JCM_ID_F_PM_ver01.0

JCM Proposed Methodology Form
Cover sheet of the Proposed Methodology Form
Form for submitting the proposed methodology
Host CountryIndonesia

Name of the methodology proponents Toyotsu Machinery Corporationsubmitting this form

Mizuho Information & Research Institute, Inc

Sectoral scope(s) to which the Proposed 3. Energy demand
Methodology applies
Title of the proposed methodology, and Replacement of conventional burners withversion number

regenerative burners for aluminum holding
furnaces, ver. 1.0

List of documents to be attached to this form

The attached draft JCM-PDD:(please check):

Additional information

Date of completion

30/04/2015

History of the proposed methodology
Version1.0

Date30/04/2015

Contents revisedFirst edition1

JCM_ID_F_PM_ver01.0

A. Title of the methodology
Replacement of conventional burners with regenerative burners for aluminum holding furnaces,ver. 1.0

B. Terms and definitions
Terms

Definitions

Regenerative burner

Burner systems which absorb exhaust gas heat to reservoir andpreheat combustion air using the absorbed heat in reservoir toimprove energy efficiency.

Conventional burner

Burner systems which do not have combustion air preheating facility.

Periodical check

Periodical investigation of furnace done by manufacturer or agent
who is authorized by the manufacturer, in order to maintain furnaceperformance.

C. Summary of the methodology
Items
GHGemission

Summary
reduction By replacing conventional burners with regenerative burners formeasuresaluminum holding furnaces, consumption of natural gas isreduced, which leads to the reduction of GHG emissions.

Calculation

ofreference Reference emissions are the CO2 emissions from the use ofemissions

reference burners in an aluminum holding furnace, which arecalculated based on the consumption of natural gas in the
project furnace and energy efficiency of the reference andproject burners.

Calculation

ofproject Project emissions are the CO2 emissions from the use of projectemissionsburners in an aluminum holding furnace, which are calculated
based on the consumption of natural gas and electricity in the
project furnace.

Monitoring parameters-

Consumption of natural gas by the project furnace-

The number of operating days

D. Eligibility criteria2

JCM_ID_F_PM_ver01.0

This methodology is applicable to projects that satisfy all of the following criteria.
Criterion 1

The project replaces conventional burners with regenerative burners foraluminum holding furnaces.

Criterion 2

Holding temperature of aluminum melt, which is determined in the furnaceuser’s specification, is within the range from 600 to 800 degree Celsius.

Criterion 3

The regenerative burners have a structure which leads all exhaust gas to flow
through the heat reservoir before discharging it into the atmosphere.

Criterion 4

Periodical check is planned at least once a year.

E. Emission Sources and GHG types
Reference emissions
Emission sources

GHG types

Combustion of natural gas in the reference furnace

CO2

Project emissions
Emission sources

GHG types

Combustion of natural gas in the project furnace

CO2Power consumption by the project furnace

CO2

F. Establishment and calculation of reference emissions
F.1. Establishment of reference emissions
The methodology results in conservative calculation of emission reductions and ensures net
reduction of emissions by the following approaches:
1. Setting energy efficiencies of burners in a conservative manner
It can be said that the energy efficiency of burners increases as the exhaust gas temperature falls(and vice versa), since high exhaust gas means that heat is released without being used. In thismethodology, the energy efficiencies are set as default values by assuming the exhaust gastemperature conservatively.
For the reference burner, the exhaust gas temperature is set as 750 degrees Celsius. When theholding temperature is designed to be within the range from 600 to 800 degrees Celsius, theactual furnace atmospheric temperature is generally in the range of 750 to 950 degrees Celsius.

3

JCM_ID_F_PM_ver01.0

Therefore, for the reference burner, the exhaust gas temperature is assumed to be equal to thelower end of furnace atmospheric temperature for the sake of conservativeness.
For the project burner, the exhaust gas temperature is set as 300 degree Celsius which is higher
than the possible temperature of the project exhaust gas when the holding temperature ranges
from 600 to 800 degrees Celsius.
Therefore, this methodology results in the conservative calculation of reference emissions byassuming the lower reference exhaust gas temperature and the higher project exhaust gas
temperature in setting the burner efficiencies.
2. Omitting reference power consumption
Although electricity is used in the reference furnace, CO2 emissions from power consumption
are not included in the reference emissions for the purpose of ensuring simplicity andconservativeness.

F.2. Calculation of reference emissions
Reference emissions are calculated as follows:

Where:

ܴ‫ܧ‬௣ = ෍൛‫ܥܨ‬௉௃,ேீ,௜,௣ × ൫ߟ௉௃,௜ ÷ ߟோா,௜ ൯ × ܰ‫ܸܥ‬ேீ × ‫ܨܧ‬ேீ ൟ௜

REp

Reference emissions during the period p [tCO2/p]

FCPJ,NG,i,pConsumption of natural gas by the project furnace i during the period p [Nm3/p]

ηPJ,iEnergy efficiency of the project burner of the project furnace i [-]ηRE,iEnergy efficiency of the reference burner of the project furnace i [-]NCVNG

Net calorific value of natural gas [GJ/Nm3]EFNG

CO2 emission factor of natural gas [tCO2/GJ]

G. Calculation of project emissions
Project emissions are calculated as follows:ܲ‫ܧ‬௣ = ܲ‫ܧ‬ேீ,௣ + ܲ‫ܧ‬௘௟௘௖,௣

4

JCM_ID_F_PM_ver01.0

Where:
PEp

Project emissions during the period p [tCO2/p]

PENG,p

Project emissions from natural gas consumption during the period p [tCO2/p]

PEelec,p

Project emissions from electricity consumption during the period p [tCO2/p]ܲ‫ܧ‬ேீ,௣ = ෍(‫ܥܨ‬௉௃,ேீ,௜,௣ × ܰ‫ܸܥ‬ேீ × ‫ܨܧ‬ேீ )௜

Where:
PENG,p

Project emissions from natural gas consumption during the period p [tCO2/p]

FCPJ,NG,i,pConsumption of natural gas by the project furnace i during the period p [Nm3/p]

NCVNG

Net calorific value of natural gas [GJ/Nm3]EFNG

CO2 emission factor of natural gas [tCO2/GJ]ܲ‫ܧ‬௘௟௘௖,௣ = ‫ܥܧ‬௉௃,௣ × ‫ܨܧ‬௘௟௘௖Where:
PEelec,p

Project emissions during the period p (from electricity) [tCO2/ p]

ECPJ,pConsumption of electricity by the project furnace during the period p [MWh/ p]

EFelecCO2 emission factor for consumed electricity [tCO2/MWh]‫ܥܧ‬௉௃,௣ = ෍൛ܴ‫ܥ‬஼஺௉,௜ × 10ି଺ × 24(ℎ‫ݏݎݑ݋‬/݀ܽ‫ܦ × )ݕ‬௢௣,௜,௣ ൟ௜Where:
ECPJ,pConsumption of electricity by the project furnace during the period p [MWh/p]

RCCAP,iThe total maximum rated capacity of auxiliary equipment of the project furnace i[W]Dop,i,pThe number of operating days of the project furnace i during the period p [day/p]

H. Calculation of emissions reductions
Emissions reductions are calculated as follows:Where:‫ܴܧ‬௣ = ܴ‫ܧ‬௣ − ܲ‫ܧ‬௣

ERpEmissions reductions during the period p [tCO2/ p]

REp

Reference emissions during the period p [tCO2/ p]5

JCM_ID_F_PM_ver01.0

PEp

Project emissions during the period p [tCO2/ p]

I. Data and parameters fixed ex ante
The source of each data and parameter fixed ex ante is listed as below.
Parameter
NCVNG

Description of data

SourceNet calorific value of natural gas

IPCC Special Report on Carbon

3

EFNG

[GJ/Nm ]dioxide Capture and Storage, Annex I,

The IPCC value is converted by gas

Table AI.10. Lower Heating Valuecomposition and molecular weight.

(LHV) is applied.

CO2 emission factor of natural gas

Country specific data or IPCC default[tCO2/GJ]

value from “2006 IPCC Guidelines for
National Greenhouse Gas Inventory”.
Lower limit value of the default CO2
emission factor is applied.

ηRE,iEnergy efficiency of the reference

See explanatory note 1.

burner of the project furnace i [-]The default value for ηRE is set as 0.682,
or the project-specific value is calculatedby the equation in explanatory note 1
using the recommended operational
value of air ratio in the manual of theexisting conventional burner.
ηPJ,iEnergy efficiency of the project burner

See explanatory note 2.

of the project furnace i [-]The project-specific value is calculatedby the equation in explanatory note 2
using the recommended operational
value of air ratio in the manual of theproject burner.
mrAir ratio for the reference burner

See explanatory note 1.

The recommended operational value inthe manual of the existing conventional6

JCM_ID_F_PM_ver01.0

Parameter

Description of data

Sourceburner, or the default value for mr set as
1.05 in conservative manner.
mpAir ratio for the project burner

See explanatory note 2.

The recommended operational value inthe manual of the project burner.
EFelecCO2 emission factor for consumed[Grid electricity]

electricity.

The most recent value available at theWhen the project furnace consumes only

time of validation is applied and fixed

grid electricity or captive electricity, thefor the monitoring period thereafter.

project participant applies the CO2

The data is sourced from “Emission

emission factor respectively.

Factors of Electricity Interconnection

When the project furnace may consume

Systems”, National Committee onboth grid electricity and captive

Clean Development Mechanism

electricity, the project participant applies

Indonesian DNA for CDM unlessthe CO2 emission factors for grid andotherwise instructed by the Joint

captive electricity proportionately.

Committee.
[Captive electricity]

Proportion of captive electricity is

CDM approved small scale

derived from dividing captive electricity

methodology: AMS-I.A

generated by total electricity consumed
at the project site. The total electricity
consumed is a summation of gridelectricity imported and captive
electricity generated* during themonitoring period.
* Captive electricity generated can bederived from metering electricity
generated or monitored operating timeand rated capacity of generator.
[CO2 emission factor]
For grid electricity: The most recent
value available from the source stated inthis table at the time of validation
For captive electricity: 0.8*7

JCM_ID_F_PM_ver01.0

Parameter

Description of dataSource[tCO2/MWh]*The most recent value available fromCDM approved small scale
methodology AMS-I.A at the time ofvalidation is applied.
RCCAP

The total maximum rated capacity ofSpecification or nameplate of auxiliary

auxiliary equipment of the projectequipment of the project furnace

furnace [W]8

JCM_ID_F_PM_ver01.0(Explanatory note 1)
ηRE =NCVNG - [GwNG * c1,r * (T1,r - T2) + A0,NG * (mr - 1) * c2,r * (T1,r - T2)]
NCVNG

Where:
ηRE

Energy efficiency of the reference burner [-]NCVNG

Net calorific value of natural gas: the default value for NCVNG is set as 36,659[kJ/Nm3] based on IPCC Special Report on Carbon dioxide Capture and Storage,
Annex I, Table AI.10, and it is converted by gas composition and molecular weight.

GwNG

Theoretical volume of wet exhaust gas from combustion of natural gas: the default
value for GwNG is set as 10.694 [Nm3/Nm3] based on the assumed natural gas
composition of CH4: 94.4%, C2H6: 3.1%, C8H8: 0.5%, and C4H10: 0.2% based onIPCC Special Report on Carbon dioxide Capture and Storage, Annex I, TableAI.10.

c1,rAverage specific heat at constant pressure of wet exhaust gas of natural gas, at thereference temperature of exhaust gas: the default value for c1,r is set as 1.455 [kJ/Nm3･degree Celsius] based on the aforementioned natural gas composition and JIS
G 0702, Appendix Table 2 (linear prediction is used for the estimation).

T1,rReference temperature of exhaust gas: the default value for T1,r is set as 750 [degreeCelsius].

T2

Ambient temperature (annual average in Jakarta): the default value for T2 is set as32.6 [degree Celsius].

A0,NG

Theoretical amount of air of the natural gas: the default value for A0,NG is set as
9.688 [Nm3/Nm3] based on the aforementioned natural gas composition.

mrAir ratio for the reference burner: the recommended operational value in themanual of the existing conventional burner, or the default value for mr set as 1.05
in conservative manner.

c2,rAverage specific heat at constant pressure of air, at the reference temperature of
exhaust gas: the default values for c2,r is set as 1.380 [kJ/ Nm3･degree Celsius]
based on the aforementioned natural gas composition and JIS G 0702, Appendix
Table 2 (Linear prediction is used for the estimation).

9

JCM_ID_F_PM_ver01.0(Explanatory note 2)ηPJ =NCVNG - [GwNG * c1,p * (T1,p - T2) + A0,NG * (mp - 1) * c2,p * (T1,p - T2)]
NCVNG

Where:
ηPJ

Energy efficiency of the reference burner [-]NCVNG

Net calorific value of natural gas: the default value for NCVNG is set as 36,659[kJ/Nm3] based on IPCC Special Report on Carbon dioxide Capture and Storage,
Annex I, Table AI.10, and it is converted by gas composition and molecular weight.

GwNG

Theoretical volume of wet exhaust gas from combustion of natural gas: the default
value for GwNG is set as 10.694 [Nm3/Nm3] based on the assumed natural gas
composition of CH4: 94.4%, C2H6: 3.1%, C8H8: 0.5%, and C4H10: 0.2% based onIPCC Special Report on Carbon dioxide Capture and Storage, Annex I, Table
AI.10.

c1,pAverage specific heat at constant pressure of wet exhaust gas of natural, at theproject temperature of exhaust gas: the default value for c1,p is set as 1.368 [kJ/Nm3･degree Celsius] based on the aforementioned natural gas composition and JISG 0702, Appendix Table 2 (linear prediction is used for the estimation).

T1,pProject temperature of exhaust gas: the default value for T1,p is set as 300 [degreeCelsius].

T2

Ambient temperature (annual average in Jakarta): the default value for T2 is set as32.6 [degree Celsius].

A0,NG

Theoretical amount of air of the natural gas: the default value for A0,NG is set as
9.688 [Nm3/Nm3] based on the aforementioned natural gas composition.

mpAir ratio for the project burner: the recommended operational value in the manualof the project burner.

c2,pAverage specific heat at constant pressure of air, at the project temperature of
exhaust gas: the default values for c2,p is set as 1.319 [GJ/Nm3･degree Celsius]
based on the aforementioned natural gas composition and JIS G 0702, Appendix
Table 2 (Linear prediction is used for the estimation).

10