ENPI BENCHMARKING IN FOUNDRY

SECTOR UNITS AT COIMBATORE &

BELGAUM

ENERGY EFFICIENCY & RENEWABLE ENERGY IN SELECTED MSME

CLUSTERS IN INDIA.

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About GEF-UNIDO-BEE Project

UNIDO is currently implementing a GEF funded project titled „Energy Efficiency andRenewable energy in selected MSME Clusters in India‟. Bureau of Energy Efficiency(BEE) is the executing agency for the same.

The project focuses on 12 clusters in 5 sectors, namelyBrass, Ceramics, dairy, Foundry and Hand tools.

The three clusters in the foundry sector are Belgaum Coimbatore and Indore.

The project proposed 29 demonstration projects across these 5 sectors and 12clusters, including the demonstration project titled ‘Energy Information Managementand Analytics System for Foundries in Belgaum and Coimbatore.

Contents

Factors considered for Benchmarking

Methodology & Improvisations

Findings &Adjustment Factors

Rankings before and after Normalization

Limitations

Way Forward

Factors Considered For Benchmarking

Raw Material

Mix

Product Mix

Age of Furnace

Capacity of Furnace

Skilled WorkForce

Methodology

• Forecasting production of FG and SG grades based on the Raw Material (Universal) list.

Forecasting Production

• Based on the ratio of FG and SG type product energy consumption is forecasted and used for SEC calculation.

Forecasting Energy • Adjustment factors for

Capacity, Product Mix, Age of the Furnace are considered to find out the Normalised SEC in respect to cluster behavior.

Normalization

Improvisations/Hacks

Using independent factors from the

considered factors for normalization

Data Manipulation

Cluster Method

This was done to

overcome the lack of

data for all intervals

Statistical methodology

used to clean data

before analyzing.

Worked on inter-dependent

factors to create factors like

Capacity/Age, Skilled

Workforce / 500 kg/Hr

Capacity

Findings

Age Capacity

~8 Years ~750 Kg/Hr

SEC (Cluster Standard)

0.578 Gcal/Ton

53%

45%

2%

Product Mix %

FG SG Others

Note: Only for Induction Furnace Foundries

Adjustment Factor Product Mix

FG% SG% Other% Exp SEC

Baseline 53% 45% 2% 0.578

UNIT XYZ 21% 79% 0% 0.608

Adjustment

Factor

-5.19%

Adjustment Factor is the % change in the SEC expected if the unit was to have the

product mix similar to that of the cluster!

Adjustment Factor Age

Age Exp SEC

Baseline 8 Years 0.534

UNIT XYZ 10 0.556

Adjustment Factor -3.95%

Adjustment Factor is the % change in the SEC expected if the unit was to have the

age same as that of the cluster average.

Adjustment Factor Capacity

Installed Capacity Exp SEC

Baseline 750 Kg/Hr 0.533

UNIT XYZ 1000 Kg/Hr 0.520

Adjustment Factor 2.58%

Adjustment Factor is the % change in the SEC expected if the unit was to have the

installed capacity same as that of the cluster average.

Adjustment Factor Skilled Workforce

Skilled Workforce (Per 500

KG/Hr)

Exp SEC

Baseline 8 0.517

UNIT XYZ 7 0.547

Adjustment Factor -5.8%

Adjustment Factor is the % change in the SEC expected if the unit was to have the

same skilled workforce as that of the cluster average.

Total Adjustment Factor

-30.00%

-20.00%

-10.00%

0.00%

10.00%

20.00%

30.00%

40.00%

Unit IF1 Unit IF2 Unit IF3 Unit IF4 Unit IF5 Unit IF6 Unit IF7 Unit IF8 Unit IF9 Unit IF10Unit IF11Unit IF12Unit IF13Unit IF14Unit IF15Unit IF16

Adjustment Factor(Age) Adjustment Factor Skill Adjustment Factor Capacity Total Adjustment

Ranking Before & After Normalization

0

2

4

6

8

10

12

14

16

18

Unit IF14 Unit IF6 Unit IF9 Unit IF12 Unit IF16 Unit IF1 Unit IF7 Unit IF11 Unit IF3 Unit IF13 Unit IF4 Unit IF5 Unit IF10 Unit IF2 Unit IF15 Unit IF8

Rank After Normalisation Rank Normal

SEC vs Cluster Standard

0.35

0.45

0.55

0.65

0.75

0.85

0.95

Unit IF1 Unit IF2 Unit IF3 Unit IF4 Unit IF5 Unit IF6 Unit IF7 Unit IF8 Unit IF9 Unit IF10 Unit IF11 Unit IF12 Unit IF13 Unit IF14 Unit IF15 Unit IF16

Actual SEC Calculated SEC Normalised SEC Industry Standard

SEC Index Product Mix

0.86

1.00

0.96

0.88 0.88

0.85

0.87

0.89

0.91

0.93

0.95

0.97

0.99

1.01

FG 200 FG 150 FG 260 FG 250 FG 300

SEC Index (FG)

SEC Index Product Mix

0.64 0.66

0.71 0.72

1.00

0.71

0.58

0.50

0.60

0.70

0.80

0.90

1.00

1.10

SG 400_10 SG 400_15 SG 400_18 SG 450_10 SG 450_12 SG 500_7 SG 600_3

SEC Index (SG)

Limitations

Limited “Volume” of data. Both in terms of horizontal and vertical spread.

Inconsistency in “Data” especially the Raw Material Details.

No major energy efficiency projects were implemented during the course of

EIMAS installation, hence couldn‟t be tracked in respect to changes in EnPIs.

Way Forward!

Zeroed down on a considerably relevant methodology that can be scaled in terms of making it dynamic and also including other factors.

Increased usage of EIMAs across sector will help in widening data base and also the consistency of the same.

Access to EnPIs will foster increased competitive spirit on Energy Efficiency and also provide insights that can help foundries look into operational improvements.

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