Since the data available with various agencies dealt with only one aspect of energy use, it becomes necessary to collect data directly from industries. This can be seen from the discussions in the last section. We concentrated on electricity and that too from supplier's end. To understand the types of fuels used and production, we need to conduct a survey as this type of data is not available or accessible. Hence we decided to conduct a survey of about 250 industries.

Since the survey was done for the first time, we went about it in many stages with help from many authorities like the Director of industries and Commerce, Govt. of Karnataka, and the Chief Inspector of Factories and Boilers. The first questionnaire prepared by us was a simple one requesting for information on the quanta of energy used and production figures for a period of two years. About 80 industries responded to this questionnaire. This was followed by another one sent by the Joint Director of Industries and Commerce, Govt. of Karnataka. This one sought information on energy consumption for one year period. A third questionnaire for one year period. A third questionnaire was also sent to various industries seeking information on their boilers-steam generated, type of fuels used and quanta of use. In spite of the fact that more than 1000 letters were sent, the response was poor.

Analysis of these pilot surveys showed some drawbacks. Many questionnaires were not completed fully. Normally production figures were left blank. It was not possible to draw any conclusions from these survey data. So it was found necessary to generate another questionnaire and get it filled up partly by visiting the industries and partly by sending requests by post.

The questionnaire was an exhaustive one. It requested for the following sets of information;

(i) energy consumption for a period of five years from 1979-80 to 1983-84 for each source like coal, coke, firewood, electricity, furnace oil, LPG, charcoal, kerosene etc., and their values:

(ii) monthly energy consumption (for electrical energy only):

(iii) electrical power and energy details, power cut details;

(iv) production figures - quantity and value - for various products manufactured;

(v) details on connected load for various types of end uses like machinery, heating, welding, lighting, rectifiers etc;

(vi) details of loads for different sections;

(vii) capacity of diesel generating sets; electricity from them;

(viii) consumption of energy by services;

(ix) details for individual types of machines like furnaces, welding units, lighting etc;

(x) conversions;

(xi) future plans;

This questionnaire numbering sixteen pages was sent to more than 250 industries. We received replies from 41 industries. These industries have understood the motive behind our studies and spent considerable amount of their time in filling up this questionnaire. They are of invaluable help to us in our analysis. Despite repeated reminders, the biggest energy guzzler INDAL, Belgaum did not respond to any of our questionnaire - whether to the earlier two simpler ones or to the detailed one.

Table 16 gives the details of the type of industries which responded to our questionnaire. Fortunately, we got a wide canvas of industry types in these responses. We have a number of industries for the groups of engineering, metallurgical, paper, textile and sugar industries. Except for the Aluminium producer, all other major industrial types are to be found in the response. The types also include glass, batteries, watches, oxygen, fertilizers, steel, electronics, tools, tiles, cement, and heavy engineering units. Hence the results will display information on a wide variety of industry types.

The questionnaire for nearly half the number of industries which responded were filled up by personally visiting the industries concerned and eliciting their answers to our queries. This involved a number of trips to each industry on timings convenient to them. This process entailed an effort of 4-5 months.

Data pertaining to energy were analyzed and results are presented in a series of tables. Table 17 shows the energy consumption by these groups during 1983-84. The following points deserve mention. The energy unit used in million kilowatt hours equivalent.

(i) Total energy consumed by these industries works out to nearly 6.0 million tons of coal equivalent. This means that we have covered more than 80% of energy consumed in industries.

(ii) But the electrical energy component is only 1,198 million units. This is less than 50% of total electrical energy consumed in the state. But as already stated, the unavoidable exclusion due to non-availability of one aluminium industry has a sizable effect on the total electrical energy. This is because this industry alone consumes about 20% of total electrical energy for industries in Karnataka. Similarly JINDAL also refused to give us information pertaining to their energy use and production despite personal visits.

(iii) Fortunately, there is a balance in the industries consuming different types of fuels. For example, paper, textile and cement industries use coal as their primary fuel; sugar industries consume mainly bagasse; metallurgical industries use coke and charcoal; chemicals and metallurgicals use furnace oil; electricity and diesel are used by most of the industries.

(iv) Electricity constitutes 19.4% of total energy; coal is the maximum with 40.4% others-coke, bagasse, LPG, kerosene - form 24.9% of the total. Firewood use is quite small mainly restricted to sugar, textiles, tiles and metallurgical industries.

Table 18 gives the energy consumption values as percentages. These reinforce the points mentioned above. A look at the total energy consumed by each sector - shown in Table 19 col.2 - reveals that metallurgical iron and steel industries consume the maximum energy followed by paper (1358.4 million units), and sugar (844.2 m. units). Engineering units consume less energy.

Since absolute energy consumption patterns do not provide any indication, we used a standard unit and calculated energy consumption in million units equivalent. To understand the significance of the predominant type of fuels consumed, percentages were calculated as in Table 18. Even this provides only this clue. The next stage of analysis is to calculate specific energy consumptions. It is our desire to know (a) how efficiently energy is used by a manufacturing unit, (b) how the efficiency changes with time and (c) how it compares amongst units manufacturing the same product. In order to look at these problems energy consumption/unit of production should be calculated. We call this specific energy consumption. Two indices are possible - energy consumption per rupee of production or energy consumption per unit of production or ton of production. The next section looks at the specific energy consumptions for