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Energy consumption figures

Name of the company: Ram Casting ltd. Industrial

estate/HSIDC ,G.T.road samalkha,Distt. Panipat-Haryana.

Product manufactured: Shaft cutting machine

Contacting person: Mr. Madan Lal.

Total production: 2000 in no. per month of 35 kg

each=70 tonnes=70,000 kg

Energy sources :Coal, diesel(in absence of

electricity),electricity

Coal expenditure: 12 tonnes=12000 kg

Energy contribution of coal: Calorific value of

coal*monthly usage=24kj/g*12000 kg=288,000kj.

Amount of diesel consumed per month in litres=200 lts.

Energy contribution from diesel: Calorific value of

diesel*amount of diesel consumed per month=38.6

Mj*200=7720, Mj

Average electricity bill per month=around 6000 Rs.(taken

as average of four months)

Energy contribution from electricity=total electricity bill

per month/4.75(price of one unit)= no. of units(in

kwh)*3.6*10^6=6000/4.75(*3.6*10^6)=4548megajoules.

Total energy consumed per month= 12556megajoules

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Specific energy consumption=total energy

consumption/total production (in

kg)=12556*10^6/70,000=179.37kj/kg.

Name of the company:Haryana iron foundry, HSIDC,G.T.road samalkha,Distt. Panipat-Haryana.

Contacting person: Mr. Ankit Mittal

Product manufactured: Agricultural cutting

equipment(crop cutting machinery).

Contacting person: Total production: 2000 in no. per

month of kg each=140 tonnes=140,000 kg

Energy sources :Coal, diesel(in absence of

electricity),electricity

Coal expenditure: 35 tonnes=35000 kg

Energy contribution of coal: Calorific value of

coal*monthly usage=840 MjAmount of diesel consumed per month in litres=1000 lts

Energy contribution from diesel: Calorific value of

diesel*mass of diesel consumed per month=38,600 Mj

Energy contribution from electricity=Total electricity bill

per month/4.75(price of one unit)=no. of units(in

kwh)*3.6*10^6=15157 megajoules.

Total energy consumed per month= 54597joules

Specific energy consumption=total energy

consumption/total production (in kg)=389.97kj/kg.

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Name of the company:Amar industries unit -1 plot no.

36,HSIDC ,G.T.road Samalkha,Distt. Panipat-Haryana.

Contacting person: Mr Amar Aneja

Product manufactured:Motor bodies(casing) using cast

iron as raw material.

Total production: total production of 60 ton i.e. 60,000 kg.

Energy sources :Coal, diesel(in absence of

electricity),electricity

Coal expenditure: tonnes=8300 kg

Energy contribution of coal: Calorific value of

coal*monthly usage=199.2 mjAmount of diesel consumed per month in litres=290

Energy contribution from diesel: Calorific value of

diesel*mass of diesel consumed per month=11194 mj

Energy contribution from electricity=total electricity bill

per month/4.75(price of one unit)=no. of units(in

kwh)*3.6*10^6=11000/4.75(*3.6*10^6)=8336megajoules.

Total energy consumed per month= 19729 mega joules

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Specific energy consumption=total energy

consumption/total production (in

kg)=19729/60,000=328.8 kj/kg

Name of the company:Amar industries unit-2 ,plot no

38,HSIDC ,G.T.road Samalkha,Distt. Panipat-Haryana.

Contacting person: Mr Amar aneja

Product manufactured:submersible motor pump parts

Total production:40 tonnes=40,000 kg

Energy sources :Coal, diesel(in absence of

electricity),electricity

Coal expenditure: 5.6 tonnes=5600 kgEnergy contribution of coal: Calorific value of

coal*monthly usage=134 megajoules.

Amount of diesel consumed per month in litres=250

Energy contribution from diesel: Calorific value of

diesel*mass of diesel consumed per month=9518

megajoules.

Energy contribution from electricity=total electricity bill

per month/4.75(price of one unit)=no. of units(in

kwh)*3.6*10^6=6000/4.75(*3.6*10^6)=6063

megajoules.

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Total energy consumed per month=15715.1 m joules

Specific energy consumption=total energy

consumption/total production (in

kg)=15715/40,000=392.2 kj/kg.

Name of the company:amar industries part 3,plot no. 45,

HSIDC ,G.T.road samalkha,Distt. Panipat-Haryana.

Contacting person:Mr. Amar aneja

Manufactured product :Pump parts.(submersible and

ground).Total production: 12000 in no. per month overall tonnage

of 12 tons.

Energy sources :Coal, diesel(in absence of

electricity),electricity

Coal expenditure: 1.5 tonnes= 1500 kg

Energy contribution of coal: Calorific value of

coal*monthly usage=36 mj.

Amount of diesel consumed per month in litres=50 lts.

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Energy contribution from diesel: Calorific value of

diesel*mass of diesel consumed per month=1930 mj.

Energy contribution from electricity=total electricity bill

per month/4.75(price of one unit)=no. of units(inkwh)*3.6*10^6=6000/4.75(*3.6*10^6)=3789.6 mjoules.

Total energy consumed per month= 5755.7 joules

Specific energy consumption=total energy

consumption/total production (in

kg)=5755.7/12000=479.8 kj/kg.

Name of the company:Aggarwal Casting ltd.

Contacting person: Mr. Aditya aggarwal.

Total production: 1500 in no. per month of 20 kg

each=30 tonnes=30,000 kg

Energy sources :Coal, diesel(in absence of

electricity),electricity

Coal expenditure: 6 tonnes=6000 kg

Energy contribution of coal: Calorific value of

coal*monthly usage=144 mj

Amount of diesel consumed per month in litres=100

Energy contribution from diesel: Calorific value of

diesel*mass of diesel consumed per month=3860 mj

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Energy contribution from electricity=total electricity bill

per month/4.75(price of one unit)=no. of units(in

kwh)*3.6*10^6=6000/4.75(*3.6*10^6)=3800 mjoules.

Total energy consumed per month= 7800 mjoules

Specific energy consumption=total energy

consumption/total production (in kg)=260 KJ/KG.

Name of the company:Pooja industries ltd.

Contacting person: Mr. Jagtaar singh

Total production: 500 in no. per month of 100 kgeach=50 tonnes=50,000 kg

Energy sources :Coal, diesel(in absence of

electricity),electricity

Coal expenditure: tonnes=12000 kg

Energy contribution of coal: Calorific value of

coal*monthly usage=288 mj

Energy contribution from diesel: Calorific value of

diesel*mass of diesel consumed per month=1930 mj.

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Energy contribution from electricity=total electricity bill

per month/4.75(price of one unit)=no. of units(in

kwh)*3.6*10^6=6000/4.75(*3.6*10^6)=9094 mj.

Total energy consumed per month=11312 mj.

Specific energy consumption=total energy

consumption/total production (in kg)=226.24 kj/kg.

Name of the company:Kissan foundary works.

Contacting person: Mr. Ram niwas

Total production: 2000 in no. per month of 35 kg

each=70 tonnes=70,000 kg

Energy sources :Coal, diesel(in absence of

electricity),electricity

Coal expenditure: 15 tonnes=15000 kg

Energy contribution of coal: Calorific value of

coal*monthly usage=360 mj.

Energy contribution from diesel: Calorific value of

diesel*mass of diesel consumed per month=1930 mj.

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Energy contribution from electricity=total electricity bill

per month/4.75(price of one unit)=no. of units(in

kwh)*3.6*10^6=6000/4.75(*3.6*10^6)=10,00 joules.

Total energy consumed per month= 12290 megajoules

Specific energy consumption=total energy

consumption/total production (in kg)=175.57

Name of the company:Kataria foundry and casting works

pvt ltd.Contacting person: Mr. Suresh Kataria.

Product manufactured:Harrow n other agricultural

equipments.

Total production: 1000 in no. per month of 50 kg

each=50 tonnes=50,000 kg

Energy sources :Coal, diesel(in absence of

electricity),electricity

Coal expenditure: 20 tonnes=20000 kg

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Energy contribution of coal: Calorific value of

coal*monthly usage=480 mj.

Energy contribution from diesel: Calorific value of

diesel*mass of diesel consumed per month=1544 mj.

Energy contribution from electricity=total electricity bill

per month/4.75(price of one unit)=no. of units(in

kwh)*3.6*10^6=6000/4.75(*3.6*10^6)=10610 mj.

Total energy consumed per month= 12634 mega joules

Specific energy consumption=total energy

consumption/total production (in kg)=252.7 kj/kg.

Name of the company:Amit castings.

Contacting person: Mr. Amit singh.

Total production: 1000 in no. per month of 35 kg

each=35 tonnes=35,000 kg

Energy sources :Coal, diesel(in absence of

electricity),electricity

Coal expenditure: 8 tonnes=8000 kg

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Energy contribution of coal: Calorific value of

coal*monthly usage=192 mj.

Energy contribution from diesel: Calorific value of

diesel*mass of diesel consumed permonth=38.6*1000=3860 mj.

Energy contribution from electricity=total electricity bill

per month/4.75(price of one unit)=no. of units(in

kwh)*3.6*10^6=8000/4.75(*3.6*10^6)=6063 mj.

Total energy consumed per month= 10115 joules

Specific energy consumption=total energy

consumption/total production (in kg)=10115/35=289.6

kj/kg.

Name of the company: Santosh foundry works.

Contacting person:Mr. Deepak kumar.

Total production: 1700 in no. per month of 40kg each=70

tonnes=68000 kg

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Energy sources :Coal, diesel(in absence of

electricity),electricity

Coal expenditure: 10 tonnes=10000 kg

Energy contribution of coal: Calorific value of

coal*monthly usage=240 mj.

Energy contribution from diesel: Calorific value of

diesel*mass of diesel consumed per month=3088mj.

Energy contribution from electricity=total electricity bill

per month/4.75(price of one unit)=no. of units(in

kwh)*3.6*10^6=8000/4.75(*3.6*10^6)= 6064mj.

Total energy consumed per month= 9391 mj.

Specific energy consumption=total energy

consumption/total production (in kg)=138.9 kj/kg

Name of the company:Mittal foundry works.

Contacting person: Mr. Rohan Mittal

Total production: 2000 in no. per month of 35 kg

each=70 tonnes=70,000 kg

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Energy sources :Coal, diesel(in absence of

electricity),electricity

Coal expenditure: 20 tonnes=20000 kg

Energy contribution of coal: Calorific value of

coal*monthly usage=480 mj.

Energy contribution from diesel: Calorific value of

diesel*mass of diesel consumed per month=1930 mj.

Energy contribution from electricity=total electricity bill

per month/4.75(price of one unit)=no. of units(in

kwh)*3.6*10^6=10000/4.75(*3.6*10^6)=7579 mj .

Total energy consumed per month=9988 joules

Specific energy consumption=total energy

consumption/total production (in kg)=142.2 kj/kg

Name of the company:Shriram Casting ltd. -1

Contacting person: Mr. Subhash Dhanda

Total production: 3000 in no. per month of 20 kg

each=60 tonnes=60,000 kg

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Energy sources :Coal, diesel(in absence of

electricity),electricity

Coal expenditure: 12 tonnes=12000 kg

Energy contribution of coal: Calorific value of

coal*monthly usage=288mj

Energy contribution from diesel: Calorific value of

diesel*mass of diesel consumed per month=1980 mj

Energy contribution from electricity=total electricity bill

per month/4.75(price of one unit)=no. of units(in

kwh)*3.6*10^6=6000/4.75(*3.6*10^6)=6063 mj.

Total energy consumed per month=8331 mj.

Specific energy consumption=total energy

consumption/total production (in kg)=138.8 kj/kg.

Name of the company:Shriram Casting ltd.-2

Contacting person: Mr. Subhash Dhanda

Total production: 2000 in no. per month of 35 kg

each=70 tonnes=70,000 kg

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Energy sources :Coal, diesel(in absence of

electricity),electricity

Coal expenditure: 12 tonnes=12000 kg

Energy contribution of coal: Calorific value of

coal*monthly usage=288 mj.

Energy contribution from diesel: Calorific value of

diesel*mass of diesel consumed per month=2316 mj.

Energy contribution from electricity=total electricity bill

per month/4.75(price of one unit)=no. of units(in

kwh)*3.6*10^6=8000/4.75(*3.6*10^6)=8200 mj.

Total energy consumed per month=10804 mj.

Specific energy consumption=total energy

consumption/total production (in kg)=154.4 kj/kg.

Name of the company:Shriram Casting ltd.-3

Contacting person: Mr. Saurabh Dhanda

Total production: 1000 in no. per month of 35 kg

each=35 tonnes=35,000 kg

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Energy sources :Coal, diesel(in absence of

electricity),electricity

Coal expenditure: 12 tonnes=12000 kg

Energy contribution of coal: Calorific value of

coal*monthly usage=288 mj.

Energy contribution from diesel: Calorific value of

diesel*mass of diesel consumed per month=3860 mj.

Energy contribution from electricity=total electricity bill

per month/4.75(price of one unit)=no. of units(in

kwh)*3.6*10^6=14000/4.75(*3.6*10^6)=9578 mj.

Total energy consumed per month= 13726 mj.

Specific energy consumption=total energy

consumption/total production (in kg)=335 kj/kg.

Name of the company:Raj foundry

Contacting person: Mr. Rajveer Singh

Total production:500 in no. per month of 80 kg

each=80tonnes=80,000 kg

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Energy sources :Coal, diesel(in absence of

electricity),electricity

Coal expenditure: 20 tonnes=20000 kg

Energy contribution of coal: Calorific value of

coal*monthly usage=480mj.

Energy contribution from diesel: Calorific value of

diesel*mass of diesel consumed per month=3860 mj.

Energy contribution from electricity=total electricity bill

per month/4.75(price of one unit)=no. of units(in

kwh)*3.6*10^6=10000/4.75(*3.6*10^6)=7578 mj.

Total energy consumed per month= 11918 mj.

Specific energy consumption=total energy

consumption/total production (in kg)=148.97 kj/kg.

Name of the company:Krishna industries

Contacting person: Mr. Krishna Roy

Total production: 1000 in no. per month of 50 kg

each=50 tonnes=50,000 kg

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Energy sources :Coal, diesel(in absence of

electricity),electricity

Coal expenditure: 12 tonnes=12000 kg

Energy contribution of coal: Calorific value of

coal*monthly usage=288 mj.

Energy contribution from diesel: Calorific value of

diesel*mass of diesel consumed per month=3860 mj.

Energy contribution from electricity=total electricity bill

per month/4.75(price of one unit)=no. of units(in

kwh)*3.6*10^6=12000/4.75(*3.6*10^6)=8578 mj.

Total energy consumed per month= 12726 mj.

Specific energy consumption=total energy

consumption/total production (in kg)=234.5 kj/kg.

Name of the company:Lalit Industries ltd

Contacting person: Mr. Lalit Anand

Total production: 1000 in no. per month of 55 kg

each=55 tonnes=55,000 kg

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Energy sources :Coal, diesel(in absence of

electricity),electricity

Coal expenditure: 12 tonnes=12000 kg

Energy contribution of coal: Calorific value of

coal*monthly usage=288 mj.

Energy contribution from diesel: Calorific value of

diesel*mass of diesel consumed per month=4860 mj.

Energy contribution from electricity=total electricity bill

per month/4.75(price of one unit)=no. of units(in

kwh)*3.6*10^6=10000/4.75(*3.6*10^6)=7578 mj.

Total energy consumed per month= 11726 mj.

Specific energy consumption=total energy

consumption/total production (in kg)=231.3 kj/kg.

Name of the company:Sharad foundry works

Contacting person: Mr. Sharad singh.

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Total production: 1000 in no. per month of 65 kg

each=65 tonnes=65,000 kg

Energy sources :Coal, diesel(in absence of

electricity),electricity

Coal expenditure: 25 tonnes=12000 kg

Energy contribution of coal: Calorific value of

coal*monthly usage=620 mj.

Energy contribution from diesel: Calorific value of

diesel*mass of diesel consumed per month=5860 mj.

Energy contribution from electricity=total electricity bill

per month/4.75(price of one unit)=no. of units(in

kwh)*3.6*10^6=10000/4.75(*3.6*10^6)=7578 mj.

Total energy consumed per month= 14058 mj.

Specific energy consumption=total energy

consumption/total production (in kg)=216.27 kj/kg.

Name of the company:Ramesh castings industries pvt ltd.

Contacting person: Mr. Ramesh Ahuja

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Total production: 2000 in no. per month of 15 kg

each=30 tonnes=30,000 kg

Energy sources :Coal, diesel(in absence of

electricity),electricity

Coal expenditure: 8 tonnes=12000 kg

Energy contribution of coal: Calorific value of

coal*monthly usage=195.2 mj.

Energy contribution from diesel: Calorific value of

diesel*mass of diesel consumed per month=2860 mj.

Energy contribution from electricity=total electricity bill

per month/4.75(price of one unit)=no. of units(in

kwh)*3.6*10^6=8000/4.75(*3.6*10^6)=6063 mj.

Total energy consumed per month= 9118.2 mj.

Specific energy consumption=total energy

consumption/total production (in kg)=303.94 kj/kg.

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Name ofthecompany

Totalproduction(in kg)

Total energyconsumption((MJ)

Specificenergyconsumption(KJ/kg)

Ramcastings

70000 12556 179.37

Haryanaironfoundry

140000 19857 141.8

Amarind.-1

60000 19729 328.8

Amarind. -2

40000 15715 392.2

Amar

ind.-3

12000 5755.7 479.8

Agarwalfoundry

30000 7800 260

Poojafoundryworks

50000 11312 226.24

Kisanfoundry

70000 12290 175.57

Katariaindustries

50000 12634 252.7

Amitcastings

35000 10115 289.6

Santoshfoundry

68000 9391 138.9

Mittal

industries

70000 9988 142.2

Shriram ind.-1

60000 8331 138.2

Shri ramindustri

es-2

70000 10804 154.4

Shri ram 35000 13726 335

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Questionnaire

Name of the company:

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Contacting person:

Production output:

1.TECHNICAL FACTORS:

a)Age of the machinery

Less than 10 years Between 10 to 20 years More than 20

years

b)type of melting furnace used (EIF=Electrical Induction

Furnace)

Firms with only EIF Firms with both EIF and cupola Only

cupola

Economic factors:

a)Plant capacity/space utilization

Above 70% Between 70-50% Less than

50%

b)Rejection rate of production

Below 5% Between 5 to 10 % More

than 10%

c)Monthly Production (in kg)

More than 100 tonnes Between 50 and 100 tonnes Less

than50tonnes

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Human resource factors:

a)Owner/supervisor qualifications

Professional/ College education School education

masters degree

b)Business experience of the owner

Previous work experience Family occupation No previous

experience

c)Labour skill level(ratio of skilled/unskilled personnel)

Above 1.5 Between 0.75to1.5 Below0.5

Organizational & Behavioural factors:

a) Work practices, Layout & Housekeeping

Very good Good Average

b) Interaction level of the organization

High Medium Low