Development of Technology for Producing Concrete and Cement Using CO2

Overview
Summary
Project Scheme

note

Project Overview

Carbon Recycling is a key technology that effectively utilizes CO₂ as a resource for realizing a carbon neutral society. Japan has a competitive edge in the field of CO₂ separation and capture, as well as certain kinds of chemicals relevant to this technology.

Due to the high potential for CO₂ fixation and the stability of products, the use of CO₂ in concrete, cement, and carbonates (hereinafter referred to as “concrete and cement fields”) in particular will be implemented in society, which is expected to greatly reduce CO₂ levels. In Japan, the United States, and Europe, R&D and demonstration projects in this area are already underway.

In order to achieve decarbonization in this field, however, it is necessary to reduce CO₂ emissions and increase CO₂ fixation of concrete, a product used all around the world, as well as promote its use by reducing costs. Cement, a material used in concrete, also emits CO₂ through the decarbonization reaction of limestone, one of its raw materials, making it another issue that needs to be addressed.

To realize a carbon neutral society, the aim of this project is to address the above issues related to the social implementation of Carbon Recycling technologies, and strategically promote their diffusion in Japan and overseas.

Project Features

Development of concrete produced with maximized volumes of CO₂ emissions reduction and CO₂ fixation

The aim of this project is by 2030 to achieve maximized levels of CO₂ emissions reduction and CO₂ fixation during the production and transportation of materials, as well as establish a manufacturing system for concrete produced with maximized volumes of CO₂ emissions reduction and CO₂ fixation that realizes costs that are less than or equal to those of existing products.

Development of technology related to quality control/fixation evaluation methods for concrete produced with maximized volumes of CO₂ emissions reduction and CO₂ fixation

By 2030, quality control methods will be realized under this project for concrete produced with maximized levels of CO₂ emissions reduction and CO₂ fixation. International standardization will also be pursued.

Design and demonstration of CO₂-recovering cement production process

The aim of this project is by 2030 to realize a CO₂-recovering cement production process capable of recovering nearly all the CO₂ from limestone and achieve cost reductions equal to or greater than current CO₂ recovery methods (e.g., chemical absorption, amine scrubbing).

Establishment of carbonic acid chloride technology using various calcium sources

The aim of this project is by 2030 to realize technologies for efficiently and economically producing carbonates by recovering CO₂ and waste, and then utilize these as raw materials for cement, along with formulating guidelines to ensure product quality.

Project Summary

Budget

Up to 56.78 billion yen

CO₂ Reduction Effect (World)

In 2030: Approximately 0.6 to 1.4 billion tons/year
In 2050: Approximately 3 billion tons/year

Economic Effect (World)

In 2030: Approximately 380 billion yen
In 2050: Approximately 156 trillion yen

Research and Development Targets for 2030

1. Concrete

Realize below targets for production, transportation, and construction of concrete.

CO₂ emissions reduction: 310-350 kg/m³ (of which CO₂ fixation is 120-200 kg/m³).

Cost equal to or lower than that for existing products.

Develop quality control methods and realize international standards for concrete produced with maximized levels of CO₂ emissions reduction and CO₂ fixation.

2. Cement

Develop CO₂-recovering cement production process and meets below standards:

Recover at least 80% of CO₂ emitted in pre-heaters.
Reduce costs in comparison with conventional amine scrubbing chemical absorption method.

Develop technologies to meet following standards for producing carbonates from recovered CO₂ and using these as raw materials for cement.

Realize at least 400 kg of fixed CO₂ per ton of carbonates, by extracting at least 10% of calcium oxide from wastes.
Produce carbonates from recovered CO₂ at cost roughly 5 times market price for conventional limestone.
Develop technology utilization guidelines in response to expanded use of carbonates.

Assumptions for estimates of CO₂ reduction effect

Estimates of CO₂ reductions calculated for both concrete and cement.
Figures based on estimates used in graph regarding market conditions for concrete included in chapter titled “Potential increase in market size due to implementation of strategic actions” in Carbon Dioxide Utilization (CO₂U) ICEF Roadmap 1.0.
Figures based on estimates for 2050 used in Figure 4: Cement production by region contained in report titled “IEA - Technology Roadmap - Low-Carbon Transition in the Cement Industry.” Estimates assume that dissemination rate of concrete produced with maximized levels of CO₂ emissions reduction and fixation will total 4% and that cement production processes capable of recovering carbon will be fully utilized.

Assumptions for estimates of economic effect

Figures based on estimates for 2030 used in Figure 4: Cement production by region contained in report titled “IEA - Technology Roadmap - Low-Carbon Transition in the Cement Industry.” Estimates assume that dissemination rate of concrete produced with maximized levels of CO₂ emissions reduction and fixation will total 0.1%.
Technologies are expected to be used in approximately 10% (or 5 kilns) of all kilns deployed in domestic cement production plants (total of 30 plants, 51 kilns).
Cost of equipment installation cost is expected to total 20 billion yen per kiln.
10% of domestic market for mixed cement is expected to be acquired.
Figures based on estimates for 2050 used in Figure 4: Cement production by region contained in report titled “IEA - Technology Roadmap - Low-Carbon Transition in the Cement Industry.” Estimates assume that dissemination rate of concrete produced with maximized levels of CO₂ emissions reduction and fixation will total 4%.
Global supply of cement is expected to be replaced by 2050 with CO₂-mixed cement produced under this R&D project, and that, by 2050, current cement production facilities are expected to be replaced by facilities necessary for this type of cement production (estimated total of approximately 5 billion tons in 2050).

Project Implementing Entities

○Concrete field
[Research and Development 1]
Development of concrete produced with maximized volumes of CO₂ emissions reduction and CO₂ fixation
[Research and Development 2]
Development of technology related to quality control/fixation evaluation methods for concrete produced with maximized volumes of CO₂ emissions reduction and CO₂ fixation

Theme	Entity
Development of materials, manufacturing methods, and a quality control system on innovative carbon negative concrete	ManagerKAJIMA CORPORATION Denka Company Limited TAKENAKA CORPORATION
Development of carbon pool concrete with advanced CO₂ utilization and implementation in pavements and structures	ManagerHAZAMA ANDO CORPORATION UCHIYAMA ADVANCE CO., LTD Haikou Onoda Remicon Co., Ltd. Osaka-Hyogo Ready-Mixed Concrete Industrial Association Taisei Rotec Corporation Central Research Institute of Electric Power Industry
R&D on standardization of evaluation methods for CO₂ fixation in concrete	The University of Tokyo *Only implement Research and Development 2

○Cement field
[Research and Development 3]
Design and demonstration of CO₂-recovering production process
[Research and Development 4]
Establishment of carbonic acid chloride technology using various calcium sources

Theme	Entity
Development of cement manufacturing process with CO₂ recovery	ManagerTAIHEIYO CEMENT CORPORATION Sumitomo Osaka Cement Co., Ltd.