September 2 nd , 2024
The 33rd "Clean Coal Day in Japan" International Symposium (2024)

Developments of Taiheiyo
Cement Group’s innovativetechnologies for carbonneutrality

Y. ISHIDA,Carbon Neutral Technology
Development Department,

Taiheiyo Cement Corporation

Today's Topics

1. Carbon Neutral Strategy 2050
2. Development Status of Innovative
Technologies for CCUS
3. Carbon Neutral Model Plant Plan
4. Summary and Future Development2024©TAIHEIYO CEMENT

2Developments of Taiheiyo Cement Group’s Initiatives

2015
2019
2020
2021

2022
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3Supply Chain Initiatives for Carbon Neutrality
Actions in the supply chain

To make the entire supply chain carbon neutral by 2050.
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CO2 emissions from the cement production process•CO2 emissions from cement kiln (average): daily 2,500–3,000
tons/kiln•

About 60% comes from raw materials, and about 40% comesfrom energy use.

→ More than 50% of CO2 emissions are derived from raw materials.
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Technology Development Roadmap

Develop andstandardize
technologies foruse of SCMs.
Develop lowCO2 cementtechnologies.

Existing technology

Cement production process

・Establish technologies that contribute to50% fossil energy replacement.
・Establish gas firing technology andstudy its introduction in our plants.

Develop CO2capture andutilizationtechnologies.

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6CCUS-related Technological Development Projects
(1)

(2)

(3)

• Our technological development has been supported by various
government subsidy programs, including GI Fund and others by NEDO
and those by JOGMEC.
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(1) NEDO Project (2020–2021*): Development of Carbon
Circulation Technology for the Cement Sector
Themes:•CO2 capture technology: chemical absorption method (amine process)•CO2 utilization technology: CO2 mineralization in cement and concretematerials④①③②2024©TAIHEIYO CEMENT* Independent testing has been ongoing thereafter

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① CO2 Capture from Kiln Exhaust Gas
Chemical absorption method≪Plant specifications andresults≫
AbsorbercolumnStrippercolumnPre-treatment
columnCO2 gas tanks(Each 25m3)

Process skid•

Method: amine solution•

Plant height: 25 m•

CO2 capture capacity: 10t/day•

Concentration ofcaptured CO2: 99% orabove•

In operation sinceDecember 2021.

A complete set of equipment built in aframe for compact installation

Demonstration test is ongoing at a scale of 10 t/day, which is the first inJapan for a technology to capture CO2 from actual kiln exhaust gas.
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9② CO2 Sequestration in Waste Concrete
CO2 sequestration demonstration plant (Kumagaya Plant)≪Plant specifications and results≫• Method: rotary kiln
• Amount of waste concrete treated:
500 kg/h• Amount of CO2 fixed: up to 125
kg/t-cement

General view

CO2 sequestration reactor
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10③ Low-carbon Concrete Products Cured in CO2 Atmosphere
CARBOFIX® cement• CARBOFIX® cement uses less limestone and can be burnt at lower
temperatures compared to ordinary portland cement, thereby
reducing the raw material-derived and energy-derived CO2 released
during manufacturing.
• High strength is developed by absorbing CO2 (fixed in the form ofCaCO3) during hardening.
• As a result, up to 60% reduction is achieved in CO2 emissions.

Appearance of CARBOFIX
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11④ CO2 Sequestration in Fresh Concrete
CARBOCATCH®
• A system that fixes CO2 in cement slurry at a high efficiency (reactionefficiency: over 90%) while the slurry is circulated through a reaction
bath filled with CO2.
• Applicable to both precast concrete and ready-mixed concrete, andcapable of fixing about 8–20 kg of CO2 per 1 m3 of concrete (dependingon the concrete mix proportions).
• Equivalent to ordinary concrete in strength development and durability.

Conceptual diagram of CARBOCATCH®
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CO2 uptake rate in CARBOCATCH® slurry
12④ CO2 Sequestration in Fresh Concrete
Applications of CARBOCATCH® slurry2024©TAIHEIYO CEMENT

13(2) GI Fund Project (2021–): Development of CO2-capturing
Cement Production Process
Themes:••CO2 capture technology: CO2-capture calciner (C2SP kiln®*)

CO2 utilization technology: methanation technology suitable for thecement process

CO2 derived from raw materials and energy
Cement rawmaterial

CO2 captured at high concentrations canbe reused as it is.

Raw material-derived CO2

CO2 utilization

CO2-capture
calciner

Energyderived CO2

Part of CO2 is converted
to energy (methane)and reused in cement
production

Methanation

CO2 + 4H2 → CH4 + 2H2O

Pre-heater

EnergyCombustion
supporting gas(O2)

Reuse ofCH4Energy
Rotary kiln

Gas flow
Material flow

Cement production process incorporating a CO2 capture system
2024©TAIHEIYO CEMENT*C2SP kiln: carbon capture suspension preheater kiln14

(2-1) Development of CO2-capture Calciner
Overview of conventional cement kilns (NSP kilns*)
Cement raw material
CycloneCO2 emission ratio

Suspension preheater 5%(raw material-derived 5%)
CycloneCalciner 70%(raw material-derived 50% + fuelderived 20%)

EnergyKiln 25%(raw material-derived 5% + fuelderived 20%)
EnergyRotary kiln

Calciner
Calcines raw materials (decarbonateslimestone), with energy source supplied.
⇒ Decarbonation rate: 80–90%
Burns decarbonated raw materials at about
1450℃ to produce clinker, with energy
source supplied.

Approx.
800℃

Gas flow
Material flow

A heat exchanger that consists of four orfive stages of cyclones. Preheats raw
materials to about 700℃ by using hot kiln
exhaust gas.

Rotary kiln

CycloneApprox.
700℃

Suspension Preheater

CoolerCoolerCools hot clinker with air.
Part of the hot (about 800℃) air after heatexchange is used as a
NSP kiln(New Suspension Preheater kiln)*Suspension preheater kiln equipped with a calciner.

Our GI Fund project aims to develop technologies to efficiently capture
CO2 generated in the calciner (70% of the amount generated).
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(2-1) Development of CO2-capture Calciner
Overview of the CO2-capture calciner
Approx. 30% of CO2 generated(raw material-derived 10% + energy-derived 20%)
Cement raw material

Captures about 70% of CO2 generated.
(raw material-derived 50% + energy-derived 20%)

CO2 is captured at highconcentrations (90–95%vol)
Dry-basedCO2-capturecalciner
EnergyCombustion
supporting gas
・O2・ circulating CO2
exhaust gas〇 Compact CO2 capture system••〇 Advantages of the conventional
NSP kiln are inherited.
••

EnergyGas flow
Material flow

Rotary kiln

CoolerTaiheiyo's technology to efficiently
and directly capture CO2 from thecalciner at the source.
The concentration of CO2 is madehigher by replacing air withoxygen to support combustion.

The high heat exchange
performance of the NSP kiln ismaintained.
Waste usage is at the same levelas, or higher level than,conventional kilns.

Carbon neutrality will be reached, with the CO2 reduction (20%) through the useof carbon-free alternative energy and the natural CO2 uptake (15%) by theconcrete in service
taken into account.
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16① Development of CO2-capture Calciner
Small-scale demonstration equipment
Location: Sanyo Onoda City, Yamaguchi, Japan (in the premises of Onoda Plant,Taiheiyo Materials Corporation)
Raw material heater
CalcinerRaw material tank

CycloneBag filter

Gas cooler

Rising duct

Rotary kiln

≪Specifications of the equipment≫
Clinker output: 5 t/day
CO2 capture capacity: 2.4 t/day
Methanation equipment: 300 Nm3 of methane/day
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Rotary kiln17

② Methanation Technology Suitable for the Cement Process• Synthesized e-methane is produced by using the CO2 captured at theCO2-capture calciner, and reused as a thermal energy source for thekiln and calciner.
• The captured CO2 has acid gases, oxygen and other components that
inhibit the methanation catalyst, which requires development ofpretreatment technology.  Joint research with IHI Corporation• Feasibility study (FS) is required for injection of e-methane synthesizedfrom the captured CO2 to city gas pipelines.  Joint research withTokyo Gas Co., Ltd.

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(3) JOGMEC Project (2023–): Japanese Advanced CCS
Projects by JOGMEC✓ CCS project in the Tohoku region on the Sea of Japan side•••

Capture CO2 emitted by the hard-to-abate sectors including steel andcement industries.
Transport the captured CO2 by ship.
Store the CO2 offshore the Tohoku region on the Sea of Japan side.

✓ Consortium members and their roles✓ Role of Taiheiyo Cement Group••Study on purification, liquefaction and shipping bases for CO2(captured by the C2SP kiln within the scope of the GI Fund project)Examine Kawasaki Plant of DC Co., Ltd. as a possible model plant2024©TAIHEIYO CEMENT

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Carbon Neutral Model Plant Plan
✓ Innovative CCUS (CO2 capture, utilization and storage) technologies need to beintroduced to make the cement sector carbon neutral.

✓ In our GI Fund project, real plant demonstration will start in 2026, anddevelopment of innovative technologies will be completed by 2030. ⇒ Our carbon
neutral model plant will be realized in 2030.

✓ Study on Kawasaki Plant of DC Co., Ltd. for the carbon neutral model plant has
been started (released on August 7, 2023).

Study points for the carbon neutral modelplant:
1) GI Fund project: real plant demonstrationof the CO2-capturing cement production
system (C2SP kiln®)
2) JOGMEC project: Feasibility Study on theImplementation of Advanced CCS Projects(2023)

Conceptual image of a CN Model Plant
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3) Study on the carbon neutral model plant
plan in which CO2 capture, CO2 utilization(CO2 mineralization, methanation, etc.) andCO2 storage technologies are implementedat the real plant level.
20Summary and Future Development(1) We have set forth the Carbon Neutral Strategy 2050, seeking to achievecarbon neutrality across the entire supply chain by 2050. To reach thegoal, a technology development roadmap and interim target for 2030 havebeen formulated.
(2) Innovative CO2 capture and utilization technologies need to be established
for the achievement of carbon neutrality. Such efforts include the GI Fundaided development of our original CO2 capture technology (C2SPkiln®) which is scheduled to be completed by 2030.
(3) Commercial introduction will start with plants in urban areas wherehydrogen and waste concrete are easily available, and then be
expanded to our Group plants, including those overseas.
(4) During the transition period until C2SP kiln® is widespread, use of blended
cements and other low-carbon cements will be promoted in parallel.

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Taiheiyo Cement Group will conduct
its business activities in harmony not
only with economic development,
but also with environmental
considerations and socialcontribution.

Thank you for your attention.
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