Energy Efficiency Opportunities in Foundry Sector
Description: Energy Efficiency Opportunities in Foundry Sector About IIF Dinesh Gupta Hon. Secy. IIF The Institute of Indian Foundrymen with HO at Kolkata has completed 73 glorious years in service of Foundry Industry since 1950 IIF serves as a nodal
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slide1. Energy Efficiency Opportunities in Foundry Sector About IIF Dinesh Gupta
Hon. Secy. IIF The Institute of Indian Foundrymen with HO at Kolkata has completed 73 glorious years in service of Foundry Industry since 1950 IIF serves as a nodal point of reference for all stakeholders for foundry industry. IIF conducts its activities through 23 chapters & 4 regional offices in the country at Kolkata, Delhi, Mumbai & Chennai & 3 centres of excellence i.e. Foundry Informatics centre (FIC) at New Delhi , Centre of Education & Training (CET) at Chennai & National Centre of Technical Services (NCTS) at Pune. IIF is run by professionally appointed secretariat in offices across India under the directions of the supreme body of elected National Council members who are represented by Hon. National Office bearers – President, Vice President, Secretary and Treasurer<br>
slide2. Energy Efficiency Opportunities in Foundry Sector Dinesh Gupta
Hon. Secy. IIF Organizes an annual flagship event the Indian Foundry Congress (IFC) and International Foundry & Equipment Exhibition (IFEX), largest international level event of its kind for the foundry sector in India. The 72nd edition of the event will take place in Bengaluru between 2-3-4 Feb 2024. About IIF IIF Publishes a periodical Indian Foundry Journal of which Vol 69, Issue 7 is the latest modestly priced at Rs 250/- carrying the latest in technology, trends, news, IIF maintains databases, price indices, and Publishes the Foundry Directory IIF is active member of World Foundry Organization, CII, EEPC, BRICS Foundry Forum, Asia Foundry Forum & represents Indian Foundry industry in various international events & forums<br>
slide3. Energy Efficiency Opportunities in Foundry Sector Status of Foundry Industry in India a brief overview :- Dinesh Gupta
Hon. Secy. IIF Since 2014, India claims about 4000 units. The number has surprisingly remained unchanged in last decade whereas India has ranked up from 6th to 2nd position as casting producer of the world.
Very few large scale units – over 85% are MSME
Majority of units exist in clusters of Punjab, Gujarat and Southwest
Mobility sector and Agrimachinery components are dominant product forms
Ferrous product forms constitute much bigger market segment over Non-ferrous product forms
Fossil Fuels are the major source of Energy<br>
slide4. Energy Efficiency Opportunities in Foundry Sector Appreciating Foundry Technology :- Dinesh Gupta
Hon. Secy. IIF Basics- Melt, Refine, Pour, Fettle, Heat treat, Machine
Melting Routes:- Blast Furnace for Iron Ore – needs coke
Cupla for Pig Iron (including DRI) – needs coke
ARC for scrap – needs electricity
Induction for scrap – needs electricity
Mindboggling variation in capacities in terms of Tons of Metal<br>
slide5. Energy Efficiency Opportunities in Foundry Sector Dinesh Gupta
Hon. Secy. IIF The major Energy consumption heads in the unit are:
Melting and holding - Furnaces
Plant utilities - sand plant, moulding, fettling, grinding, compressed air
Auxiliaries like pollution control, cranes, cooling pumps and others
Transmission losses
Opportunities for Energy Savings are immense Appreciating Foundry Technology :-<br>
slide6. Energy Efficiency Opportunities in Foundry Sector Dinesh Gupta
Hon. Secy. IIF Appreciating Foundry Technology :- Typical Energy consumption segments –
Note that nearly 3.5% are transmission losses Sham Arjunwadkar
NCTS – IIF<br>
slide7. Energy Efficiency Opportunities in Foundry Sector Dinesh Gupta
Hon. Secy. IIF Appreciating Foundry Technology :-
Identifying heat loss …. Higher the temperature, higher the heat transfer rate
During heat up cycle to reach melting temperature, furnace loses heat
After pouring, remaining heat is lost from the refractory
From the moulds- heat of solidification of metal is lost
High current and high frequency electricity usage suffers heating losses
Flue gases
Holding and Heat treatment processes have thermal losses
These losses are inherent to Foundry process in addition to the generic losses which are common to all industrial environments.
How much of this heat can be conserved or recovered?<br>
slide8. Energy Efficiency Opportunities in Foundry Sector Dinesh Gupta
Hon. Secy. IIF Major Initiatives by IIF in this direction : -
Cluster Development programmes & creation of common facilities
Conservation of natural resources, waste reduction & sand recycling in clusters
Efficient energy management in foundries - energy audits & interventions
Lean manufacturing programmes - waste reduction & enhanced productivity
Foundry simulation software services at nominal cost
Publication on Best Practices in foundry operations jointly with PCRA, Ministry of Petroleum & Natural Gas with focus on efficient energy management
Submission of research project on greening of products & processes to Ministry of Environment & Forests
Closely working with Ministry of MSME pertaining to skilling, creation of training modules, IT application, upgradation of Technology Centres & ITI, revision of CLCSS scheme & definition of MSMEs etc & with Ministry of Environment & Forests regarding categorization of foundry industry etc
Active engagement with Policy makers to initiate policies to promote sustainable development of foundry sector –Formation of Foundry Development Council under Chairmanship of Secretary to Govt of India, DIPP<br>
slide9. Energy Efficiency Opportunities in Foundry Sector JUST TO MENTION A FEW PROJECTS ….definitely not an exhaustive list ! Dinesh Gupta
Hon. Secy. IIF UNIDO-BEE project on Induction Furnace optimization in Coimbatore Cluster TERI project on divided blast cupola (DBC) in Ahmedabad Cluster. TERI – Detailed Energy Audits in Rajkot Cluster Major Govt. projects undertaken by IIF
Energy Mapping and Energy Efficiency Roadmap for the Foundry Sector in India, BEE project with Pricewaterhousecoopers (PwC) supported by IIF
Jointly developed a Book on Energy Efficiency with Petroleum Conservation Research Association (PCRA)
Collaborated with UNDP/GEF regarding Energy Efficiency Project wherein 50% of the energy audit cost in foundry units was borne by UNDP
With DC-MSME for studying the Cluster Development Programme
With Ministry of MSME for survey on foundry industry
With the Department of Scientific and Industrial Research (DSIR) - Project for Development of Database on Foundry Industry which was a 3 years project<br>
slide10. Energy Efficiency Opportunities in Foundry Sector What can a Foundry do on its own? Dinesh Gupta
Hon. Secy. IIF Implement ISO50001 for self assessment . It is a voluntary standard.
Step 1 : Define purpose , scope and responsibilities of all stake holders
Step 2: Collect all Energy relevant data. If you cannot measure, you cannot control
Step 3: Monitor the energy performance and benchmark EPI
Step 4 : Identify Energy conservation measures
Step 5 : Consider Capital Intensive measures
Step 6 : Estimate, prioritise and plan
Step 7 : Implement , monitor, report and communicate<br>
slide11. Energy Efficiency Opportunities in Foundry Sector Energy Saving Potential : Dinesh Gupta
Hon. Secy. IIF<br>
slide12. Energy Efficiency Opportunities in Foundry Sector Effect on Profit by Energy Efficiency : Dinesh Gupta
Hon. Secy. IIF<br>
slide13. Energy Efficiency Opportunities in Foundry Sector Global scenario and way forward : Dinesh Gupta
Hon. Secy. IIF The energy efficiency measures and focus in the last decade have been commendable.
India has arrived at world scene.
Honourable Prime Minister Mr Narendra Modi’s vision and mission of make in India has brought us here
All the concerned departments and ministries of the Govt of India have done the hand holding and the pace of policy making, drives and initiatives has been fast, effective and productive
But what in next decade?<br>
slide14. Energy Efficiency Opportunities in Foundry Sector Global scenario and way forward : Dinesh Gupta
Hon. Secy. IIF GREEN is the mantra of the future.
Hydrogen is the fuel of the future. Carbon is the devil of the future.
Indian Foundries have to distance from Carbon and produce Green castings to continue with their exports advantage.
India is abundant in Renewable Energy- Green Energy …
Are we wasting this resource and killing ourselves each day?
Each day gone without harnessing is a permanent loss never redeemable INDIA MUST INVEST URGENTLY and INTELLIGENTLY in GREEN ENERGY!!!<br>
slide15. Energy Efficiency Opportunities in Foundry Sector What the Financial Institutions can do ? Dinesh Gupta
Hon. Secy. IIF Resolve the CAPEX challenge of MSME foundries collateral free.
Grants for research in India for development of affordable Technology and Optimised Equipment, developments in Machine Learning, Game theory, Automation
Grants to public and member service organisations for setting up and running common use facilities
Generate more trust and confidence in the MSME sector for change, technology adoption and its benefits<br>
slide16. Energy Efficiency Opportunities in Foundry Sector Thank you Dinesh Gupta
Hon. Secy. IIF<br>
Hon. Secy. IIF The Institute of Indian Foundrymen with HO at Kolkata has completed 73 glorious years in service of Foundry Industry since 1950 IIF serves as a nodal point of reference for all stakeholders for foundry industry. IIF conducts its activities through 23 chapters & 4 regional offices in the country at Kolkata, Delhi, Mumbai & Chennai & 3 centres of excellence i.e. Foundry Informatics centre (FIC) at New Delhi , Centre of Education & Training (CET) at Chennai & National Centre of Technical Services (NCTS) at Pune. IIF is run by professionally appointed secretariat in offices across India under the directions of the supreme body of elected National Council members who are represented by Hon. National Office bearers – President, Vice President, Secretary and Treasurer<br>
slide2. Energy Efficiency Opportunities in Foundry Sector Dinesh Gupta
Hon. Secy. IIF Organizes an annual flagship event the Indian Foundry Congress (IFC) and International Foundry & Equipment Exhibition (IFEX), largest international level event of its kind for the foundry sector in India. The 72nd edition of the event will take place in Bengaluru between 2-3-4 Feb 2024. About IIF IIF Publishes a periodical Indian Foundry Journal of which Vol 69, Issue 7 is the latest modestly priced at Rs 250/- carrying the latest in technology, trends, news, IIF maintains databases, price indices, and Publishes the Foundry Directory IIF is active member of World Foundry Organization, CII, EEPC, BRICS Foundry Forum, Asia Foundry Forum & represents Indian Foundry industry in various international events & forums<br>
slide3. Energy Efficiency Opportunities in Foundry Sector Status of Foundry Industry in India a brief overview :- Dinesh Gupta
Hon. Secy. IIF Since 2014, India claims about 4000 units. The number has surprisingly remained unchanged in last decade whereas India has ranked up from 6th to 2nd position as casting producer of the world.
Very few large scale units – over 85% are MSME
Majority of units exist in clusters of Punjab, Gujarat and Southwest
Mobility sector and Agrimachinery components are dominant product forms
Ferrous product forms constitute much bigger market segment over Non-ferrous product forms
Fossil Fuels are the major source of Energy<br>
slide4. Energy Efficiency Opportunities in Foundry Sector Appreciating Foundry Technology :- Dinesh Gupta
Hon. Secy. IIF Basics- Melt, Refine, Pour, Fettle, Heat treat, Machine
Melting Routes:- Blast Furnace for Iron Ore – needs coke
Cupla for Pig Iron (including DRI) – needs coke
ARC for scrap – needs electricity
Induction for scrap – needs electricity
Mindboggling variation in capacities in terms of Tons of Metal<br>
slide5. Energy Efficiency Opportunities in Foundry Sector Dinesh Gupta
Hon. Secy. IIF The major Energy consumption heads in the unit are:
Melting and holding - Furnaces
Plant utilities - sand plant, moulding, fettling, grinding, compressed air
Auxiliaries like pollution control, cranes, cooling pumps and others
Transmission losses
Opportunities for Energy Savings are immense Appreciating Foundry Technology :-<br>
slide6. Energy Efficiency Opportunities in Foundry Sector Dinesh Gupta
Hon. Secy. IIF Appreciating Foundry Technology :- Typical Energy consumption segments –
Note that nearly 3.5% are transmission losses Sham Arjunwadkar
NCTS – IIF<br>
slide7. Energy Efficiency Opportunities in Foundry Sector Dinesh Gupta
Hon. Secy. IIF Appreciating Foundry Technology :-
Identifying heat loss …. Higher the temperature, higher the heat transfer rate
During heat up cycle to reach melting temperature, furnace loses heat
After pouring, remaining heat is lost from the refractory
From the moulds- heat of solidification of metal is lost
High current and high frequency electricity usage suffers heating losses
Flue gases
Holding and Heat treatment processes have thermal losses
These losses are inherent to Foundry process in addition to the generic losses which are common to all industrial environments.
How much of this heat can be conserved or recovered?<br>
slide8. Energy Efficiency Opportunities in Foundry Sector Dinesh Gupta
Hon. Secy. IIF Major Initiatives by IIF in this direction : -
Cluster Development programmes & creation of common facilities
Conservation of natural resources, waste reduction & sand recycling in clusters
Efficient energy management in foundries - energy audits & interventions
Lean manufacturing programmes - waste reduction & enhanced productivity
Foundry simulation software services at nominal cost
Publication on Best Practices in foundry operations jointly with PCRA, Ministry of Petroleum & Natural Gas with focus on efficient energy management
Submission of research project on greening of products & processes to Ministry of Environment & Forests
Closely working with Ministry of MSME pertaining to skilling, creation of training modules, IT application, upgradation of Technology Centres & ITI, revision of CLCSS scheme & definition of MSMEs etc & with Ministry of Environment & Forests regarding categorization of foundry industry etc
Active engagement with Policy makers to initiate policies to promote sustainable development of foundry sector –Formation of Foundry Development Council under Chairmanship of Secretary to Govt of India, DIPP<br>
slide9. Energy Efficiency Opportunities in Foundry Sector JUST TO MENTION A FEW PROJECTS ….definitely not an exhaustive list ! Dinesh Gupta
Hon. Secy. IIF UNIDO-BEE project on Induction Furnace optimization in Coimbatore Cluster TERI project on divided blast cupola (DBC) in Ahmedabad Cluster. TERI – Detailed Energy Audits in Rajkot Cluster Major Govt. projects undertaken by IIF
Energy Mapping and Energy Efficiency Roadmap for the Foundry Sector in India, BEE project with Pricewaterhousecoopers (PwC) supported by IIF
Jointly developed a Book on Energy Efficiency with Petroleum Conservation Research Association (PCRA)
Collaborated with UNDP/GEF regarding Energy Efficiency Project wherein 50% of the energy audit cost in foundry units was borne by UNDP
With DC-MSME for studying the Cluster Development Programme
With Ministry of MSME for survey on foundry industry
With the Department of Scientific and Industrial Research (DSIR) - Project for Development of Database on Foundry Industry which was a 3 years project<br>
slide10. Energy Efficiency Opportunities in Foundry Sector What can a Foundry do on its own? Dinesh Gupta
Hon. Secy. IIF Implement ISO50001 for self assessment . It is a voluntary standard.
Step 1 : Define purpose , scope and responsibilities of all stake holders
Step 2: Collect all Energy relevant data. If you cannot measure, you cannot control
Step 3: Monitor the energy performance and benchmark EPI
Step 4 : Identify Energy conservation measures
Step 5 : Consider Capital Intensive measures
Step 6 : Estimate, prioritise and plan
Step 7 : Implement , monitor, report and communicate<br>
slide11. Energy Efficiency Opportunities in Foundry Sector Energy Saving Potential : Dinesh Gupta
Hon. Secy. IIF<br>
slide12. Energy Efficiency Opportunities in Foundry Sector Effect on Profit by Energy Efficiency : Dinesh Gupta
Hon. Secy. IIF<br>
slide13. Energy Efficiency Opportunities in Foundry Sector Global scenario and way forward : Dinesh Gupta
Hon. Secy. IIF The energy efficiency measures and focus in the last decade have been commendable.
India has arrived at world scene.
Honourable Prime Minister Mr Narendra Modi’s vision and mission of make in India has brought us here
All the concerned departments and ministries of the Govt of India have done the hand holding and the pace of policy making, drives and initiatives has been fast, effective and productive
But what in next decade?<br>
slide14. Energy Efficiency Opportunities in Foundry Sector Global scenario and way forward : Dinesh Gupta
Hon. Secy. IIF GREEN is the mantra of the future.
Hydrogen is the fuel of the future. Carbon is the devil of the future.
Indian Foundries have to distance from Carbon and produce Green castings to continue with their exports advantage.
India is abundant in Renewable Energy- Green Energy …
Are we wasting this resource and killing ourselves each day?
Each day gone without harnessing is a permanent loss never redeemable INDIA MUST INVEST URGENTLY and INTELLIGENTLY in GREEN ENERGY!!!<br>
slide15. Energy Efficiency Opportunities in Foundry Sector What the Financial Institutions can do ? Dinesh Gupta
Hon. Secy. IIF Resolve the CAPEX challenge of MSME foundries collateral free.
Grants for research in India for development of affordable Technology and Optimised Equipment, developments in Machine Learning, Game theory, Automation
Grants to public and member service organisations for setting up and running common use facilities
Generate more trust and confidence in the MSME sector for change, technology adoption and its benefits<br>
slide16. Energy Efficiency Opportunities in Foundry Sector Thank you Dinesh Gupta
Hon. Secy. IIF<br>