Do the Rajkot foundry cluster's totals for power, coke and castings add up against the unit figures in the Energy and Resources Institute profile?

Mostly, but it depends on one choice. The Energy and Resources Institute (TERI) profile prints 460,000 tonnes of castings, 297 million kilowatt hours (kWh) and 31,500 tonnes of coke. At its own unit figures, power, coke and oil explain about 406,000 to 456,000 tonnes, up to 12% below the printed total.

What the profile prints

• Castings: about 1,500 tonnes a day, or about 0.46 million tonnes a year.
• Cluster energy in 2014-15: 297 million kWh of power, 31,500 tonnes of coke and 1,296 kilolitres of furnace oil.
• An induction foundry uses 1,000 to 1,200 kWh per tonne of good castings, of which 600 to 700 is melting. Elsewhere the same profile says the energy per tonne of good castings is generally higher, in the range of 1,100 to 1,350 kWh.
• A cupola uses 15% to 20% coke on good castings (10% to 15% on metal melted).
• About 12 oil-fired furnaces, each with a capacity of about 45 tonnes a month and burning about 9,000 litres a month.

Working back from the energy to the tonnes

• Oil: 12 furnaces x 45 tonnes x 12 months = 6,480 tonnes. Oil litres: 12 x 9,000 x 12 = 1,296,000, which is the printed 1,296 kilolitres. That ties exactly if the 45 tonnes and 9,000 litres are per furnace, which is how I read the profile. The 45 tonnes is a capacity, so actual output may be lower.
• Induction: 297 million kWh at 1,100 kWh a tonne is about 270,000 tonnes. At 1,350 it is about 220,000 tonnes. 1,100 is the low end of the 1,100 to 1,350 range and is what the profile's own unit table gives, for example 1,100,000 kWh for 1,000 tonnes.
• Cupola: 31,500 tonnes of coke at 17.5% of good castings is about 180,000 tonnes.
• Add them: 270,000 + 180,000 + 6,480 = 456,480 tonnes at 1,100 kWh, within 1% of the printed 460,000. At 1,350 kWh it is 220,000 + 180,000 + 6,480 = 406,480 tonnes, 12% below.
• So the total is about 406,000 to 456,000 tonnes, up to 12% below 460,000. The edges of the unit ranges give a wider 405,000 to 507,000 tonnes from power and coke alone, which also brackets 460,000.

Why this matters to you

• The totals roughly hold together, and more tightly if the cluster sits near 1,100 kWh a tonne. Use the unit benchmarks as a range, not a point: about 1,100 to 1,350 kWh a tonne for an induction foundry, about 17.5% coke for a cupola foundry. Check your own figure against both ends.
• The test is the same for any cluster. Divide the printed energy by the printed unit figure and see whether the tonnes land near the printed total.
• The money lines tie too. Power cost rupees (Rs) 2,524 million over 297 million kWh, which is Rs 8.50 a kWh, between the profile's Rs 8 and Rs 9 tariffs. Coke Rs 756 million over 31,500 tonnes is Rs 24,000 a tonne, inside its Rs 23,000 to 25,000 range for hard coke.

What it does not tell you

Cupola units also use power for blowers, moulding and fettling, and the profile does not say how much. So the induction share of the 297 million kWh is a little lower than the sum assumes. That would pull the induction tonnes down and leave a small gap, well inside the ranges the profile gives. Your own unit's two figures, kWh and coke per tonne of good castings, are what a buyer will want.

Example: your foundry against the profile

• Electricity 1,320,000 kWh a year, good castings 1,200 tonnes (example numbers)
• 1,320,000 / 1,200 = 1,100 kWh a tonne, the profile's middle figure
• Or coke 210 tonnes on 1,200 tonnes = 17.5%, the middle of its cupola range
• At 1,100 kWh and 0.675 kilograms a kWh: 743 kilograms of carbon dioxide (CO2) a tonne from power alone

The unit numbers are examples. 1,100 kWh, 17.5% and the cluster totals are from the TERI profile, which uses 2014-15 data.

What Senseible does here

Senseible reads fuel invoices and electricity bills into monthly records, so the kWh and the coke or oil bought each month are on file. You bring your own castings tonnes to run this test. Production counters can be added on request.

• Rajkot foundries: coke, power and a unit's share
• Induction foundry kWh per tonne by size
• CO2 per tonne of good castings
• Furnace oil per tonne: Pune, Rajkot, Chennai
• Your carbon number for buyers and banks

Sources: TERI, Energy profile: Rajkot foundry cluster (SAMEEEKSHA)

Last reviewed 2026-11-07. The profile's data are for 2014-15. The sum is my arithmetic on TERI's printed figures, and the tie depends on the kWh a tonne you pick. Update if TERI issues a newer Rajkot foundry profile.