What is the energy use and CO2 of foundries in the Durgapur belt?

TERI's 2024 situation analysis counts about 20 foundries around Durgapur making 141,600 t a year and using 16,254 toe: 64.3 million kWh, 12,000 t of coal and 5.4 million scm of natural gas. At Senseible's factors that is about 75,600 t CO2, roughly 0.53 t per tonne (estimate).

What the foundries make and burn

• Grey iron castings for railways, engineering and construction, ductile iron castings and DI pipes.
• Melting in induction furnaces, at 550 to 650 kWh per tonne by TERI's range.
• Coal or natural gas in heat treatment furnaces at some units: 37% and 29% of the segment's energy.
• Electricity is 34% of the energy but more than half the CO2.

One number to check against your own

64.3 million kWh over 141,600 t is about 454 kWh per tonne of output, below TERI's own melting range and below what any induction furnace needs once yield is counted. The table's output and power do not square. Do not benchmark against it; benchmark your kWh per tonne of good castings against your own past months and against the 550 kWh an IGBT furnace reaches per tonne melted.

Which castings face CBAM

Cast iron pipes under CN 7303 are in CBAM's iron and steel list, so a DI pipe maker selling into the EU needs a direct emissions figure per tonne: here, the coal and gas in heat treatment plus the iron you buy in. Electricity is left out for iron and steel goods. Castings declared as other cast articles or as machine parts are not on the list, but buyers still ask for a footprint.

Savings TERI listed

• Replace old furnaces running at 750 kWh or more per tonne melted with IGBT furnaces at about 550.
• Fit lids: 6 to 8% of input is lost from open furnaces, and a lid pays back within a year.
• Replace motors rewound twice or more with IE3 or IE4: 3 to 5% better, 2 to 3 year payback.
• Replace compressors over 15 years old with permanent magnet motor units.

Durgapur foundries, CO2 a year at Senseible factors (estimate)

• Electricity: 64.294 million kWh x 0.675 kg = 43,398 t
• Coal: 12,000 t x 1.76 = 21,120 t
• Natural gas: 5.4 million scm x 2.05 kg = 11,070 t
• Total: about 75,588 t, or 0.53 t per tonne of castings; TERI's table gives 81,891 t at its own factors
• CBAM direct emissions for a DI pipe exclude the 43,398 t from power

Counts, output and energy from TERI's Situation Analysis of Durgapur Secondary Steel Cluster (2024). CEA FY 2025-26 grid factor; Indian coal 1.76 kg CO2 per kg; natural gas 2.05 kg per scm.

What Senseible does here

Senseible reads electricity bills, coal invoices and gas bills into monthly CO2 per tonne, with fuel and electricity on separate lines, so a CBAM direct figure and a full footprint come from the same records.

• Your MSME carbon number
• Ductile iron pipes CN 7303
• Durgapur secondary steel and DRI
• Induction foundry kWh per tonne by size

Sources: TERI, Situation Analysis of Durgapur Secondary Steel Cluster, 2024 (SAMEEEKSHA), Regulation (EU) 2023/956 establishing CBAM, consolidated, CEA, CO2 Baseline Database for the Indian Power Sector, version 22.0

Last reviewed 2026-11-01.