B-6E

Moonshot Goal 4 Annual Report 2023

C4S Research & Development Project

PM: Takafumi NOGUCHIThe University of Tokyo, Professor
PJ participating organizations:
The University of Tokyo
Hokkaido University
Recommissioned organizations:Tokyo University of Science
Kogakuin University
Utsunomiya University
Shimizu Corporation
Taiheiyo Cement
Masuo Recycle1Annualproduction of cement
セメントの年間生産量（百万t）(million tons)

120

6,000

年間生産量
Annual

累積生産量
Cumulative

脱炭酸による累積CO2排出量
Cumulative CO2 from calcination

100

5,000

80

4,000

60

3,000

40

2,000

20

1,000

0

0
1920

1930

1940

1950

1960

1970

1980

1990

2000

2010

2020

World

(million tons)

Annual production of cement
セメントの年間生産量（百万t）

6,000

2030

120,000

Cumulative
累積生産量

Annual
年間生産量

Cumulative CO2 from calcination
脱炭酸による累積CO2排出量

5,000

100,000

4,000

80,0003,000

60,0002,000

40,0001,000

20,000

0

0
1920

1930

1940

1950

1960

1970

1980

1990

2000

FY2023 Results Report Meeting for NEDO Moonshot R&D Program Goal 4

2010

2020

31 January 2024

2030

セメントの累積生産量およびセメン
Cumulative
cement production (million tons)
Cumulative
CO2 emissions from calcination
ト生産時の脱炭酸による累積CO
2排
during cement出量（百万t）
production (million tons)

Japan

セメントの累積生産量およびセメン
Cumulative
cement production (million tons)
Cumulative
CO2 emissions from calcination
ト生産時の脱炭酸による累積CO
2排
during cement出量（百万t）
production (million tons)

Background (Cement production & CO2), Objective

Total CO2 in air
2.8 trillion tons
CO2 emission from
calcination during
cement production
Cumulative
World 55 billion tons
Japan 2 billion tons
AnnualWorld 2.1 billion tons
Japan 26 million tons

Capture &Utilization (CCUS)
by Concrete2

Background, Method for CCUS
Extraction of limestone (CaCO3) to produce cement, etc.

Always generate CO2 when using calcium (Ca)Concrete, which is no longer used around the world,
is a valuable source of calcium (Ca)
(Reacting with CO2 to form carbonate)

Crushing waste concrete

Binding CO2 in the air

CaCO3 formation

CCC

Produce calcium carbonate concrete (CCC) to capture and fix CO2
in the air released by calcination of limestone during cement
production with Ca, and permanently circulate CO2 and Ca
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Overall Picture of C4S R&D Project
Target:Japan:
World:

Amount of DAC in 2050
in case of C4S realization(50% of concrete is CCC)
▲13 million tons-CO2/year▲1 billion tons-CO2/year

Production of
CCC members

CO2
utilization

Manufacturing principles for CCC components (PJ I)
Structural design for CCC structures (PJ III)

CCC members: manufacturing, structural form, performance evaluation
CCC structures: structural design and construction
The University of Tokyo
Tokyo University of Science
Shimizu Corporation

CCC reaction control (PJ I)

Infrastructures

CCC unit: reaction mechanism, formulation
design, manufacturing and quality control,
performance evaluation
CCC unit manufacturing plant: pilot design

Calcium
Recycledaggregate bicarbonate
solution
CO2 utilization(DAC)

The University of Tokyo
Kogakuin University
Utsunomiya University

Institutional design related to building codes
Design of resource recycling scenarios
CO2 emission reduction/fixation effectiveness analysis

Production of
CCC units

Assembly &construction of
CCC members

Waste concreteSocial implementation (PJ III)The University of Tokyo
Taiheiyo Cement

CCC raw material manufacturing process (PJ II)
Crushing of waste concrete and fixation of CO2 absorption
Improvement of efficiency and scale
Deployment to pilot plant
Hokkaido Unibersity
Masuo Recycle

Production of CCC
raw materials

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Development Schedule, Targets
R&D items

Target at the end of
FY2023

Target at the end of
FY2024 (Interim)

Target at the end of FY2029 (Final)

KPI

φ15x30cm specimen withstable strength of 20MPa
Started manufacturing
column and beam atbench plant

30MPa strength in specimens
12MPa strength in column
Production of column and beamat bench plant
Construction of mockup
structures

30MPa strength in column
Started supplying earthquake-resistantand durable low-rise buildings

Fabrication of bench plant
φ0.15x0.3m column unit
0.2x0.1x1m beam
Clarification of
manufacturing principles
for components with stable
quality and performance

Member manufacturing atbench plant
120 column units/month
42 beam units/month
Construction of mockup
structures
W×D×H=2×1×3m 2-layer
structure

Manufacturing components in pilot
plant
250 φ0.3x0.6m pillar units/month
120 0.4x0.2x2m beam units/month
Building construction
2 stories

Fabrication of bench plant
Determination of efficient
raw material production
process
Determination of efficient
CO2 capture process

Raw material production atbench plant
5 tons/month
CO2 capture
2960 kg/year

Raw material production at pilot plant
90 tons/month
CO2 capture
54 tons/year

Collection of structuraldesign data
Clarification of datarequired for Minister ofConstruction approval,
etc.
Prediction of waste
concrete emissions basedon regional characteristics
Identification of CO2
emission and absorption
balance at bench plant

Establishing outline ofstructural design method
Clarification of procedures andcollection of necessary materials
for obtaining Minister ofConstruction approval, etc.
Presentation of the direction of
optimal resource circulation
scenario
Presentation of measures forminimizing CO2 emissions andmaximizing absorption

Establishment of methods for structuraldesign and durability design
Obtaining Minister of Construction
approval for structural methods
Proposal of revisions to technicalstandards regarding building materials
Completion of optimal resource
circulation scenario
Confirmation of C4S validity based on
LCA evaluation①PJ I

Development of
CCC reaction
control technology
and component
manufacturing
principles②PJ II

Development of
manufacturing
processes for CCC
raw materials③PJ III

Development ofstructural design
and performance
evaluation methods
for CCC structuresand social
implementation of
C4S

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CCC Structure Construction Procedures
Production of CCC
raw material

Production of CCC units
Carbonatedparticles

Waste concretePrimary crushing
1st screening

Drying (80℃)
over

２次破砕

below

CCC hopper

Mixing with
Ca(HCO3)2
solution

CCC dedicatedcrusher

0.6-1.2mm

1.2-2.5mm

2.5-5.0mm

Pressure
Drying (105℃)

Carbonation by
particle size

Carbonatedparticles

Ca(HCO3)2 solution
CO2
Ca

CCC units
Column assembly(Thin-walled steel
tube CCC）

Wall assembly(CCC blocks)

Prestressing

Prestressing

CCC column

CCC wallDelivery

Delivery

Placing into
mold, vibratorycompactionover

2nd screening

0-0.6
mm

Particle size
adjustment

Production and constructionof CCC members

CO
CO2 2
Ca
Ca

Air

Post-curing
under Ca(HCO3)2
solution

Construction

CCC structures

CCCユニット

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The University of Tokyo
Hokkaido University
Tokyo University of Science
Kogakuin University
Utsunomiya University
Shimizu Corporation
Taiheiyo Cement
Masuo Recycle

P. 7

Development of Manufacturing
Processes for CCC Raw Materials

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Methods for CO2 Capture Acceleration
Granulation

Crushing and classification of waste concrete → Single particle size →Securing of aeration channels → Acceleration of carbonation by dry/wet
repetition for each particle size → Enhancement of DAC
2.5-5mm

1.2-2.5mm
Classification

Human head-sized
waste concrete
Crushing

0.6-1.2mm
0-0.6mm

Repeatedwetting & drying

Acceleration of carbonation
CaO＋CO2→CaCO3

Enhancement of DAC

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Methods for CO2 Capture Acceleration
Drip method
Flame

FilterDistilled
water

Waste concrete crushed particles

CO2CO2
capturerate
absorption(g/g-cement
paste)(g/g-waste
concreteparticles)

100％ CO2 capture

Pump

Dripping water periodically on
8.238mlevery 12 hours
every 24 hours
crushed waste concrete particles for 15 seconds
1.677gRepeatedwetting & drying
Carbonation of Ca(OH)2
Accelerated carbonation of CSH

0.2

Classified
分級
Drip_12h
Drip
every
12時間おき
12
hours
に滴水

0.15

Classified
分級
Drip_24h
Drip
every
24時間おき24
hoursに滴水
Classified
分級
RH60
Constant
一定湿度
RH
60%
（RH60%）

0.1

Classified
分級
RH85
Constant
一定湿度
RH
85%
（RH85%）

0.05

Unclassified
未分級
未分級
Constant
一定湿度
RH
60%
RH60
（RH60%）

00

10Practically reasonableproduction period(3days)Drip method
the most practicallyadvantageous
method forcarbonation by DAC
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20

30

Time
(days)
Period(days)

Initial CO2
fixation

CO2 fixation throughcarbonation of
Ca(OH)2

CO2 fixation bycarbonation of
CSH

56.2 times

Unclassified Classified
RH 60%
7 daysClassified
RH 85%Classified
Drip
every 12hrs
7dyas

Classified
Drip
every 24hrs

9

Methods for CO2 Capture Acceleration
Dripping water
Easy to manage and extremely fast,
but particles being more fragile
Water

Waste concrete particles

Mist supply

CaCO3

CO2 fixation reaction field: surface + outside
Ca2+

CO32-

CO32-

WettingOH-

Ca2+

Distilled water
mist

Surface wetting
CO2

CO2

Ca2+ Drying

Ultrasonicatomizer

Moisture penetration

Drying

CO2 fixation reaction field:
surface + inside the pore
CO 2- CO2

Voids & Cracks

Large amount of surface water

0.1ml in 5 seconds

3

Constant humidity

DryingDifficult to control, slow speed, buthigh particle density

Ca2+

Rapid precipitation in pores

CO2 fixation reaction field: inside the pore
Small amount ofcondensed water CO2

CO32-

CO2

Ca2+

Slow precipitationin the poreConstant humidity
FY2023 Results Report Meeting for NEDO Moonshot R&D Program Goal 4

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Easy to manage
Aiming to promote CO2 fixation
through surface and internal
reactions by spraying a small
amount of mist10

Toward the Installation of a Pilot Plant
Improving the accuracy of operations on a small site
Planning of actual installation, including flow line images
Introduction of grab forks (plant maintenance andoperational testing)
Improving efficiency of manual operation methods
Addition of carbonation accelerators such as misting
equipment

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The University of Tokyo
Hokkaido University
Tokyo University of Science
Kogakuin University
Utsunomiya University
Shimizu Corporation
Taiheiyo Cement
Masuo Recycle

Development of CCC Reaction Control &Stabilized Manufacturing Technologies
Before hardening

After hardening

Acicular crystals(Aragonite)

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Various Manufacturing Methods for CCC
Precipitation method

Pressurization method

Stacked pressurization method

Issues forSocial Implementation

Larger size and higher strength
Reduction of energy consumption
Improvement of productivity

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Cold Sintering Method
Mechanism of strength
development

Initial pressurization
Increase of actual volume ratio by particle filling
Increase of contact area between particles
Long-term pressurization
Increases of bonding surface and strength by pressure-solution

Pressure: 50MPa

Re-precimitation

Pressure

Pressure dissolution

Solutionmembrane

Ion diffusion
Re-precipitation

Particle filling
Particle-to-particle contact

Crystal nucleation andprecipitation of calcite & aragonite

Pressure

Re-precipitation

Optimization of Particle size
distribution

Reduction of CCC porosity
Increase in aggregate-to-aggregate contact area
Strengthening of CCC skeleton after pressure molding

Increase of compressive strength

Drying of CCC after pressurecompaction

Precipitation of CaCO3 at the aggregate interface

Densification
Bonding of aggregate particles

Immersion in Ca(HCO3)2
solution and drying(secondary curing)

Ca(HCO3)2→CaCO3+CO2+H2O
Further precipitation of CaCO3
Further carbonation of uncarbonated portions by the resulting CO2

Increase of compressive strength
Large energy consumption

Larger size

Higher strength
Currently, 20MPain φ100x200mm size
without any problems

Block

FY2023 Results Report Meeting for NEDO Moonshot R&D Program Goal 4

Cylinder31 January 202414

Cold Sintering Method
Effect of applied pressure
Pressure: 10MPa

Larger

25MPa

Porosity

Pressure: 10MPa

50MPa

Smaller
25MPa

50MPa

Increasing pressure decreases porosity and increases compressive strength of CCC.
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Effect of Raw Material on CCC Strength
Effect of aggregate content in waste concrete(mother concrete)

Amount of aggregate in RCA (%volume)■The lower the amount of aggregate
in the waste concrete
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The higher the compressive
strength of the CCC
16

Effect of Raw Material on CCC Strength

Post-curing in
Ca(HCO3)2 solution

Compressive strength of waste concrete(mother concrete) is highCompressive strength of CCC increases with
post-curing
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Aggregate volume in waste concrete(mass%)

Compressive strength of CCC(MPa)

Effect of strength of waste concrete (mother concrete)
Effect of post-curing of CCC

Compressive strengthof CCC is highPost-curing is highly
effective17

Effect of Raw Material on CCC Strength
Waste concrete (mother concrete) isof low quality
Improved strength by mixing
with high-quality waste concreteCompressive strength vs Other properties
As with ordinary concrete, other properties
can be controlled by controlling compressive
strength

Percentage of high-quality concrete in waste concrete

Elastic Modulus (GPa)Compressive strength of CCC(MPa)

Addressing quality variations in waste concrete

Without post-curing
With post-curing

Compressive strength of CCC (MPa)FY2023 Results Report Meeting for NEDO Moonshot R&D Program Goal 4

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Practical Measures to Stably Produce CCC
Strength improvement measures (quality control)when CCC is produced from low-strength (low-quality)
waste concrete

Mixing of more than 30% of high-quality waste concrete(selective qualifying separation is required)
Maximum size of crushed waste concrete particles 0.6 mm or
less
Repeated soaking and drying in Ca(HCO3)2 solution at least 6
times

If the volume of raw aggregate in the waste concrete isless than 70%, CCC with a compressive strength of
12MPa or higher can be produced.

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The University of Tokyo
Hokkaido University
Tokyo University of Science
Kogakuin University
Utsunomiya University
Shimizu Corporation
Taiheiyo Cement
Masuo Recycle

Development of Methods for Structural
Design and Construction of CCC Structures

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Structural Members Using CCC Units
Structural form

Reinforced
structureMembers type and manufacturingmethodThin-walled steel tube +internal PS
Stacking/Pressurization

JointsJointsPrestressed block

Selected
Prestressing

CS/Pressurization/Precipitation

Beam and
Joint
Cage filled

Axial compression,
bending, shear and joint

Reinforced block (conventional)Interior: 20MPa and over
Exterior: 30MPa and over

Axial compression,
bending, shear and joint
Axial compression,
bending, shear and outof-plane deformation

Study ofoverall structure

Reinforcing

Axial compression,
bending, shear and outof-plane deformation

Laminated

Manufacturing

Bending and shear

Steel composite

Manufacturing

Bending and shear

CS/Pressurization/Precipitation
Slab

Performance
evaluation

Verification by numerical analysis

Thin-walled steel tube +external PS

CS/Pressurization/PrecipitationWallstructure

Problems

Cage filled
Investigation as wall structure

FY2023 Results Report Meeting for NEDO Moonshot R&D Program Goal 4

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Axial compression,
bending, shear and outof-plane deformation
21

Structural Members Using CCC Units
Thin-walled steel tube + external PS
Improved strength by restraining thinwalled steel tube
Verification and optimization ofmember performance by FEM analysis
Demonstration test of member
performance using a simulated CCC
memberAnalysis using FEM

Experiments on simulated CCC columns

11N/mm2

15N・m

140

柱せん断力（kN）

120
100
80
60
40
20
0
0

Simulated
CCC column
FY2023 Results Report Meeting for NEDO Moonshot R&D Program Goal 4

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層間変位（mm）

8

10

Axial force: 141kN（0.15σB）
Py=496kN（930N/mm2）
Prestress: 283kN (531N/mm2)→CCC-7N/mm2（0.30σB）

22

Structural Members Using CCC Units
Evaluation of bearing capacity of simulated CCC members and CCC members
Two units of different heights were prepared assuming the manufacturing process
Three-point bending / Ohno's method reverse symmetry bending shear

For thin steel tube and external PS type,change the loading area, etc.
Three-point bending

φ9.2 PC tendon
CCC filled steel tube
Φ100x160mm

Candidate for performance
evaluation tests in the future

Ohno's method reverse symmetry bending shear

FY2023 Results Report Meeting for NEDO Moonshot R&D Program Goal 4

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PC tension force: 35kN/piece
280kN for 8 pieces

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Structural Members Using CCC Units
Overall structure using CCC
members
How to join members
Optimal use of CCC

Prestressedblock structure
W/C=100%, C:S=1:3
Mortar block with viscous agent

Arch (compression only)

Honeycomb
construction

Image
FY2023 Results Report Meeting for NEDO Moonshot R&D Program Goal 4

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Cage

24

The University of Tokyo
Hokkaido University
Tokyo University of Science
Kogakuin University
Utsunomiya University
Shimizu Corporation
Taiheiyo Cement
Masuo Recycle

4
Social Implementation of C S

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Resource Circulation Scenario Design①Conducting research and estimation on the amount of waste concrete generated (CCC raw materials) based on regional characteristics②Planning of efficient intermediate treatment plant layout, development of types, characteristics, and acceptance conditions of waste
concrete, and presentation of newly required production system updating methods③Construction of resource circulation scenarios based on CCC applications (structure type, site, and product) and conditions for waste
concrete discharge and treatment①Prediction of the amount of CCC raw materials accumulated and generated

Construction
Input!
Cumulative concrete production for all construction starts: 11.8 billion tons
By structure: RC 38.3%, S 33.3%, wood 19.2%, SRC 8.5%
By region: comparison by city (Kanto/Kansai), by prefecture (all 47), etc.
*Recovered ready-mixed concrete statistics (METI): Historical production volume:
approx. 30 billion tons (construction 40%, civil engineering 60%)

AnnualArchitecture
Civil products and structures

Accumulation

Waste concrete generated(2020-2050: 30 years)

Buildings: 3.9 billion tons (0.126 billion tons/year in average)
Products: 3.0 billion tons (0.1 billion tons/year in average)

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Resource Circulation Scenario Design②Siting plan for an intermediate treatment plant to facilitate CCC production
Classification B = CCC generation by urban - specialized processing areas x
Selection of manufacturing sites
Overlapping
visualization

Mapping ofintermediate
treatment
plants (N) by
prefecture

Y: Intermediate
treatment plant relative
X: Intermediate treatment
treatment volume
scope ofrange (man/facility) plant geographic
2
work (km /facility)

Regional
characteristics
4 classification

B: Urban - Specialized
treatment type

B: Urban Specialized
treatment type

A: Urban - Combined
treatment type

A: Urban - Combined
treatment type

X+Y: Urban to ruralintermediate
treatment
classification (ABCD)

Database of information on industrial waste treatment by prefecture (certified excellent
companies) + intermediate treatment facilities specializing in concrete mass (CCC production sites)

Debris (dedicated)

Results

Candidate for
CCC manufacturingsite

Debris + Ceramic debris

Estimation of the amount of concrete mass generated by prefecture by 2050 Future Issues
Understanding of conditions for installation of
Identification of excess and deficient treatment capacity of intermediate
intermediate treatment plants, etc. under several laws
treatment plants by prefecture
Development of optimal intermediate treatment
Establishment of four regional classifications by potential treatment capacity
systems and manufacturing technologies for PCa
and physical treatment area of intermediate treatment plants by prefecture
plantsIdentification of the number of possible facilities in "CCC production base areas"

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Estimation of CO2 Emission
Basic scenario

1. Calculated using standard emission factor (kg-CO2/MJ) provided by CR2-LCA-WG
2. Carbonation by airflow DAC during CCC raw material production
3. Required heat and CO2 emissions calculated based on actual measured water
consumption, etc., assuming 100% thermal efficiency
Heating energy is assumed to be equivalent to that of a
PCa plant.
Theoretically, energy consumption for temperature
maintenance could be reduced by improving insulation,
but this is not taken into account here.

PCa plant
Heating

Scale-up scenario

Laboratory

Precipitation
Cementproduction

Cold sintering
Heating

Low strength concrete
W/C=65%
Cement content 291kg/m3

Pressurization
Stackedpressurization
Heating

Press

Press

CO2 capture

CO2 capture

Repeated
immersion
drying(Consideration oflower heating
efficiency)

Precipitation
CoolingHeatingHeating
Water sprinkling & blast

CO2 capture

CO2 capture

CO2 captureLine with 100% CO2 capture rate
For pressurization energy, refer to the basic unit fortile production (wet type)
CCC unit: 210x100x60mm, 5 pressurizations/unit toproduce 1m3
Assuming 5 units pressurized in series for efficiency

Blast energy in the productionof CCC raw materials is basedon the design value of PJ II.

Cooling

CO2 capture

CO2 capture

CO2 capture (test value)
Assumed waste concrete
Cement content 300kg/m3
Ordinary Portland cement

Mixing energy for CCC production is assumed to be the same intensity as that ofconcrete
Vibratory compaction is assumed to be equivalent to the repeated immersion method
Solution production is assumed to be equivalent to that of ready-mixed concrete andsludge tanks.

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Examination of Systems on Building Codes① When it can be regarded as equivalent to ordinary concrete

Designated building material (Article No.37 of the Building Standard Law)
Available as JIS A 5308 compliant productEvaluated according to the current public notice, and available after obtaining
the approval by the Minister of Construction
Can be evaluated by modifying the public notice, and can be used after
obtaining the approval by the Minister of Construction② Similar to but not considered equivalent to ordinary concrete

Categorized in the definition of concrete (JIS A 0203)
Positioned as a designated building material
Newly positioned as "special concrete" in the public notice and need to be evaluated③ Different from (not similar to) ordinary concrete
Not a designated building material

In case of CCC: ③

Individual approval by the Minister of Construction as stipulated in Article No.20 of the BuildingStandards Act is required for design methods, quality control, etc.
Participating in the "Environmentally Friendly Concrete Response Study Committee" of the Japan
Building Disaster Prevention Association
Ministry of Construction-subsidized project "Project for Ensuring Smooth Enforcement of the BuildingStandard Law, the Building Official Law, etc.”
Chairperson: Takafumi Noguchi, Committee members: Manabu Kanematsu, Ippei Maruyama, etc.

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Plans for Construction of Actual Structures
Exhibit at Future Society Showcase Project at Osaka Expohttps://www.expo2025.or.jp/en/news/news-20230914-01/→Application for 13m2 periodic exhibitions in the Future Life Experience

Precipitation of CaCO3 (≒CO2)

CCC raw materials

100 μmVisualization of CO2 in CCC化

1m
CCC units

1m
2m

1m

Structure using CCC(Shape to be further elaborated)

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Thank you for your kind attention!
To realize a carbon neutral society in 2050,
we will continue to study the social
implementation of CCC in FY2029.

Save the Earth!

FY2023 Results Report Meeting for NEDO Moonshot R&D Program Goal 4

With C4S!!

31 January 202431