JCM_ID_F_PDD_ver02.0

JCM Project Design Document Form
A. Project description
A.1. Title of the JCM project
Energy saving through introduction of Regenerative Burners for aluminum holding furnaces of
the automotive components manufacture in the Republic of Indonesia
A.2. General description of project and applied technologies and/or measures
The proposed JCM Project aims to reduce consumption of natural gas and consequently
emissions of greenhouse gas (GHG) by replacing conventional burners with regenerative
burners for aluminum holding furnaces in the automotive components manufacturing factory.
Regenerative burners absorb exhaust gas heat to reservoir and preheat combustion air using theabsorbed heat in reservoir to improve energy efficiency.
The project is expected to reduce 98 t-CO2 of GHG emissions annually through replacement ofthe eleven conventional burners with regenerative burners at the factory of PT. Yamaha Motor
Parts Manufacturing Indonesia (YPMI) in the Karawang International Industrial City (KIIC),
Karawang, West Java Province, Indonesia.
In line with the JCM approved methodology ID_AM009, reference emissions are calculated
based on the consumption of natural gas in the project furnace and energy efficiency of thereference and project burners, while project emissions are calculated based on the consumptionof natural gas and electricity in the project furnace.
A.3. Location of project, including coordinates
Country

The Republic of Indonesia

Region/State/Province etc.:

West Java Province

City/Town/Community etc:

Karawang

Latitude, longitude

S 6° 21’ 45’’ and E 107° 16’ 15’’

A.4. Name of project participants
TheRepublicIndonesia
Japanof PT. Yamaha Motor Parts Manufacturing Indonesia(YPMI)
Toyotsu Machinery Corporation1

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A.5. Duration
Starting date of project operation

12/01/2015

Expected operational lifetime of project

9 years

A.6. Contribution from Japan
The proposed JCM Project was partially supported by the Ministry of Environment, Japanthrough the financing programme for JCM model projects, which provided financial supportof less than half of the initial investment for the projects in order to acquire JCM credits.
As for technology transfer, the proposed JCM Project implemented opportunities for OJT
training of YPMI’s Indonesian technicians on operation and maintenance of regenerative
burners as follows;
1st OJT-Date: 9th and 10th December, 2014
-Site: PT.MATAHARIWASISO TAMA (Local furnace maker)-Menu: The way of handling regenerative burner and conditioning fuel-Lector: 3 engineers of YOKOI KIKAI KOSAKUSYO CO., LTD (Regenerative burner maker)-Trainee: Several workers of YPMI
2nd OJT-Date: 16th -20th July, 2018
-Site: YPMI
-Menu: The way of adjusting air ration for optimal operation and maintenance-Lector: 1 engineer of HOKURIKU TECHNO CO., LTD (Furnace maker)-Trainee: Several workers of YPMI
Consequently reduces technical and operational impediments to introductions of energyefficient regenerative burners in Indonesia where energy demands have recently been surging
but regenerative burners have been rarely introduced.
The special skills required for operation and maintenance of regenerative burners are, forexample:1.

to install the right quantity and density of the heat absorber that is unique to regenerativeburners;

2.

to operate the burner keeping appropriate air ratio; and3.

to maintain the heat absorber’s cleanness and damage within the acceptable range.

2

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B. Application of an approved methodology(ies)B.1. Selection of methodology(ies)
Selected approved methodology No.

ID_AM009

Version number3.0

B.2. Explanation of how the project meets eligibility criteria of the approved methodology
Eligibility

Descriptions specified in theProject information

criteria

methodology

Criterion 1

The project replaces conventional

The proposed JCM Project replaces theburners with regenerative burners

eleven conventional burners withfor aluminum holding furnaces.

regenerative burners for aluminum
holding furnaces in the factory of YPMI.

Criterion 2

Holding temperature of aluminum

YPMI’s specification determines thatmelt, which is determined in theholding temperature of aluminum melt isfurnace user’s specification, iswithin the range from 600 to 800 degrees

within the range from 600 to 800

Celsius.

degrees Celsius.
Criterion 3

Criterion 4

The regenerative burners have a

All the regenerative burners introduced

structure which leads all exhaustin this project have a structure which

gas to flow through the heatleads all exhaust gas to flow through thereservoir before discharging it into

heat reservoir before discharging it into

the atmosphere.

the atmosphere.

Periodical check is planned at least

Periodical checks of the aluminum

once a year.

holding furnaces are planned to be
conducted once a year in YPMI’s
specification

C. Calculation of emission reductions
C.1. All emission sources and their associated greenhouse gases relevant to the JCM project
Reference emissions
Emission sources

GHG type

Combustion of natural gas in the reference furnace

CO2

Project emissions
Emission sources

GHG type3

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Combustion of natural gas in the project furnace

CO2Power consumption by the project furnace

CO24

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C.2. Figure of all emission sources and monitoring points relevant to the JCM project

C.3. Estimated emissions reductions in each year
YearEstimated

Reference Estimatedemissions (tCO2e)

Project EstimatedEmissions (tCO2e)

Emission

Reductions (tCO2e)

2013

­­

­

2014

­

­

­

2015

268.5

233.9

34

2016

761.4

663.3

98

2017

761.4

663.3

98

2018

761.4

663.3

98

2019

761.4

663.3

98

2020

761.4

663.3

98

2021

187.7.

163.6

24

2022

­

­

­

5

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2023

-

--

2024

-

--

2025

-

--

2026

-

--

2027

---

2028

---

2029

---

2030---

Total (tCO2e)

548

Note:
The estimated emission reductions in each year are rounded down after the decimal point.

D. Environmental impact assessment
Legal requirement of environmental impact assessment for No
the proposed project

E. Local stakeholder consultation
E.1. Solicitation of comments from local stakeholders
In order to cover a diverse group of stakeholders, in the period from 27 August – 28 August
2015, a series of meetings were conducted with government of West Java Province, Karawang
Regency Government and Karawang Chamber of Commerce, and Karawang International
Industrial City (KIIC). The schedule of the meetings is provided in the table below.
NoDATETIMEORGANIZATION

1

2015/8/27 08:15-09:15 Government of West Java Province,Industry and TradeDepartment2

09:30-10:30 Regional Environmental Management Board of West JavaProvince, Legal Affairs and Partnership Division3

11:00-12:00 Regional Development Planning Board of West Java Province,
Economic Division and Physical Division (Energy Related)

4

14:00-15:45 Government of West Java Province, International Cooperation
Division, Regional Autonomy and Cooperation Bureau

5

Government of West Java Province, Economic Administration
Bureau6

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6
7

19:00-20:00 Karawang Chamber of Commerce
2015/8/28 08:15-11:00 Karawang Regency Government, Economic Bureau/ Board ofInvestment and Integrated Services

8

Karawang Regency Government, Department of Industry,Trade, Mining, and Energy

9Regional Environmental Agency of Karawang Regency

10

14:00-15:00 Karawang International Industrial City (KIIC) secretariat

At each meeting, a brief introduction of the project was made and opinions of the stakeholders
were solicited. A summary of the comments received is provided in Section E.2. below.
E.2. Summary of comments received and their consideration
Stakeholders

Comments receivedConsideration of comments
received

Government of West Java

This technology is great

No action is needed.

Province, Industry and Trade

because that can contribute(Diffusion of this technology

Department

energy and climate changeis needed)issues. Please consider toapply it to other sector.
Regional Environmental

I understand that regenerative

Management Board of Westburner is advanced technology.

Java Province, Legal Affairs

I’d like to support the project.

No action is needed.

and Partnership Division
Regional Development

Energy saving andPlanning Board of West Java

environment issues areProvince,

important for Indonesia

Economic Division andgovernment. We would like toPhysical Division (Energyhelp the project if you need.

No action is needed.

Related)Government of West JavaThe regenerative burner isProvince, Internationalenergy saving andCooperation Division,

environment-friendly

Regional Autonomy andtechnology. It can contribute toCooperation Bureau

the government policy.

Government of West Java

7

No action is needed.

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Province, Economic
Administration Bureau
Karawang Chamber ofWe will help to diffuse theNo action is needed.

Commercetechnology.

Karawang Regency

Please consider to diffuse thisNo action is needed.

Government, Economictechnology.

(Diffusion of this technology
is needed)

Bureau/ Board of Investment
and Integrated Services
Karawang Regency
Government, Department ofIndustry, Trade, Mining, andEnergy
Regional Environmental
Agency of Karawang
Regency
Karawang International

We understand the technology

Industrial City (KIIC)

and JCM.

No action is needed.

secretariat

F. References
Reference lists to support descriptions in the PDD, if any.

Annex
-Revision history of PDD
VersionDate

Contents revised

01.0

13/02/2017

First Edition

02.0

03/10/2019

Revision to:Change version of the approved methodology applied forthe project8JCM_ID_F_PDD_ver02.0

Change to the most recent value for CO2 emission factor
for consumed electricity according to “Emission Factorsof Electricity Interconnection Systems”, NationalCommittee

onCleanDevelopment

Mechanism(Indonesian DNA for CDM), based on data obtained by
Directorate General of Electricity, Ministry of Energy
and Mineral Resources, Indonesia
03.0

10/12/2019

Revised based on the findings from validation:(Section C.3.)

30/03/2020

Initial registration by the Joint Committee through electronicdecision9