JCM Model Project

Host Country: Indonesia

Introduction of High Efficiency Once-through BoilerIn
Golf Ball Factory of PT. Sumi Rubber Indonesia

By. Akmal M Kartajaya
12 July 2017
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JCM Model Project

Host Country: Indonesia

1. Project Overveiw
1.1. Location of JCM Model Project

PT Sumi Rubber Indonesia
Indotaisei Industrial Estate, Sector 1A, Blok Q3
Cikampek, West Java
Golf Ball Plant

West Java

Tyre Plant

Indotaisei Industrial Estate2

JCM Model Project

Host Country: Indonesia

1.2. Structure and Role of JCM Model Project3

JCM Model Project

Host Country: Indonesia

1.3. Background1.3.1. Boiler is needed for production of golf ball
Function of BOILER :Change water become steam for production process
In Golf Ball Factory, mainly steam is for :- Curing the plug rubber become core ball in Press Machines
STEAM for Heating

Plug of rubberCore Ball
Core ball press machines

Golf ball Construction(1pcs type)- Humidity & Temperature Control of Finishing RoomFinishing RoomFinished Goods4

JCM Model Project

Host Country: Indonesia

1.3.2. Old Boiler (#1 factory boiler)• Model• Fuel• Efficiency• Capacity

Fire Tube BoilerNatural Gas
89 %4000 L /hour

1.4. Install The Facility of JCM Model Project- A high efficiency (95%) once through boiler will install at a Golf Ball factory- The boiler reduces fuel consumption by incorporating gas single fueltype. Furthermore, electricity consumption is also reduced by inverter
function of feed water pump and forced draft fan.

Inverter Control ofForced Draft Fan5

JCM Model Project

Host Country: Indonesia

2. Project Implementation
2.1. Schedule of Project6

JCM Model Project

Host Country: Indonesia

2.2. Installed Facility of JCM Model Project- A high efficiency (95%) once through boiler is installed at a Golf Ball factory

WaterTreatment

2.3. Currrent Progress of Project

Since 18 June 2016, Boiler is already continuously running until now
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JCM Model Project

Host Country: Indonesia

2.4. Challanges of ProjectThis project have been done by cooperation between Indonesia company andJapanese company.
For getting faster effect, we did short time for installation and start up.
• We can Install for 4 month after project decide• Short time delivery of boiler by japanese company• Short time start up with Indonesia and Japanese company• The Boiler is not same type with the previous boiler• We must changed many piping by Indonesia company• Tuning the boiler control to fulfill our factory demand only 3 days bytwo company
Install area is small for old type boiler• Select one through boiler

8JCM Model Project

Host Country: Indonesia

2.2. Benefits of Project-Get special cost support (50%)
High boiler Efficiency(until 95%, Cost Reduction = USD 13,532 / year)
Low electricity consumption (down 30%,Cost Reduction = USD 3,935/year)
More environmental friendly (CO2 reduction )Contribution to sustainable development of Indonesia( by technology transfer, energy saving activity, level up employee )- Easy Operation for start, run and stop Boiler- Easy monitoring for Boiler Operation / Performance• Fuel consumption• Steam consumption• Electricity consumption• Water consumption• others

Automated data collection
with Comprehensive
monitoring system(EVERY FIT)

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JCM Model Project

Host Country: Indonesia

3. GHG Emission Reduction

We have not achieved the target yet, because :- The golf ball production is down compare with original plan
- Energy saving another activity, makes reduce steam consumption- The JCM Boiler is running as main supply parallely with another boiler tomaintain normal steam, it does’t make fully capacity.
This condition is now improving with the project company
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JCM Model Project

Host Country: Indonesia

4. Measurement, Reporting, Verification (MRV)

To keep these effect we do- Maintenance program weekly, monthly and yearly done correctly- Daily inspection use data logging system to easy control- Boiler water conductivity and blowdown rate keep in range standard
To keep good environment- Measuring data in every year to make sure O2, CO, NOx emission
in range standard
Progress of the JCM Project Cycle is not yet decided the Methodology
and The JCM methodology is under development.

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JCM Model Project

Host Country: Indonesia

5. Next plan

1. In our company
we will change old type boiler to one through boiler
when renewal for #1 GB factory boiler and tire factory boiler.
2. In Indonesia
It is said that annualy 1,000 unit of boilers are newly installed /replaced in Indonesia in many sectors.
(i) “water tube boiler” imported from China(ii) Euroasiatic (leading) and other brands: “fire tube boiler”
Higher efficiency “Oncethrough Boiler” will haveover 50% of share in near
future from 36％ in 2015
2015

In Japan once through boiler
share is already 89%(2013) 12