Regenerative burners
for Aluminum holding furnace
Indonesia JCM Model Project

July 12, 2017

TOYOTSU MACHINERY CORORATION
11. Company Profile
Head Office:Establishment:
Capital:Gross sales:
Employees:
Share holder:

Symphony Toyota Bldg,
4-11-7 Meieki Nakamura-ku, Nagoya, aichi, 450-0002 JapanFebruary 23 1978
JPY 325,000,000
JPY 174,860 million
705 people （as of Apr, 2017）
TOYOTA TSUSHO CORP.

Company BaseJapan 17Company Base
Oversea 92

2. JCM Project Summary
Counterpart

PT.Yamaha Motor Parts Manufacturing Indonesia
PT.Toyota Tsusho Indonesia

Project Site

Kawasan Industri KIIC, West JavaTechnology

High efficiency Regenerative burnerSuperviser

Hokuriku Techno co., ltd , PT.Hokuriku Techno indonesia

Local manufacturer

PT.Matahari Wasiso Tama

Project Site

Jjakarta

PT. YPMI PLANT

33. Needs & Regenerative burner

Production (Thousand Cars)

Increasing of Aluminum casting demand with energy reduction

2,000

Outlook

1,500
1,000
50002005

2010

2015

2020

Automotive production outlook

High efficiency Regenerative burner will reduce energy consumption
44-1. Crucible Holding Furnace
Crucible holding furnace with Regenerative burner will achievefuel reduction （over 50%）
Open top crucible can use GBF and Semi
solid mixer etc., and supply high quality
molten metal for castingwith compact self type regenerative burner
Crucible self regenerative burner

Installation photo

Type: CRU-10
5

4-2. Crucible Holding furnace

Crucible

Regenerative burner realize uniform
temperature distribution and longer
crucible lifeAB

Furnace body w/ burner
65. Eligibility 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 degrees 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.

Aluminum
MeltingFurnace

HoldingFurnace

Casting
MachineMelting Process

Holding Process

Casting Process（ Parts）
Products

aluminum
ingot

Regenerativeburners
ware introduced7

6. Monitoring ＆ Emission Reduction
Monitoring parameters¾ Consumption of natural gas
by the project furnace¾ The number of operating days

Air Flow meter
forAir ratio tuning

Gas Flow meter

Holdingfurnace iEmission Reduction
Working days

Fuel consumption（Project）
Natural gas

Reference emission－+Project emission

Electricity＝Emission
Reduction
87. Fuel consumption reduction; ResultAverage
reduction rate:

30,000Natural gas (Nm3 /Month)

25,00030%

20,000Natural Gas

15,00010,0005,000

0Conventional burner

Conventional burner

Regenerative burner

Regenerative burner

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8. GHG Emission Reduction

ERp
REp
PEp

Emissions reductions during the period p [tCO2/ p]
Reference emissions during the period p [tCO2/ p]
Project emissions during the period p [tCO2/ p]

11 Holding furnaces; 47 tCO2/ p（Jan 2016 ～ Dec 2016）

For more reduction;¾ Severe Air ratio tuning¾ Maintain crucible – furnace top sealing109. Project Schedule & Project Subject■ Result■ Plan¾ Feasibility Study : 2013
¾ Installation: 2014 ~ 2015

¾ Validation report ： Jul ~ Aug 2017
¾ Project registration : Aug ~ Sep 2017

¾ Validation1: Mar 2016
¾ Public comment : Apr 2016
¾ Approved Methodology : Feb 10, 2017
¾ PDD public comment : Mar 2017
■ Widespread of Regenerative burner■ Technology replication opportunities

1. Promotion activities in Indonesia
2. Build Maintenance and support system
3. Standardize and cost reduction ofCrucible holding furnace

1. Develop the soaking furnace field forferrous parts.

■ Contribution to sustainable development
1. Reduction of natural gas consumption.
2. Environmental preservation by reducing CO2 and NOx emissions
3. Technology transfer to a furnace manufacturer in Indonesia.
（Production and construction by Indonesian manufacturer）
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Regenerative burners
for Aluminum holding furnace
Indonesia JCM Model Project

Thank you for your attention
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