Bureau of Energy Efficiency

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Cleantech biotech ICT

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Clean Technology

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Opportunity details

Technology Requirement

Clusters Technology and Process intervention needs:

1. Needs for significant technology upgradation still remains within induction furnaces in the cluster.

2. Need for temperature and frequency controls, harmonic loss reduction, etc., to achieve large savings in induction furnace foundry units.

3. Need to improve energy efficiency per tonne output - Energy required to melt is 1506 kWh per tonne 3 times higher than best practice Energy to produce a tonne of good casting is at 2713 kWh 2.3 times higher than the best practice.

4. Need to reduce consumption of sand - Average sand required to produce one tonne of casting is 21% higher than the best practice.

5. To increase the process yield - The melting loss for the cluster stands at 6.5% can be brought down to 1% as observed in best practice - Pig and spillage for these foundries is 6.1% twice more than that of the best practice.

6. To increase effective production - Production loss for these foundries is 12 times more when compared the best practices. - Number of bad molds produced is more than twice that in Western EU.

7. To increase Plant Utilization (TEEP) - Average plant utilization to produce good casting is less than 40% against 60% in best practice.

8. To reduce the amount of scrap produced - Scrap produced in the cluster is as high as 6.5% twice higher than similar foundries in Western EU.

Opportunity Description

About the Kolhapur Foundry Cluster in the State of Maharashtra, India: The Kolhapur foundry cluster in India contains approximately 200 foundries with an estimated combined tonnage of over 450,000 tonnes per annum which equates to an average of 2250 tonnes per annum per foundry. An audit was conducted for 45 foundries with 203,790 tonnes per annum output as below to understand the cluster that require technology and process interventions based on the following data to reduce energy consumptions and increase productivity, efficiency and process yield. - Large Foundries 1 - Medium Foundries 11 - Small Foundries 33 About the Project: The Financing Energy Efficiency at MSMEs is part of the World Bank funded Global Environmental Facility (GEF) programmatic Framework for energy efficiency in India with an objective to increase energy efficiency investment in targeted MSME clusters. The Project is jointly executed by Government of India�¢??s Bureau of Energy Efficiency (BEE) and Small Industries Development Bank of India (SIDBI). The audit also establishes the current technology parameters in the cluster against some of best practices observed, particularly against Western Europe

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