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An awareness workshop on ‘Energy Efficient Japanese Technologies and Best Practices’ was organised on 25th September 2014, at Hotel Chalukya, Bangalore under the ‘MRV and Capacity Building in India Project’ being undertaken by TERI, with support from Institute for Global Environmental Strategies (IGES) , Japan. A summary of the discussions at the workshop is presented below.

Welcoming the participants to the workshop, Mr Prosanto Pal, TERI mentioned that the objective of the event was to raise awareness of Indian stakeholders about Japanese low carbon technologies related to the metal casting sector and Joint Crediting Mechanism (JCM) scheme including Measurement, Reporting and Verification (MRV) methodologies. He mentioned that TERI and IGES have been working for several years on capacity building of Indian stakeholders on CDM aspects. Presently, new bilateral mechanisms like JCM are emerging which would be useful for promoting energy efficient technologies among industries in India.

Welcoming the Japanese experts to Bangalore, Dr H Sundaramurthy, Institute of Indian Foundrymen (IIF) thanked IGES and TERI for organising the event. He mentioned that IIF has an MoU with JFS (Japanese Foundrymen Society) and this can be used to develop further cooperation between the two sides.

Mr S Rudre Gowda, a leading foundry entrepreneur from Shimoga cluster provided an over view of the Shimoga foundry cluster which is located about 280 km from Bangalore. The cluster has 45 foundries and produces about 65,000 tpa (tonnes per annum) of ductile iron, grey iron and steel castings. Some of the foundries in the cluster are also exporting castings. Mr Ramaswamy, KFA (Karnataka Foundry Association) mentioned about the new foundry park which has come-up in Hospet near Bangalore. The foundries relocating to the new location have an opportunity to adopt new technologies in their operation.

Dr Rabhi Abdessalem, IGES made a detailed presentation about the recently concluded ALCT project, undertaken by IGES and TERI with support from JICA/JST. Under the project, hard technologies from Japan like Gas Heat Pump (GHP) and Electric Heat Pump (EHP) as well as soft technologies/best operating practices in compressed air and induction furnaces were demonstrated by Japanese experts among SMEs in India. He also explained the working of a proposed bilateral scheme called Joint Crediting Mechanism (JCM). He mentioned that JCM, when signed by Government of India, would provide a good opportunity for financing of new energy efficient Japanese technologies among industries in India. A copy of his presentation is attached.

Mr Junichi Takeuchi, IGES/ Sintokogio expert made a presentation on ‘Energy saving measures in casting’. He mentioned that Japan has about 1,500 foundry units and produce about 5.5 million tonnes of castings, whereas India has about 4,500 foundry units producing about 10 million tonnes. He presented details of different fuels consumed in Japanese foundry industry and felt that India should also collect cluster level details of energy consumption. Melting accounts for nearly 72 per cent of energy consumption in a foundry unit. In 1997, 34 per cent of foundry units in Japan used cupola, 63 per cent of the foundry units used induction furnace and three per cent of foundry units used electric arc furnace. In the recent years, there has been a trend to shift to cupola furnace due to electricity shortage with the closing down of many nuclear power plants. He mentioned that Japanese foundry industry has been able to save substantial amount of energy through Kaizen activities. These activities have helped foundries reduce reduction and improve yield leading to energy savings. A copy of his presentation is attached.

Mr Kenji Shiotani, IGES/Ishikawa Malleable Co. Ltd., Japan made a presentation on ‘Energy saving operation in foundry’. His company (Ishikawa malleable) is one of the major producers of ductile iron castings for the automobile sector. It producers about 7,600 tonnes of casting per month from two plants – one located in China and the other in Japan. Induction furnaces are used for producing ductile iron of various grades (FG 450, 500 and 600). He outlined various energy efficiency best practices from his company such as differential metal tapping, better matching of melting with moulding operation, marking of the grade on the runners and risers, full power operation, no stoppage for lunch and so on.

The workshop concluded after a question and answer session.


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