Aggresive Carbon Reduction Program
Toward Energy Half at 2025 byCGS (Co-Generation System)
By PT Denso Indonesia
30th September, 2020Irvan JP Elliika
JCM Webinar – via Zoom MeetingOutline

2/12

1. DENSO Outline

2. DENSO ESA* Policy
3. Emission Reduction Activity• DNIA** CGS Project• Pandemic Issue Counter Activity

4. Next Action* ESA : Energy Saving Activity** DNIA : Denso Indonesia
Denso Indonesia JCM Webinar / Sep 30th, 2020 by Irvan JPE – Facility Engineering Center© DENSO CORPORATION All Rights Reserved.

1.1 DENSO Outline

3/12DENSO is a leading supplier of advanced automotive technology, systems
and components for all the world's major automakers
Japan

Employees

76,770Business Description
Car A/C, Radiator, Plug, Stick Coil,O2 Sensor, Magneto, etc.
Share Composition
DENSO Int. PTE. LTD. 68.34%
ASTRA Otoparts 25.66%
TOYOTA TSUSHO Corp. 6.00%

Revenue

3,266.0

Number of Employee
3,588

Including
DENSO CORPORATION

EuropeCompanies‹Consolidated subsidiaries›

71

Companies

America‹Consolidated subsidiaries›

Companies

2635

Employees

16,688

Revenue

652.5

Revenue

1,212.4
Billion YenBillion Yen

Billion Yen

Employees

25,126PT DENSOINDONESIAAsia‹Consolidated subsidiaries›

Others‹Consolidated subsidiaries›

Companies

6Employees

3,309

Revenue

72.7

Billion YenCompanies

DENSO Indonesia GroupPT DENSO SALESINDONESIA

74

Employees

50,099
Revenue

1,416.4

PT DENSO
MANUFACTURING
INDONESIA

Billion Yen

PT HAMADEN
INDONESIAPT DENSO TENINDONESIAPT TD AUTOMOTIVECOMPRESSORINDONESIADENSO Produce the Core of Automotive & Technology
Denso Indonesia JCM Webinar / Sep 30th, 2020 by Irvan JPE – Facility Engineering Center© DENSO CORPORATION All Rights Reserved.

1.2 DNIA Local Network
A. Outline

B. Location

Company
namePT. DENSO INDONESIA[DNIA]

EstablishedMay. 12, 1975

Capital

US $ 5,65 Mil.

Employees

4
4/12

Jakarta
airportIndonesia

3,588

C. DNIA Factories Image

Jakarta①DNIA Bekasi plant③HDI Bekasi plant①DNIA Fajar plant⑤DMIA#1 plant⑥TNIA⑤DMIA#2 plant④TACIFajar
Plant

Bekasi
Plant

SunterPlant①DNIA Sunter Plant
②DSIA
⑦TNAI
③HDI Sunter Plant

Plant Relocation at 2021
Prod. startJan., 1978 (39.5years)

Prod. start

July, 1996 (21years)

Prod. start

February, 2014 (3.5years)

Land area

38,000m2

Land area

100,000m2

Land area

200,040m2

Plant area

19,000m2

Plant area

49,050m2

Plant area

Employee

804 Man Power [Aug’20]

Employee

2,061 Man Power [Aug’20]

Employee

Products

Spark plug, O2 sensor,
Cu Radiator

Products

HVAC, Radiator, Condenser, Hose,Tube,
Bus A/C, Magneto

Products

39,700m2

Project
Established
964 Man Power [Aug’20]
Ni Plug, SIFS, ECU2W, VCT, Alt,Starter, Meter, ECU4W, Sonar,WSS, AISS, O2 Sensor

With all these factories, DENSO supplies to almost all automakers in Indonesia
Denso Indonesia JCM Webinar / Sep 30th, 2020 by Irvan JPE – Facility Engineering Center© DENSO CORPORATION All Rights Reserved.

2.1 Denso Global Policy Related to Environment

55/12

Background : Denso not only produce things, but also create the core of technology to make global citizen long life & happy
Theme : Denso Ecovision

SAVE
THE EARTH
And Deliver Bright Future To The Next Generation

Half Energy

Double Green

Double Clean

Automobile Fuel efficiency ½

Double green environmentaltechnology
Double Rich greenery Nature
Double Protection of nature

Double Confidence of customer
Double Security of regionalsociety
Double Environment
consciousness

Monozukuri CO2 ½Life transfer energy

Sustain the core business with preservation is the key of the DENSO Management
Denso Indonesia JCM Webinar / Sep 30th, 2020 by Irvan JPE – Facility Engineering Center© DENSO CORPORATION All Rights Reserved.

2.2 DNIA Energy Policy & Road Map
Diversity
EnergyThingking Way

Need of Business sustainability
with enviroment preservation+Energy Ministry

Proposal WindGenerator

ESA Road Map with 4 Pillars

Denso Indonesia

CGS is reliable& most proper
2019 : Installin economic System
value compare
Co-Generation
to reduce
CO2Significantlywith another energy source
Continuous ESA Kaizen

Establish ESA Modul
Training toAll Member

As
Platform

Final Goal

Efficiency
EnergyStrive to Expand
Energy Source Application to Gain
High Rate Energy Reduction

Starting
CGS in Fajar Plant

AsDirection

Denso Global

66/12

For All Machines & Equipment to beHigh Efficiency Energy

Conserve
EnergyChangeCA to N2Improve
ESA SGA
By Evaluating
Expand ESA SGA Process

Expand Best Practice

DNIA Reduce Carbon
Unit by 50% at 2025

Create ESA SGA
ModelAccel Implementation
Of Common Improvement

DNIA Energy Policy

Standardized Energy
Behavior

Change
LPG to LNG

Leverage Standard Behaviour to Ensure
No Loss Energy
Integrated Production
Energy Supply

Sustainability

Training & Check on Site
Standardized
No Energy day

JIT Energy

Develop Energy
Efficienfy in Factory

CreateESA Mind
Astra Energy
AwardEliminate
Loss

CentralizedActivity

Facility Global
Champion

Facility Global
Champion

2012
Denso Indonesia JCM Webinar / Sep 30th, 2020 by Irvan JPE – Facility Engineering Center© DENSO CORPORATION All Rights Reserved.

2016

CEM Award
ASEAN Energy
National EnergyAward 2020~2025
Astra Energy Award Astra EnergyAwardAwardISO 50001

2017

2018

2019

20202025

3.1 DNIA Carbon Emission Reduction Activity

7
7/12

A. General Direction of Long Term Action Plan
ECO List

Conserved &Efficiency Energy

Diversity Energi

DNIA TargetAction

Rate

kt-CO2PIC

Genba Kaizen

EnergyJIT, Air・Steam-less,PEF dsb

13％

90

All Area (User &Facility)

High Efficiency Machine

Mengganti dengan mesin yang lebih tinggi efisiensinya(Air-Conditioner, Compressor, Boiler, lighting)

6％

42

All Area (User &Facility)

1/ N・DANTOTSU Line

10％

70

Concept of high efficiency energy machine after 2020

8％56High Efficiency CGS

Implement at high basic energy to ensure very high performance

15％

105

Facility

Renewable Energi

Solar (PV), Windmill, etc

4％28Facility

Tech
Innovation

R&DDevelopment

Focus at User Area

CGS use low carbon energy to produce electricity at the same rate as BAU

B. Project Structural : JCM Carbon Reduction ProjectUtilize JCM subsidy to make the project become favorable.
Japan Gov’t
3
Ministry of Environment
Issuance of credit

Engineering
Procurement &Contractor

32JPN

JCM Secretary
54Japan InstituteInternational Consortium

Denso Indonesia JCM Webinar / Sep 30th, 2020 by Irvan JPE – Facility Engineering Center© DENSO CORPORATION All Rights Reserved.

INA

Indonesian Gov’t
Coordinating Ministry ofEconomic Affair

1Denso Indonesia(Denso Japan)

Issuance of credit

Design &Implement Project3.2 CGS Overview

88/12

Was

Electric Supply

Electriccompany

Factory

Electric Chiller
Ventilated Supply

3 x 300 RT

Now
CGS is the power plant that generate electricity andSample valve
useful heat (and cooling) at the same time
Silencer

Natural gas
company

Chiller
BeforeAfterStatus
Electric #1
ONONElectric #2
ONStandby OFF Saving
Electric #3 Standby OFF Standby OFFABSON-Stack

Exhaust air
384 °C~ 10 Bar

300.0 RT

385.5 RT

BoilerVentilated Supply

Exchanger

4 – 6 BarGas engine 2.0 MW

Sync at
11 kVElectric Supply
Step up/down
11kV-> 20kVElectric company

Start Operation Sep 2019 and The Project supported by JCM
Denso Indonesia JCM Webinar / Sep 30th, 2020 by Irvan JPE – Facility Engineering Center© DENSO CORPORATION All Rights Reserved.

300.0 RT

300.0 RT

Hot water
Hot Water 1,848 kW

Hotwater

Meter Gas Station

Existing Electric Chiller

ABS (Absorption) chiller

Factory3.3 CGS Monitoring Result99/12

A. CGS Project Benefit Result

Carbon Reduction ▲34%
Reduce Carbon Emission volume by
780 ton-CO2 per month

Environment

Skill Up +30%

SkillDevelopment

Necessary skill to ensure self
Operation & Maintenance
Increase self-suffiency power up by
2 Mega Watt

Optimize heat recovery system togain most benefit of CGS

Energy Cost ▲14%

Economic

Self-Power ▲57%

Reliability

B. CGS Project Carbon Output Result
Some trouble still happen

Improved condition

Covid Streak!

780 ton-CO2

[X]

[X]

[X]

[X]

[O]

[O]

Denso Indonesia JCM Webinar / Sep 30th, 2020 by Irvan JPE – Facility Engineering Center© DENSO CORPORATION All Rights Reserved.

[O]

[X]

[X]

Time to recover...

3.4 CGS Pandemic Counter Improvement#1 : Gap Power Reduction
Background :MV grid

Purpose :GReduce min supply to increase
CGS output during same low
factory load

LV gridC/M :CGS Factory Load
Before[1,200kW]

Gas Engine out 900 kW
Max 350 kW

Set at 300 kW
After

Min 200 kW[1,200kW]

Gas Engine out 1,000 kW
Max 200 kW

Set at 200 kW

Min 100 kWImpact
Increase
CGSoutput100 kW
during low
factoryload(<2MW)
CarbonAdd.
Carbonreduction
0.21 tonCO2/hour

Background :Background :Pandemic issue lead to extremely low sales. DNIA case,production load is lower than 2MW especially in night shift

Maximize chiller supply rate to 100% & switch off theelectric chiller
ABS Chiller

Balancing production load between day shift and night shift
to get optimal CGS output

Purpose :C/M :30±20C
50%130±20C

232±10C

Electric Chiller

Purpose :C/M :Required thermal energy

1 Off electric chiller so canmaximize ABS chiller to 100%

2 Confirm with production toincrease factory temp. by 20C

Current[O]

Step#1[X]

Final Step[O]

BEFOREAFTERElectric SupplyDenso Indonesia JCM Webinar / Sep 30th, 2020 by Irvan JPE – Facility Engineering Center© DENSO CORPORATION All Rights Reserved.

#3 : Production Load Switch Balance

ABS Chiller performance is 80% & not able to improve sinceelectric chiller operation can’t be reduce (non-inverter type)

100%

Backward (Import)

100%

Backward power from CGS is notallowed by setting min supply 300
kW for electric coy.

80%

Normal (Export)#2 : Chiller Capacity Optimization

Thermal energy [Calory]

Electric Coy

1010/12Impact
OFF total electricchiller by utilizing
ABS chiller
CarbonAdd. Carbon
reduction 0.27
ton-CO2/hour

Coordinate w/ all user to adjust production schedule

ImpactOutput CGS at night shift
improve 75% 100%CarbonAdd. Carbon reduction
0.11 ton-CO2/hour

3.5 CGS Result & Pandemic Issue Counter Activity

1111/12

A. CGS Project Benefit Result After Kaizen
Gas Engine

Chiller

Gap Power Reduction

Chiller Capacity Optimization

1,000

600

Operation Hour

16458149
115

0 0 0780 ton-CO2253

0 0 0400200

FS Project Target

Recovery Action Result

1,200800

Production Load Switch Balance

163685556

80 0 01640 0 0 Kaizen#1

54137

Kaizen#1,#2,#3

106

48
122
94

Kaizen#1,#2,#3

1,000
800

253

400685360

355

200363355-0

Sep19 - Dec19[X]

Jan20 - Mar20[O]Apr20 - May20

[X]

[X]

Jun-20[O]

Jul-20Aug-20[O]

Recovery
Total output
impact addperformance▲41% output
is 162 %

600

186

186

1,200

Operation Hour (Hour)CGS Output (ton-CO2)

1,400

Normal Operation[O]

Recovery action
as pandemic
counter succeed
to secure in longterm result

B. KPI of EnPI [Energy Performance Index] : Carbon Basic Unit = Carbon emission / Revenue
Normal Target : Annual ▲5% Carbon Unit Reduction

Gap(-)

(X)

(O)

(O)

(O)

(O)

(O)

(O)

Result : 47%
Target : 50%
Remaining Gap 3% from 2020 to 2025

Denso Indonesia JCM Webinar / Sep 30th, 2020 by Irvan JPE – Facility Engineering Center© DENSO CORPORATION All Rights Reserved.

Even exceeding thecurrent target, DNIA
will still commit toreduce %5 annuallyto provision thefuture4. Next Action : Future ESA DevelopmentDiversity
Energy4 Pillars of ESA Long
EfficiencyTerm

Strive to Expand

EnergyEnergy Source Application to Gain
Starting
High Rate Energy Reduction
CGS in Fajar Plant

Establish ESA Modul
Training toAll Member

Proposal Wind
Generator
ChangeCA to N2

Change
LPG to LNG

Technology for noloss and highefficiency energy

PLATFORM :Autonomous
operation basedon IOT principle

Conserve
EnergyHuman skill
development for
ESA self-relianceContinuous ESA Kaizen
For All Machines & Equipment to beHigh Efficiency Energy

Improve
Expand Best Practice
ESA SGA
By Evaluating
Expand ESA SGA Process

Create ESA SGA
ModelAccel Implementation
Of Common Improvement

Standardized Energy
Behavior

Integrated Production
Energy Supply

Standardized
No Energy day

JIT Energy
CreateESA MindCentralized
Activity

Facility Global
Champion

Facility Global
Champion2012

CEM Award
ASEAN Energy Award
National Energy
2020
~2025
Astra Energy Award Astra EnergyAwardAward
ISO 50001

Astra Energy
AwardEliminateLoss2016

2017

2018

Denso Indonesia JCM Webinar / Sep 30th, 2020 by Irvan JPE – Facility Engineering Center© DENSO CORPORATION All Rights Reserved.

Implementing
ESA Not Only
Contribute toSustain Company
Sustainability
Life, But Also
Sustain The
Clean & Green
Environment
Where We LiveLeverage Standard Behaviour to Ensure
No Loss Energy

Training & Check on Site
Develop Energy
Efficienfy in Factory

12
12/12

201920202025

THANK YOU

Denso Indonesia JCM Webinar / Sep 30th, 2020 by Irvan JPE – Facility Engineering Center© DENSO CORPORATION All Rights Reserved.

13

CGS Operation

ElectricCompanyMinimum
PowerSupply

14
13/12

Profitable Area
Loss Area

CGS will start after factoryload > 300 kW
ABS Chiller ON for min CGS operation at 400 kW
Generator minimum operation at 700 kW for total balance cost
Denso Indonesia JCM Webinar / Sep 30th, 2020 by Irvan JPE – Facility Engineering Center© DENSO CORPORATION All Rights Reserved.

Ideal merit
CGS operationat factory load> 2300kW
Minimum merit CGS operation at 700 kW

CGS Documentation

1514/12Heat Exchanger Boiler

CGS Plant Image

Project Layout
CGS plant
Electricsynchrone
panel

Chimney ~9 mtr

Utility stanchion
chilledwater pump

Transformer

Natural Gas
Piping

Cooling Tower + Radiator

MeterGasStation

Cooling Tower

Transformer
Control Room

Denso Indonesia JCM Webinar / Sep 30th, 2020 by Irvan JPE – Facility Engineering Center© DENSO CORPORATION All Rights Reserved.

Gas Engine (+Chiller) Room3.4.1 CGS Kaizen #1 : Optimizing Minimum Power LoadCurrent

16Improvement

CL Power trend load during overtime before reseting

After Re-setting there is still gap
90 kW. That condition still save (will not export power to CL )Gap between 0 kW to Min CL
load still big enough. Has
potential to reduce

Max 350 kW
Min 250 kW

Denso Indonesia JCM Webinar / Sep 30th, 2020 by Irvan JPE – Facility Engineering Center© DENSO CORPORATION All Rights Reserved.

CL Power trend load during overtime after re-setting

Max 200 kW
Min 90 kW

3.4.2 CGS Kaizen #2 : Balancing Production Load
Current

Improvement

Night shift load is 67.5% only
Denso Indonesia JCM Webinar / Sep 30th, 2020 by Irvan JPE – Facility Engineering Center© DENSO CORPORATION All Rights Reserved.

Night shift load become 100.0%.

17