Senseible

If every Jamnagar brass unit took the Bureau of Energy Efficiency measures, how much fuel, power and money would that save?

The Bureau of Energy Efficiency (BEE) Jamnagar manual lists 13 measures. Summing its own unit counts in Table 5.1 gives 1.59 million litres of furnace oil, 3,990 tonnes of coal, 61,418 million kilocalories of net gas-switch heat and 4.93 million kilowatt hours (kWh). It prints 90,142 tonnes of carbon dioxide (CO2) a year and no factors.

The totals, summed from Table 5.1

And in rupees

The manual does not total the rupees. Multiplying each measure's yearly saving by its unit count gives about rupees (Rs) 4,064 lakh a year, about Rs 40.6 crore. The biggest items are coal to gas pit (595 units x Rs 3.4 lakh = Rs 2,023 lakh) and furnace insulation (700 x Rs 1.02 lakh = Rs 714 lakh). That is my sum, and a ceiling, not a forecast: the unit counts add to 3,920 for a cluster the manual counts at 3,500 units, which suggests one unit can appear under several measures, and some fixes are alternatives to each other.

The 90,142 tonnes the report prints, and two sets of totals

Chapter 4 says annual greenhouse gas reduction potential in the cluster is around 90,142 tonnes of CO2. It prints no factors, and it prints a different coal and oil total in Table 5.2 than the sums above.

Table 5.2 (page 62) says the measures "will save the 4,931,520 kWh of electrical energy, 44,132 tonne of coal and 1,085,000 liters of furnace oil", about 8,005 tonnes of oil equivalent (the manual writes MTOE), 11.9% of the 66,775 it gives for the cluster. The electricity matches Table 5.1. The coal and oil do not: Table 5.1 sums to 3,990 tonnes of coal and 1,593,000 litres of oil, and the page never mentions the conflict. 44,132 tonnes is the whole coal use of foundry units in Table 5.2, so it reads as all foundry coal, not a saving. 1,085,000 litres is only 840,000 + 245,000, the two furnace replacements.

A test of whether 90,142 can be reproduced, on the factors used here: 44,132 tonnes x 1.76 = about 77,700 tonnes of CO2. Add oil 1,085,000 litres x 2.97 kilograms = about 3,220 and power 4,931,520 kWh x 0.675 = about 3,330, and Table 5.2's totals give about 84,200 tonnes, within 7% of 90,142. My reading, not the report's statement: the printed figure looks closer to Table 5.2's larger coal and oil totals than to Table 5.1's sums.

Table 5.1's own sums give much less. Coal 3,990 tonnes x 1.76 = about 7,020 tonnes. Furnace oil 1,593,000 litres x 2.97 kilograms = about 4,730. Power about 3,330. Those three lines make about 15,080 tonnes, roughly a sixth of the printed figure.

The gas switches are harder. Table 5.1's mkCal are a net heat saving: coal 1.08 mkCal a tonne of brass less gas 0.69 for the pit furnace, and 1.08 less 0.57 for the rotary. They are not coal displaced, so reading 61,418 mkCal as coal at 6,500 kilocalories a kilogram (about 9,450 tonnes of coal, 16,630 tonnes of CO2) is only an order of magnitude check. On a gross basis the swap replaces 1.08 x 200 tonnes x (595 + 140) units = 158,760 mkCal of coal heat, about 24,400 tonnes of coal or 43,000 tonnes of CO2, and burns about 98,070 mkCal of gas, which would have to come off. I have not netted the gas, so I do not give a total for the switches.

So the gap does not prove the report wrong, and the report does not show its working. Do not quote 90,142 without saying where it comes from.

Which measures the report short-listed

Table 5.1 marks four measures Yes for a detailed project report: the new reheating furnace, coal to gas pit, coal to rotary and the efficient oil pit furnace. The other nine are marked No, including every electricity measure.

Rebuilding the oil, power and coal lines (estimate)

Furnace oil at about 0.95 kilograms a litre and the Intergovernmental Panel on Climate Change (IPCC) default, Indian coal at 1.76 from India's Second Biennial Update Report, grid at the Central Electricity Authority's financial year (FY) 2025-26 factor. All estimates on the author's reading of Tables 5.1 and 5.2.

What Senseible does here

Self-serve, Senseible reads fuel invoices and electricity bills into monthly records; it does not model a cluster programme.

Sources: BEE, Manual on energy conservation measures in brass cluster Jamnagar (Winrock International India), IPCC 2006 Guidelines, Volume 2 Energy, CEA, CO2 Baseline Database for the Indian Power Sector, version 22.0, India, Second Biennial Update Report to the UNFCCC, Table 2.3 (Indian coal 1.76; list of reports)

Last reviewed 2026-11-06. Sums are the author's, from the unit counts and per-unit savings in Table 5.1 and the totals in Table 5.2 of BEE's Jamnagar manual, which prints no year on the pages used. The two tables disagree on coal and oil; the CO2 comparison is an estimate on the author's reading.