India is the second largest producer of metal castings in the world, with over 5,000 foundries producing nine million tonnes of castings annually. The foundry industry is one of the most energy intensive MSME sub-sectors in India. There are about 20 prominent foundry clusters that offer considerable potential for energy savings and CO2 reductions through the adoption of relatively simple and low-cost energy efficiency measures.
In this context, TERI with support from BEE organized four training programs on ‘Energy efficiency improvements in foundries’ during June–August 2014 in four major foundry clusters— Coimbatore (Tamil Nadu), Belgaum (Karnataka), Indore (Madhya Pradesh) and Kolhapur (Maharashtra). The training programs were organized under the ongoing World Bank–GEF project titled ‘Financing Energy Efficiency at MSMEs’, and received an overwhelming response, particularly from the local foundry units in each cluster. In all, about 170 participants from foundry units (including 120 energy professionals), along with representatives from MoMSME, BEE, UNIDO, and cluster level industry associations, attended the training programs.
The training programs focused on capacity building of foundry sector energy professionals on key technical aspects such as energy auditing methodology; performance evaluation of major energy consuming areas in a foundry industry—namely, the electrical and thermal systems, and the melting furnaces; and technology options including better operating practices for energy conservation in metal casting units. The melting furnace sessions covered both electrical induction furnaces and cupola furnaces. Actual case-studies were presented on each of these focus areas to provide the participants with in-depth knowledge. In each program, the extensive classroom sessions were followed by a half-day visit to a leading metal casting unit in the cluster.
Recognizing the importance of strengthening the ability of MSMEs to access finance for adopting energy efficient technologies (EETs), the training programs also focused on building the capacities of energy professionals on important financial aspects such as developing a good bankable DPR, and providing information on various financial incentives and subsidies offered by MoMSME and banks to adopt EETs. A generic template for developing investment grade DPR (IGDPR) was provided to the participants. Additionally, the necessary monitoring and verification (M&V) protocols for EET projects were also highlighted.
- Energy audit methodology of electrical systems
- Energy audit methodology of thermal systems
- Energy conservation in induction furnace
- Energy conservation in cupola furnace
- Investment grade DPRs and Monitoring & Verification_Protocol
- Financial schemes for MSMEs and case studies on energy conservation
- Scheme of DC (MSME)
- Energy conservation in foundry QUIZ