Pune forging and heat treatment units burn oil, gas and power: what is the cluster's footprint?

TERI counted about 70 MSME units in Pune, 50 forging and 20 heat treatment, using 24,252 toe in 2011 to 12. Furnace oil was half of it at 11,995 toe, electricity 6,794. On IPCC factors and today's grid that is roughly 108,000 t CO2 a year, about half from power (estimate).

The cluster TERI surveyed

• About 70 MSME units: 50 forging and 20 heat treatment, mostly small, each forging 500 to 3,500 t a year.
• Output in 2011 to 12: about 80,000 t forged and 28,000 t heat treated.
• Products: propeller shafts, front axles, crown wheels, gears, connecting rods, camshafts and wheel hubs, mostly for automotive OEMs.
• Heating takes 80% to 90% of a unit's energy. Most units heat billets in box furnaces and heat treat in pit or pusher furnaces.

The fuel mix, in toe a year

• Furnace oil 11,995
• Electricity 6,794 (about 79 million kWh)
• Light diesel oil 3,044
• Natural gas 1,294
• High speed diesel 592
• LPG 533
• Total 24,252

The cluster in CO2

Furnace oil gives about 38,900 t, light diesel and HSD about 11,300 t, gas about 3,000 t and LPG about 1,400 t: roughly 54,600 t from fuels. Grid power at 0.675 kg per kWh adds about 53,300 t. Together, roughly 108,000 t a year, or about 1,540 t for an average unit.

What moves your own number

• Swapping an oil box furnace for an induction billet heater: TERI puts the energy saving at 30% to 70%.
• Moving heat treatment from oil to gas: 10% to 20% saving, and gas carries less CO2 per unit of heat than furnace oil.
• Burner, blower and temperature controls on oil or gas furnaces: up to 5% to 10%.
• Measure before and after on your own bills, per tonne forged, so an OEM sees the drop.

Worked example: the cluster figure, step by step

• 1 toe = 41.868 GJ, so furnace oil: 11,995 x 0.041868 TJ = 502.2 TJ x 77.4 t CO2 per TJ = 38,871 t
• LDO and HSD: 3,636 toe = 152.2 TJ x 74.1 = 11,280 t
• Natural gas: 54.2 TJ x 56.1 = 3,039 t; LPG: 22.3 TJ x 63.1 = 1,408 t
• Electricity: 6,794 toe at 860 kcal per kWh = 79.0 million kWh x 0.675 = 53,325 t
• Total: about 107,900 t CO2; per unit: 107,900 / 70 = about 1,540 t

Estimate. 2011 to 12 activity with IPCC 2006 defaults and the FY 2025-26 grid factor. If TERI's toe were counted on gross calorific value, the fuel share is about 5% lower. Your own bills give your real number.

What Senseible does here

Senseible reads your furnace oil, LDO, gas and power bills into a monthly Scope 1 and 2 record for your unit, so the figure you send an OEM is your own, per tonne forged and traced to each bill.

• Your carbon number for buyers and banks
• Forging footprint per tonne
• Induction heater vs oil furnace
• Carbon data for Chakan suppliers

Sources: TERI, Cluster profile report: Pune forging cluster (SAMEEEKSHA, 2012), IPCC 2006 Guidelines, Volume 2 Energy, Table 1.4, CEA CO2 Baseline Database, version 22.0

Last reviewed 2026-10-30. Cluster energy is for 2011 to 12. Update if a newer Pune forging profile is published.