in the Energy Conservation activity conducted by IIF in Kolhapur Foundry Cluster.

Kolhapur is a Foundry Cluster in Western India. About 150 foundries are present in this cluster belonging to Large, Medium and Small sectors. Few foundries are selected based on variety, metal melted and power consumed. This work was done by IIF  in association with The Energy Resources Institute (TERI) as the nodal agency with the support of Small Industries Development Bank (SIDBI) and Bureau of Energy Efficiency (BEE). The scope and work was limited to Micro, Small and Medium Enterprises (MSME) as these units need the hand holding in conducting energy audits.

The highlight of the work conducted may be summarized as below:

Walk through energy audit conducted                  159 units

Detailed Energy audit conducted                           102 units

Complete implementation                                       022 units

Partial implementation                                            065 units

Case studies                                                                025 numbers

Number of Energy Saving recommendations       546

Total investment identified   USD (Million)          4.64

Actual investment made   USD (Million)               2.20

Total Energy Saving identified    USD(Million)      4.68

Actual Energy Saving achieved   USD (Million)      2.74

TERI having already involved with energy conservation activity in Indian foundries acceptance of the agency was not a problem. Still market conditions played a role in creating interest in the individual units. TERI had already established credibility with various stake holders and hence the success was quite satisfactory. The work went on over a period of 8 months.

Some case studies are presented to cover variety:

1.MSME Grey Iron Foundry:

The unit manufactures graded grey iron castings and the annual production during 2011-12 was 432 MT of castings. The total energy consumption of the unit during the last 12 months was 75.09 tons of oil equivalent (TOE) which is equivalent to USD 122,740.

 Electrical Energy accounts for 100% of energy consumed.  Energy bill accounts for 14.3% of annual turnover. The total CO2 emission is estimated to be 777 tonnes.

 The molding is mostly manual molding with one sand mixer for sand preparation. The melting is in a medium frequency Induction Furnace. Pouring, fettling etc are all manual operations with very little simple handling and motion technologies.

The actions recommended and initiated are replacement of existing induction furnace with a new generation high performance induction furnace and replacement of the old raw water pump with a energy efficient pump. Improvements were also made in matching the melting and pouring operations to reduce holding time.

2.MSME Aluminium Foundry:

The unit manufactures aluminium alloy castings to National and International specifications. The production during 2011-12 was 66MT. Total energy consued during the last 12 months was 24.9 tons of oil equivalent which is  USD 28,600. Furnace oil accounts for 94% of energy consumed with electricity for other uses. Energy bill accounts for 9.6% of annual turnover. The total CO2 emission is estimated to be 89.1 tonnes.

The casting is done by Gravity Die process and melting is done in oil fired furnace using furnace oil. All other process like pouring, fettling are performed manually.

 

Some of the actions initiated are replacement of furnace oil fired furnace to electric resistance furnace, reduction in pressure setting in air compressor and plugging the leakage, changing the roof sheets to transparent sheets and changing the lighting fixtures and layout.

3. MSME Grey and SG Iron Foundry:

The unit manufactures graded  grey and SG iron castings. The production during 2011-12 was 772MT. Total energy consumed during the last 12 months was 211.5 tons of oil equivalent which is  USD 323,800. Electricity, LPG and Diesel are considered for energy calculations. Electricity  accounts for 84.5% of energy consumed.. Energy bill accounts for 9.6% of annual turnover. The total CO2 emission is estimated to be 1946 tonnes.

The molding is mostly manual molding with one sand mixer for sand preparation. The melting is in a medium frequency Induction Furnace. Pouring, fettling etc are all manual operations with some  simple handling and motion technologies.

Some of the highlights of the actions initiated are downsizing the existing induction furnace to meet the requirement, changing the old air compressor with a new screw air compressor, plugging the compressed air leakage, and changing the layout of light fixtures.

 

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