What do a Type 1, Type 2 and Type 3 steel re-rolling mill in Sihor burn and emit in a year, and does the carbon dioxide (CO2) line in the profile of The Energy and Resources Institute (TERI) tie to its coal and power?

TERI prints 2,917, 4,736 and 7,231 tonnes of CO2 a year for a Type 1, 2 and 3 Sihor mill. Its own energy column fixes the coal at about 5,600 kcal a kilogram. On that coal and today's grid factor the mills come to 2,508, 4,124 and 6,401 tonnes, so TERI's lines are 13 to 16% higher.

The three mill types

• Type 1, furnace up to 30 feet, 3.5 tonnes an hour, 26 mills: 1,268,750 kilowatt hours (kWh) and 744 tonnes of coal a year, 526 tonnes of oil equivalent (toe), rupees (Rs) 13.5 million energy bill.
• Type 2, furnace 30 to 50 feet, 6 tonnes an hour, 49 mills: 1,875,000 kWh and 1,288 tonnes of coal, 883 toe, Rs 21.2 million.
• Type 3, furnace over 50 feet, 10 tonnes an hour, 15 mills: 2,500,000 kWh and 2,125 tonnes of coal, 1,405 toe, Rs 30.9 million.
• TERI says the reheating furnace takes 80 to 85% of a mill's energy input and electricity 15 to 20%.

Does the mill table tie to the cluster?

Yes, closely. 26 x 1,268,750 + 49 x 1,875,000 + 15 x 2,500,000 = 162.4 million kWh, against 162 million printed for the cluster. Coal: 26 x 744 + 49 x 1,288 + 15 x 2,125 = 114,331 tonnes, against 114,304 printed. The printed CO2 lines add to 26 x 2,917 + 49 x 4,736 + 15 x 7,231 = 416,371 tonnes, against 416,304 printed for the cluster.

Does the CO2 line tie to the coal and power?

• The profile prints no coal factor and no grid factor, but its total-energy column fixes the coal's heat. Type 1: 526 toe, less electricity at 0.086 toe per 1,000 kWh (1,268,750 kWh gives 109 toe), leaves 417 toe on 744 tonnes of coal. That is 23.5 gigajoules (GJ) a tonne, about 5,600 kilocalories (kcal) a kilogram. Types 2 and 3 give the same ratio. The 0.086 is the usual conversion of 860 kcal a kWh; the coal heat is my own working from the profile's rows, not a figure TERI prints.
• At the Intergovernmental Panel on Climate Change (IPCC) 2006 default for other bituminous coal, 94.6 kg of CO2 per GJ, that coal is about 2.22 kg of CO2 per kg, not the 1.76 we use for Indian coal by default. With 0.675 kg per kWh for power, Type 1 is 744 x 2.22 + 1,268,750 x 0.675 = 1,651 + 856 = about 2,508 tonnes; Type 2 is 2,859 + 1,266 = about 4,124; Type 3 is 4,713 + 1,688 = about 6,401.
• TERI's lines are then 16%, 15% and 13% higher. If power is put at 0.82, the factor TERI's other profiles imply, the mills come to about 2,692, 4,396 and 6,763 tonnes and the gap is 8%, 8% and 7%. The profile does not say which coal or grid factor TERI used, so this narrows the gap without naming a cause.
• Comparing TERI's coal with a lower-grade default of 1.76 would show a gap of about 35%, but that overstates it, because it changes the coal's heat as well as the factor.

Does the energy bill tie to the tariffs?

The profile prints Rs 8.50 per kWh for a high tension connection, inclusive of energy charges, demand charges, other penalty or rebate and electricity duty, and Rs 9.00 per kWh for low tension, inclusive of energy charges, demand charges and electricity duty, with no penalty or rebate. It prints Rs 6,000 per tonne of coal from the local market. For a Type 1 mill at the high tension rate that is 1,268,750 x 8.50 + 744 x 6,000 = Rs 15.2 million against Rs 13.5 million printed; Type 2 gives Rs 23.7 million against 21.2; Type 3 Rs 34.0 million against 30.9. The printed bills run about 10% under the arithmetic. The profile does not say why, and says coal prices move with the market.

Type 2 mill, two ways

• TERI's line: 4,736 t CO2 a year
• Coal heat from the profile: 883 toe less 161 toe of power = 722 toe on 1,288 t, about 23.5 GJ a tonne
• Coal: 1,288 x 23.5 GJ x 94.6 kg = about 2,859 t. Power: 1,875,000 x 0.675 = 1,266 t. Total 4,124 t
• Gap from TERI: 4,736 / 4,124 = 1.15. With power at 0.82: 2,859 + 1,538 = 4,396 t, gap 1.08

TERI's mill table (the profile's production year is 2015-16) with 0.675 kg per kWh, the grid factor for financial year (FY) 2025-26, and the IPCC default for the coal's heat. Estimates: the coal in Sihor is bought from local distributors and its grade is not printed, so the heat comes from the profile's own energy column.

What Senseible does here

Senseible reads fuel invoices and electricity bills into monthly records, so a year of coal, power and fuel bills gives you your own totals to set beside these. It does not measure boilers or read a profile report, and it is not a third-party verifier.

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Sources: TERI, Energy profile: Bhavnagar (Sihor) steel re-rolling mill cluster (SAMEEEKSHA), CEA, CO2 Baseline Database for the Indian Power Sector, version 22.0 (FY 2025-26 grid factor), 2006 IPCC Guidelines, Volume 2 Energy, Chapter 2 Table 2.2 (other bituminous coal)

Last reviewed 2026-11-05. The mill table is from TERI's profile, whose production year is 2015-16. The coal heat is worked out from the profile's energy column and is my reading; use your own coal invoices and your supplier's grade where you can.