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| Tapping
metal from a DBC |
Foundry industry is an important segment of the small and micro enterprises
in the country. It is important from many points of views: employment,
exports, linkages with the infrastructure sector, and energy and environmental
issues. Of the 4500 foundry units in the country, nearly 95% are in
the small-scale sector. The sector provides employment to an estimated
half a million people. Exports of iron castings during 2003/04 was
Rs 1925 crore (USD 442 million). The ‘Energy Sector Study’
undertaken by TERI during 1994/95 observed low resource efficiencies,
lack of modern technologies and associated pollution in foundry sector.
The foundry sector, thus, was marked as an area of intervention by
TERI, with support from SDC (Swiss Agency for Development and Cooperation)
to address energy and environmental issues. The overall objectives
of the intervention at that time were enhancement of energy efficiency
and reduction of stack emissions.
Diagnostic
studies and project strategy
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| Manual
charging is still prevalent in some clusters |
The genesis of these interventions, however,
lay in an earlier effort in the form of a diagnostic
study to shortlist some sectors of intervention. Initial surveys
included many other sectors besides foundry. After the study
was completed, a screening workshop was held with the stakeholders
for the purpose of short-listing sector.
The action plan was developed with the
stakeholder participation. It was decided to intervene in the foundry
sector at the melting furnace stage, where the maximum energy is
generally consumed. The initial surveys of energy usage in Agra
foundries had revealed that low energy efficiency mainly in the
iron melting furnaces or the cupolas. The low energy efficiency
was mainly due to the older technology, improper design, and wrong
selection of combustion air blower. It was decided that an energy-efficient
DBC (divided blast cupola) would be demonstrated as a possible solution
for foundries to both cut costs and reduce energy (coke) consumption. |
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| Rajkot delegates
at Techno4 2010 exhibition |
TERI strives to build upon and upscale the benefits of its ongoing
work in the MSME sector under CoSMiLE, by synergizing these benefits
with other initiatives aimed at development of the sector through
technology improvement, knowledge sharing, and capacity building.
One such initiative is the Renewable Energy & Energy Efficiency
Partnership (REEEP) project being implemented by TERI in the Coimbatore
foundry cluster, which focuses on promoting energy efficient melting
technologies such as the TERI-designed DBC through technology demonstration
and the building of cluster-level capacities. Another is the World
Bank-led multi- agency/multiactivity project to improve the access
of small and medium enterprises (SME) to finance and business development
services (BDS), being implemented jointly by Small Industries Development
Bank of India (SIDBI) and TERI in two SME clusters—the Rajkot
engineering cluster and the Chandigarh– Mohali–Panchkula
‘tricity’ engineering cluster.
As an example of this synergetic approach, a team of seven delegates
from the Rajkot engineering cluster, comprising entrepreneurs and
BDS providers associated with foundries and pump manufacturing industries,
visited Coimbatore – a hub of engineering industries including
foundries and pump manufacturing units – from 9 to 11 April
2010. The visit was organized by the SIDBI–Rajkot project.
During their tour, the delegates visited prominent pump manufacturing
industries in the industrial estate at Coimbatore. They were deeply
impressed by the high levels of quality maintained in the plants,
and by the exemplary work culture.
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| Rajkot delegates
at Coindia centre |
The delegates also interacted with the office bearers of Coimbatore
Industrial Infrastructure Association (COINDIA), a very dynamic
and successful association of MSME entrepreneurs of Coimbatore,
who shared their experiences with the visiting delegates and also
inspired the office bearers of the Rajkot Engineering Association
(REA) to replicate their own successful strategies.
The delegates were particularly fascinated by the development and
manufacturing related services provided by COINDIA to the local
industry such as training, testing, sand reclamation facilities
for small foundries, rapid prototyping, and tool room facilities.
The delegates also visited Small Industries’ Testing and Research
Centre (Si’Tarc), an NABL-accredited testing and calibration
laboratory having facilities for testing and development of pump
designs.
The highlight of the tour was a visit to a technology exhibition
– ‘Techno4 2010’– that showcased the products,
technologies, and services related to four engineering sectors:
pumps and ancillary equipments, motor and rotating machines, foundry,
and the light engineering industry. The event was organized by Orbitz
Exhibitions in association with SIEMA (Southern India Engineering
Manufacturers’ Association). Visitors at the exhibition included
CEOs, senior executives from industry, engineering companies, consultants,
R&D professionals, manufacturers, technocrats, advisors, and
policy makers. There were around 200 exhibitors, 50 overseas participants,
and more than 100 000 global visitors at the exhibition. The event
provided the Rajkot delegates
with a great opportunity to learn about new technologies, products
and services, share knowledge, and network with entrepreneurs and
BDS providers from elsewhere in India and abroad.
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Knowledge exchange: Rajkot entrepreneurs visit Coimbatore engineering
cluster 