# What is the energy and fuel mix of the Pune aluminium casting cluster?

Canonical: https://senseible.earth/answers/pune-aluminium-casting-cluster-energy-mix

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.

- [CBAM for exporters](https://senseible.earth/cbam)
- [Melting energy by furnace type](https://senseible.earth/answers/pune-die-casting-melting-energy-by-furnace)
- [Are aluminium castings covered by CBAM?](https://senseible.earth/answers/are-aluminium-castings-covered-by-cbam)

Sources: [TERI, Cluster profile: Pune aluminium casting industries (2015)](https://sameeeksha.org/pdf/clusterprofile/Pune_Aluminium_Casting_Maharashtra.pdf), [SAMEEEKSHA, Cluster summary: Pune aluminium casting cluster](https://sameeeksha.org/index.php?option=com_content&view=article&id=179&Itemid=502), [CEA, CO2 Baseline Database for the Indian Power Sector (grid factor 0.675 kg CO2 per kWh, FY 2025-26)](https://cea.nic.in/cdm-co2-baseline-view?mappingId=234&lang=en), [IPCC 2006 Guidelines, Volume 2 Energy (fuel emission factors)](https://www.ipcc-nggip.iges.or.jp/public/2006gl/vol2.html)

Last reviewed 2026-10-31.