What is the energy use and CO2 of the Bankura secondary steel cluster in West Bengal?

About 5.96 million t CO2 a year, by TERI's 2025 profile. Bankura's 37 or so units (sponge iron, ferro alloy, induction furnace and re-rolling) burn 1.61 million t of coal and use 4,246 million kWh, about 1.09 million toe, for some 3.6 million t of product.

Four kinds of unit

• Sponge iron (DRI): 10 units, 13,96,500 t a year, coal-fired rotary kilns.
• Ferro alloy: 11 units, 3,06,740 t, submerged arc furnaces.
• Induction furnace steel melting: 11 units, 12,63,600 t of ingots and billets.
• Re-rolling: 5 units, 6,32,966 t of TMT bars, rods and angles.
• Power comes from DVC or WBSEDCL; coal is both domestic and imported.

Where the carbon sits

• DRI: 1.53 million t of coal, 2.87 million t CO2. Coal is 66% of the cluster's energy, almost all of it in the kilns.
• Ferro alloy: 2,883 million kWh, two thirds of the cluster's electricity, and 2.2 million t CO2 from only 8% of the output.
• Induction furnaces: 1,200 million kWh, 0.86 million t CO2.
• Re-rolling: 51 million kWh, 0.036 million t CO2.

Cuts the profile prices

• Waste heat power on a 2 x 100 tpd DRI plant: about 5 MW and 23.5 million kWh a year, about 15,860 t CO2 at the FY 2025-26 grid factor, for about Rs 500 million.
• Better kiln lining on a 100 tpd kiln: about 580 t of coal a year, 1,021 t CO2 on Indian coal.
• Clean, dry scrap and full-power melting in induction furnaces: 5 to 10% of electricity.

If billets or DRI go abroad

DRI, billets and bars are CBAM goods. For iron and steel, CBAM counts direct emissions only, so kiln coal decides a DRI figure and an induction furnace's power is left out, though both still count in a buyer's own footprint.

CO2 per tonne by unit type (from the profile)

• DRI: 2.87 million t CO2 / 1.40 million t = 2.06 t CO2 per tonne (about 1.1 t coal and 80 kWh)
• Ferro alloy: 2.2 / 0.307 = 7.2 t CO2 per tonne (about 9,400 kWh)
• Induction furnace billet: 0.86 / 1.26 = 0.68 t CO2 per tonne (about 950 kWh)
• Re-rolling: 0.036 / 0.633 = 0.06 t CO2 per tonne (about 80 kWh)
• Check at FY 2025-26 factors (estimate): 1.61 million t coal x 1.76 + 4,246 million kWh x 0.675 = about 5.7 million t

Quantities and CO2 from TERI's 2025 Bankura profile; the check uses India's coal factor and CEA FY 2025-26. A bar made from DRI melted in an induction furnace carries the stages it passed through.

What Senseible does here

Senseible reads coal invoices (1.76 t CO2 a tonne Indian, 2.44 imported) and DVC or WBSEDCL bills into monthly records; the CBAM pages show what a direct-emissions figure means for an EU buyer.

• CBAM for Indian exporters
• DRI waste heat power: what 5 MW saves
• Is sponge iron covered by CBAM
• Giridih secondary steel compared

Sources: TERI, Energy profile: Bankura secondary steel cluster (2025), Regulation (EU) 2023/956 (CBAM), consolidated text, CEA, CO2 Baseline Database for the Indian Power Sector (grid factor 0.675 kg CO2 per kWh, FY 2025-26), IPCC 2006 Guidelines, Volume 2 Energy (fuel emission factors)

Last reviewed 2026-10-31.