C0SMiLe -About

Interventions in Foundry Sector

Foundry Sector

Background

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 Cooperatio) 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

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.