What is the energy and fuel mix of the Pune aluminium casting cluster?
Furnace oil and grid power, with little else. TERI's profile of Pune's 50 or so casting units counts 44,153 kL of furnace oil and 350 million kWh a year, about 77,500 toe in all: 61% thermal for melting, 39% electricity. On FY 2025-26 factors that is roughly 377,000 t CO2.
Eight large units set the number
- 12 micro units (up to 100 t a year) make about 1,500 t together.
- 30 small and medium units (100 to 5,000 t) make about 54,000 t.
- 8 large units (above 5,000 t) make about 3,40,000 t, close to 86% of the cluster's capacity of 3,95,500 t.
- About 35 of the 50 units sit in Pimpri-Chinchwad-Bhosari MIDC and Chakan MIDC.
Fuel by fuel, one year
- Electricity: 350 million kWh (30,063 toe). It runs holding furnaces, PDC and GDC machines, core shooters, shot blasting, machining and compressors in every unit, whatever the melting furnace.
- Furnace oil: 44,153 kL (43,579 toe), mostly in skalner, tower and crucible melting furnaces.
- Diesel: 2,592 kL (2,536 toe), for DG sets during load shedding in Bhosari and Chakan.
- Natural gas: 1.206 million scm (1,025 toe). LPG: 210 t (263 toe), partly for die heating on GDC and LPDC lines.
Energy share and carbon share are not the same
Electricity is 39% of the energy but close to two thirds of the CO2, because each kWh on India's grid carries more carbon than the oil that would give the same heat. A unit that melts in an oil skalner and does everything else on power usually finds its electricity bill, not its oil bill, drives the footprint its OEM sees.
Using the cluster figure for your own unit
Don't. A micro unit with an electric crucible and a large unit with a tower furnace have almost nothing in common. Add up your own furnace oil, gas, LPG, diesel and kWh for twelve months and divide by tonnes of good castings shipped.
Cluster CO2 on FY 2025-26 factors (estimate)
- Electricity: 350 million kWh x 0.675 kg = 236,250 t CO2
- Furnace oil: 44,153 kL x 2.97 t = 131,134 t CO2
- Diesel: 2,592 kL x 2.645 t = 6,856 t CO2
- Natural gas: 1.206 million scm x 2.05 kg = 2,472 t CO2
- LPG: 210 t x 2.98 = 626 t CO2
- Total about 377,300 t, or about 0.95 t CO2 per tonne of capacity
Quantities from TERI's cluster profile (2014 data). Grid factor CEA FY 2025-26; fuels IPCC 2006. The aluminium you melt carries its own, much larger footprint and is not included.
What Senseible does here
If your castings go to the EU under a covered code, Senseible's CBAM tools work from the same furnace oil, gas and diesel invoices; your electricity bills are read into monthly records for the OEM footprint, which counts power.
Sources: TERI, Cluster profile: Pune aluminium casting industries (2015), SAMEEEKSHA, Cluster summary: Pune aluminium casting cluster, 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.