Feasibility Study project for the JCM （2016FY）

Feasibility Study project for the JCM on substantial GHG emissions

reduction by applying and diffusing

mineral carbon capture technology in the Thai cement sector

March 16th

2017

Nippon Concrete Industries Co., Ltd.

Contents

MCC&U Introduction Project - Thailand

1. Summary and objectives of the study ....................................................................................... 1

2. Climate change policy in Thailand ........................................................................................... 4

3. Explanation about MCC&U technology ................................................................................... 6

4. Results of the study ................................................................................................................. 13

5. MRV Methodology ................................................................................................................. 43

6. Analyses of economic effects and impact on Thailand ........................................................... 56

7. Issues ....................................................................................................................................... 61

8. Invitations and training reports ............................................................................................... 64

9. Policy proposals ...................................................................................................................... 66

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MCC&U Introduction Project - Thailand

1. Summary and objectives of the study

1.1 Summary of the study

The Kingdom of Thailand (“Thailand”) set out the national “Climate Change Master Plan

(2015-2050)” in January 2015 and submitted the Nationally Determined Contribution

(“NDC”) to the United Nations on September 21, 2016. In the NDC, the nation has set a target

to reduce its greenhouse gas (“GHG”) emissions by 20% from the projected business-as-usual

(“BaU”) level by 2030.

The cement industry, which accounts for approximately 35% of the CO2 emissions of all

industries in Thailand, has reduced its GHG emissions by introducing advanced

energy-conservation technologies such as waste heat recovery power plants. However, the

cement industry emits a large amount of CO2 in much higher concentrations than the amount

emitted by the fossil fuel consumption of any other industries due to CO2 emitted from raw

material limestone in the conversion process. Thus, taking more effective measures in

reducing GHG emissions in addition to energy conservation is an urgent task for the cement

industry in Thailand.

The study explores the feasibility of introducing the mineral carbon capture and utilization

(“MCC&U”) technology developed by Nippon Concrete Industries Co., Ltd. (“NC”) based on

a cooperation research program between businesses and academia to Company A in Thailand

as a Joint Crediting Mechanism (“JCM”) project. If this technology is realized, it will not only

enable Company A to reduce its CO2 emissions more efficiently, but also contribute to the CO2

emission reduction of the whole cement industry in Thailand. The specific activity targets of

the study are as follows:

(1) Policy recommendations for JCM in Thailand

To propose policy recommendations for promoting the introduction of MCC&U

technology as a JCM project in Thailand.

(2) Study of project towards commercialization

To develop a business plan for introducing MCC&U technology in Thailand.

(3) Development of emission reduction methodology and estimation (by provisional

calculation) of GHG reduction effect

To develop a MRV methodology applicable to projects using MCC&U technology and

estimate by calculation of GHG emissions reduction at the project site and those

estimated throughout Company A.

(4) Analyses of economic effect and impacts on Thailand

To conduct an analysis of impact to economic effect by the introduction of MCC&U

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technology at the project site and also analyze how the technology will affect Thailand on

the technology deployment in the country.

(5) Extraction of issues

To extract and study the issues for future commercialization, and the success factors and

issues to resolve for turning the technology into a JCM project.

(6) Providing training for a government official and a private company of Thailand in Japan

To invite a government official and a private company to Japan for further understanding

of JCM and MCC&U technology and relationship building through site tours, training

and other programs.

1.2 Objectives

One of the objectives of the study is to investigate into the feasibility of a project that will

contribute to the CO2 emission reduction in Thailand by making effective use of the concrete

sludge generated from secondary concrete product manufacturing plants and ready-mixed

concrete plants as industrial wastes which are reacted with the highly-concentrated CO2

contained in the exhaust gas from cement kilns in Thailand to form “precipitated calcium

carbonate”. Another objective is to drastically shorten its payback period by selling PAdeCS®,

a by-product of MCC, as an environmental remediation agent, or by recovering the

phosphorus contained in wastewater from washing rice in Thailand where, like in Japan, the

main diet is rice, and commercializing it for sale as raw materials of better-quality organic and

phosphoric fertilizers, and eventually to explore possibilities for promoting dissemination of

the technology throughout Thailand and into neighbouring countries where the cement

industry is active.

1.3 Study schedule

The schedule of the study is shown below. Two field studies in Thailand were conducted in

August and October 2016, and one training program for a site tour to an MCC&U plant in

Japan including technical discussions was organized for one engineer from a private company

and one member from Thailand Greenhouse Gas Management Organization (“TGO”) in

charge of JCM in Thailand from November 28 until December 2, 2016.

In February 2017, the third meeting was held to discuss the summary report on the results of

the study and future collaboration for commercialization with Company A by reviewing the

draft business plan developed through the study including the impact of CO2 emission

reductions, a construction plan for a bench-scale plant, and the feasibility of

commercialization in Thailand.

Before kicking off the study, the JCM joint workshop hosted by the governments of

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Thailand and Japan was held to introduce MCC&U technology and made a presentation on

our prospects for GHG emissions reduction on July 6, 2016.

Table 1 Schedule of Study Implementation

Seminor

Site Survey

①Policy advice

②Business plan

③Methodology · Calculationof GHG emission reductioneffect

④Economic effect/ impact analysis

⑤Extract task

⑥Study tour in Japan

Report preparation

2016 2017

July Augest September October November December January February March

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2. Climate change policy in Thailand

2.1 NDC

Thailand has ratified the Paris Agreement and submitted the NDC to the UNFCCC on

September 21, 2016. The NDC has set a target to reduce GHG emissions by 20%, while the

BaU level is expected to be approximately 555 MtCO2e in 2030 on the assumption that the

emissions are based on approximately 192 MtCO2e in the reference year 2005. With

international technical and financial support, the country would aim at a further 25% reduction.

Breakdown by emitting sector shows that especially GHG emissions from energy-intensive

industries accounted for 67% in 2000 and 73% in 2012. Therefore, it is critical for the

transportation and other energy industries to make efforts to reduce emissions. Since the

emission reduction target is not built from the bottom-up like in Japan, the Government of

Thailand would develop policies towards the reductions and allocate reduction obligations by

industries in the future.

The Thai Government is currently studying the detailed implementation plan to reach the

2030 reduction target. The framework of the NDC consists of the Climate Change Master Plan

(draft) of 2012 with a long-term perspective up to 2050, and the Nationally Appropriate

Mitigation Action (NAMA) presented in 2014. The Master Plan has not been approved yet,

but sets forth various commitments up to 2050. The Master Plan refers to GHG intensity

reduction (the Master Plan expresses it as “less GHG emissions per GDP”) as well as the

energy intensity reduction, and then suggests large-scale GHG reductions through various

combinations of energy conservation with measures such as CO2 capture and storage (CCS)

technology. The Thai Government has actively promoted GHG reduction by energy

conservations by providing low-interest loans, subsidies and tax exemptions since the

introduction of the Energy Conservation Promotion Act in the 1990s. As achievement of the

voluntary reduction target of Thai companies require improvement in energy intensity through

the introduction of further high-efficiency energy conservation technology, or improvement of

GHG intensity through introduction of such innovative technologies as MCC&U technology,

the significance of technology transfer and human resources development are pointed out in

the NDC.

2.2 Support by the cement industry

The cement industry, which accounts for approximately 35% of the CO2 emissions of all

industries in Thailand, has reduced GHG emissions by introducing low carbon technologies

such as waste heat power generation systems. However, process CO2 emissions from the

calcination of limestone as a key raw material remain an important challenge for the cement sector.

The limestone causes emissions of more than two times higher CO2 concentrations in larger

quantities than the CO2 emissions from other industries using fossil fuels. Therefore,

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implementation of GHG emission reduction measures such as CCS is an urgent issue for the

cement industry in Thailand.

As shown in 2.1, there is currently no emission reduction target for the cement industry in

Thailand. However, Company A group set a voluntary reduction target for 2020 and already

achieved a 70% reduction in 2016. As an example, the company has installed waste heat

power generation equipment in all cement plants. If the company continues to make energy

conservation efforts in this manner, it will meet the target in 2020.

Hence, if partially commercialized MCC&U technology using industrial wastes such as

concrete sludge is introduced and implemented to Thailand thorough the JCM program among

the technologies under research and development in Japan, this would contribute to achieve

the national GHG emissions reduction target for 2030. Unlike Japan, Thai Cement Association

does not set a voluntary sector target based on bottom-up approach. Therefore, it is impossible

to obtain information on how other cement companies in Thailand are challenging on the

climate issue.

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3. Explanation about MCC&U technology

3.1 Summary of technology

MCC&U technology is a technology to fix carbon dioxide in the form of carbonates by

using the carbonation reaction of a basic calcium or magnesium compound. Such

calcium/magnesium compound must be in the form of an oxide or hydroxide. If simplified, the

following chemical equations can be established:

CaO/MgO + CO2 → CaCO3/MgCO3 (Equation -1)

or

Ca(OH)2/Mg(OH)2 + CO2 → CaCO3/MgCO3 + H2O (Equation -2)

However, the reaction speed is extremely slow when CO2 gas is reacted directly with a solid,

calcium/magnesium compound. Therefore, the reaction should be accelerated in a liquid

medium by interposing water between them, in which case, the CO2 concentration in the gas

does not need to be 100%: Even emissions containing low levels of CO2 can be directly used

for MCC&U technology.

As a result of the above reaction, MCC&U technology produces calcium or magnesium

carbonates which are industrially useful. Hence, it is possible to reduce the cost required to

store CO2 by widely promoting the products' utilization.

3.2 Features of technology

The features of MCC&U technology are itemized as follows:

i. Innovative technology can be easily introduced, even in developing countries.

The CO2 fixation reactions of this technology proceed according to the reaction

equations as shown above. This reaction proceeds without adding chemicals at normal

temperatures and pressures, unlike the conventional CCS technology that requires

sophisticated technology. Thus, since operation of this technology is easy and safe, it is

possible to deploy the technology into developing countries.

ii. Large-scale reduction of CO2 emissions by using waste is possible.

The most applicable wastes to MCC&U technology is concrete sludge generated

from the secondary concrete products and ready-mixed concrete industries. Further

reduction of CO2 emissions is possible by use of waste concretes obtained from

demolition of concrete buildings. This technology, therefore, enables CO2 fixation as

well as the waste treatment.

iii. Marginal abatement cost of GHG is reduced.

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The cost incurred by MCC&U technology can be reduced by selling the by-products

produced by MCC&U technology.

iv. Efficiency enhancement of resources (reutilization of by-products)

With MCC&U technology, two types of by-products, high-purity precipitated calcium

carbonate and PAdeCS, can be obtained during the process of CO2 fixation.

Precipitated calcium carbonate can be used as raw materials and their aids for

recycled aggregate, building materials, paints, rubber products, glass, plastic products

and others in various industries, as well as for calcareous fertilizers.

PAdeCS performs as a phosphorus absorbent, neutralizer for acid wastewater,

algal-bloom generation suppressing agent and absorbent for arsenic or other hazardous

heavy metals (cadmium, zinc, etc.). More details of these by-products are described in

3.4.

v. Recovery and recycling of phosphorus resources

The phosphorus in wastewater can be recovered by feeding PAdeCS into wastewater

containing phosphorus. In Japan, there are cases of applying PAdeCS to wastewater

from washing rice. PAdeCS recovers a high concentration of phosphorus in wastewater

from washing rice, and the recovered material can be reused as raw material for

fertilizers.

Phosphate ore is an exhaustible resource, and we are dependent on imports for all of

our fertilizers. Under the circumstances, additional economic effects can be expected

from production and sale of domestic fertilizers at lower prices.

3.3 Materials applicable to MCC&U technology

Raw materials containing calcium or magnesium which are usable for MCC&U technology

include (but not limited to) various types of basic rocks (for instance, wollastonite (CaSiO3),

serpentine ((Mg,Fe)3Si2O5(OH)4), etc.), concrete wastes (concrete sludge and waste concrete)),

and ferrous and non-ferrous smelting slags, among which the raw materials containing free

calcium (free lime) which does not bond with a silicon or the like are highly reactive and

suitable for use in MCC&U technology. For instance, the concrete waste called concrete

sludge contains a lot of Ca(OH)2 and is highly reactive, and therefore one of the materials

most suitable for use in MCC&U technology.

3.3.1 Concrete sludge

Concrete is obtained by a hydration reaction when mixing cement with coarse aggregates

(gravel), fine aggregates (sand) and appropriate ratio of water. Concrete sludge used in this

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report includes concrete wastes generated from ready-mixed concrete plants or secondary

concrete product plants and high alkali slurry containing cement such as washing water for

concrete facilities. Four types of the sludge are indicated in the Table 2.

Table 2 Concrete Sludge

No. Name

Materials

Coarse

aggregates

Fine

aggregates

Cement Water

1 Concrete Sludge ○ ○ ○ ○

2 Mortar Sludge - ○ ○ ○

3 Cement Sludge - - ○ ○

4 Washing Sludge - - - ○

Sources of the sludge are specified as follow:

From ready-mixed concrete plants

Surplus concrete remained in an agitating dram of ready-mixed vehicle is

discharged at the plant. This concrete is called as “Concrete Sludge”.

The “Concrete Sludge” with removal of coarse aggregates is called as “Mortar

Sludge”.

Washing water of the agitating dram of ready-mixed vehicle and ready-mixed

concrete treating facilities contains called as “Washing Sludge” since it contains a

small amount of cement.

From secondary concrete product plants

Waste concretes during process or out of specified products contained with water

are called as “Concrete Sludge”.

Sludge generated during centrifugal molding containing water and cement (less

aggregate) is called “Cement Sludge” and it is the most appropriate material to

apply the MCC&U.

Washing water of the mold for concrete or concrete manufacturing equipment

such as mixer is called as “Washing Sludge”.

Though there is no exact statistics, it is said that a few percent of concrete manufactured

becomes the waste as concrete sludge. The concrete sludge consists of cement particles

being hydrated, water and aggregate. Currently, concrete sludge mostly ends up in landfills

for land reclamation as waste after dewatering, neutralization, solidification or other

treatment. The cost of such treatment is as high as 5,000 to 10,000 yen per ton, which has

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been an issue.

Concrete sludge contains basic calcium compounds, such as calcium hydroxide or

calcium silicate hydrates (3CaO·2SiO2·4H2O, etc.), in large quantities. It is possible to

produce calcium carbonate from reaction of those calcium contents with carbon dioxide

and reuse the carbon dioxide. The reactions throughout the process are represented by the

following equations for example. In any of those reactions, Gibs energy change is negative,

and the reactions proceed voluntarily under normal environmental conditions.

Ca(OH)2 + CO2 → CaCO3 + H2O (Equation -3)

3CaO·2SiO2·4H2O + 3CO2 → 3CaCO3 + 2SiO2 + 4H2O (Equation -4)

Concrete sludge contains a highly reactive basic calcium compound and a magnesium

compound and therefore is usable for MCC&U technology in a simple process. For

instance, the process consists of two processes: One of the processes is to extract the

calcium and magnesium contents into water from the concrete sludge, and the other process

is to introduce the exhausted gas containing carbon dioxide to the extracted water

containing calcium and generate calcium carbonate and magnesium carbonate.

3.3.2 Waste concrete

Waste concrete discharged from concrete buildings when renewed is also applicable to

MCC&U technology because of the relatively high reactivity of the contained calcium.

Concrete is one of the substances that we use in large quantities next to water. Concrete is high

in compressive strength and widely used as low-cost building material all over the world.

Concrete used for concrete buildings and the like are discharged in large quantities as waste

concrete lumps by renewal of buildings accompanying demolition. The composition of

concrete is almost the same as that of the concrete sludge described in the preceding paragraph,

and it contains such compounds as calcium hydroxide (Ca(OH)2) and calcium silicate hydrates

(3CaO·2SiO2·4H2O, etc.). However, the hydration reaction of waste concrete is already

finished and solidified. Therefore, compared with concrete sludge, waste concrete features

some disadvantages such as having difficulty in separating aggregate which does not

contribute to the CO2 fixation, and the low reactivity of calcium to CO2.

3.3.3 Coal ash (fly ash and bottom ash)

Coal ash particles that result from the combustion of coal are known as fly ash and bottom

ash and discharged in large quantities from coal fired power plant. Fly ash and bottom ash are

also reused for such purposes as an admixture of concrete to increase its fluidity. They consist

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primarily of silicon dioxide, but also contain basic calcium compounds and can be used for

MCC&U technology.

3.4 Features of by-products

3.4.1 Calcium carbonate

In MCC&U, CO2 is mainly stored in the form of calcium carbonate. CO2 weighing 440 kg

is fixed per ton of calcium carbonate produced. The calcium carbonate produced when only

cement sludge is used for MCC&U are of high purity and fine, and therefore can be used to

form material equivalent to quality of precipitated calcium carbonate which is produced in

chemical factories. Precipitated calcium carbonate is usable for multiple purposes such as

paper or plastic packing materials, flue gas desulfurization agents, athletic field line paint, a

concrete admixture and a minor additional constituent of cement.

In Japan, the precipitated calcium carbonate produced using our MCC&U technology

developed by NC is named “Eco Tankaru” for which we are developing sales channels. In the

study, we will also explore uses of calcium carbonate in Thailand.

3.4.2 PAdeCS

On the other hand, the hydrate containing concrete mineral, which is produced from the

extraction residue of the solid content of concrete sludge, can be used as an environmental

remediation agents for water and soil.. We named the PAdeCS, which stands for Phosphorus

Adsorbent derived from Concrete Sludge.

PAdeCS contains Ca(OH)2, ettringite (Ca6Al2(SO4)3(OH)12·26H2O) and other compounds

that remain without being extracted. Ca(OH)2 is usable for neutralizing acid wastewater and

removing phosphorus, boron, fluorine and various heavy metals from water due to its

contribution in increasing pH levels and supply of calcium ions and can also be used for such

applications as insolubilization of contaminated soil. On the other hand, ettringite has

anion-exchange abilities and is therefore effective for removing arsenic, selenium, chrome,

phosphorus, boron, fluorine and other elements in water, and also can be used as a minor

additional constituent of cement, algal bloom remover, and deodorizer or decolourizer.

The study covers the study on these uses of PAdeCS in Thailand.

3.5 Flow of system

NC group has been producing secondary concrete products ( concrete pole etc.,) by the

centrifugal molding technology in our Kawashima plant. In our Kawashima plant, cement

sludge is mainly generated in the category as mentioned previously. A part of that can be

recycled by MCC&U technology. Fig. 1 shows the flow of MCC&U technology system

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introduced in our Kawashima Plant. The flow is not complicated, and the minimum required

equipment for CO2 fixation is two tanks and ancillary equipment. The flow is described below,

following the figure.

First, add water to cement sludge in a calcium extraction reactor tank and agitate them,

which will cause a hydration reaction of the unhydrated cement to proceed and elute calcium

ions in the water. The composition of the water solution in which calcium ions are fully eluted

can be considered to be almost equal to saturated calcium hydroxide solution (approximately

700 mg-Ca/L at 25oC).

For the cement sludge diluted with water, separate the solid content from the solution by

such means as a filter press for solid-liquid separation. This solid content, if let to dry naturally

and then crushed for mechanical stabilization, is usable as PAdeCS for multiple purposes.

Bubble the gas emissions containing carbon dioxide in the solution transferred into a

crystallization tank and precipitate the calcium carbonate. In the pure Ca-H2O-CO2 system, the

saturated solubility of the calcium in equilibrium with the gas with a carbon dioxide

concentration of 10% is approximately 130 mg-Ca/L at 25oC. Dissolved calcium ions

precipitate as calcium carbonate by that difference in solubility, where the lower the carbon

dioxide concentration in the gas phase, the lower the saturated solubility of the calcium in the

water solution becomes. Therefore, the process does not require highly-pure carbon

dioxide-containing gas. Next, separate the precipitated calcium carbonate from the liquid. The

water with a lower calcium ion concentration can be reused for calcium extraction. By

repeating this operation, calcium can be extracted from the cement sludge and can fix carbon

dioxide in the form of the calcium carbonate.

Some of the advantages of this process are as follows: It can be operated at normal

temperature and pressure; the process uses only water; and the process does not need

highly-pure carbon dioxide. Moreover, the calcium carbonate produced in this process age

industrially important chemicals and is profitable when sold.

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Fig. 1 Flow of MCC&U system

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4. Results of the study

4.1 Results of study

This chapter discusses the study on concrete sludge, results of CO2 fixation study based on

the results and usage of calcium carbonate and PAdeCS.

The study results of concrete sludge are reported in two cases: In the case of a ready-mixed

concrete company and a secondary concrete product company.

4.1.1 Obtaining of concrete sludge samples

In order to verify that the concrete sludge generated in Thailand is actually applicable to

MCC&U technology, we obtained mortar sludge samples from a ready-mixed concrete plant

and cement sludge samples from a secondary product plant at the site. Solidified samples or

washing sludge samples were obtained according to the sampling point.

Solid content samples of the cement sludge that we obtained can be broadly divided into

two types: For one of the types, we obtained a sample immediately after the secondary

concrete production process. This sample was slurry just after being obtained but solidified in

a few hours. This solidified sample was used for analysis. The other solid content sample was

concrete sludge sample already solidified at the plant site.

Washing sludge samples were specifically wastewater generated from washing the

equipment related to the production of ready-mixed concrete. They seem that the higher the

calcium concentration of the Washing Water, the more applicable it is to MCC&U technology.

In reality, the calcium content extracted from the cement sludge and mortar sludge is used in

MCC&U technology. Therefore, the content percentages of the calcium contained in those

solid contents are extremely important.

● How to analyze concrete sludge:

We used ICP-AES to measure such data as the concentrations of the calcium contained in

concrete sludge.

For washing sludge samples, solids were dissolved by dropping nitric acid and diluted to

prepare ICP-AES solutions for measurement.

Solid content samples (mortar sludge, cement sludge and solidified samples) were dried at

105 °C for more than 24 hours and crushed with a mortar. Then it was dissolved by

microwave into solutions and diluted to prepare ICP-AES solutions for measurement.

Twenty-one elements contained in the samples were measured with an ICP-AES. Hereafter,

analytical results of main 7 elements (Ca,Mg, P, Si, S, Cr, and Pb) were summarized in this report.

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4.1.2 Study on mortar sludge produced from ready-mixed concrete plant (within a 100-km

radius of Company A’s cement plant)

4.1.2.1 What is Company B?

Company B has manufactured ready-mixed concrete in an integrated system throughout

Thailand. In the study, we requested plants within a 100 km radius of Company A (“K

factory”) for sampling and survey of mortar sludge.

4.1.2.2 Processing method of mortar sludge produced by Company B, and generation quantity

Processing method of mortar sludge

Company B takes measures so the surplus ready-mixed concrete after use may not be waste.

Furthermore, it employs a circulation system for the mortar sludge that has become waste to

keep wastewater from being discharged from the plant. We saw that the used ready-mixed

concrete was processed differently according to the elapsed time. The elapsed time means a

period of time starting with the time when aggregate, water and cement, which are the raw

materials of ready-mixed concrete, are mixed and agitated and start a hydration reaction.

The specific processing method is as follows. No such processing by elapsed time can be

seen in any of the Japanese ready-mixed concrete plants.

I. In cases where the elapsed time is less than 2 hours:

If the ready-mixed concrete is expected to be reused, it is sold as a product after adding

ingredient-adjusted ready-mixed concrete.

II. In cases where the elapsed time is no less than 2 hours and no more than 3 hours:

Concrete blocks without reinforcing bars (30 cm by 30 cm by 5 cm) are manufactured.

The blocks manufactured in this way are donated to schools and temples.

III. In cases where the elapsed time is more than 3 hours:

Aggregate is recovered by using a vibrating screen, and washing water is flown into the

reservoir. If the concrete volume is beyond the processing capacity of the vibrating screen,

it will be discharged directly into the reservoir.

Since the types of ready-mixed concrete in Japan are much more than those in Thailand, the

above processing method is not applicable to Japanese ready-mixed concrete.

The processing method of ready-mixed concrete after more than 3 hours have elapsed is

described in more detail as follows:

i. A concrete mixer truck is washed 10 times a day at Company B’s Plant K. The amount

of water for use in one washing is 400 litres. The 400 litres of washing sludge is used

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for one washing of the mixer truck’s tank. (The mixer truck is washed after

transporting concrete to 4 sites.)

ii. The water (mortar sludge) coming out of the washed mixer truck is discharged into the

pond.

iii. The substance discharged into the pond is separated into solids and liquids. The liquid

parts are pumped up into the first and second clear water reservoirs respectively.

iv. The liquid in the second clear water reservoir is distinguished from the other for such

applications as washing the mixer truck and sprinkling on the premises (watering

plants, etc.).

v. The solidified mortar sludge is excavated with a backhoe to be used for land

reclamation every 1.2 to 1.5 years.

Amount of concrete sludge generation

Company B’s Plant K that we visited in August and October, 2016 produces 360 to 480

tons of ready-mixed concrete per day and generates 4 tons of mortar sludge per day during the

production of ready-mixed concrete. The ready-mixed concrete plants in Japan generate

mortar sludge equal to 2 to 3% of the output of ready-mixed concrete, while Company B’s

Plant K generates only about 1%. It can be considered that the mortar sludge generation of

Company B is less than that in Japan because of its efforts as stated above.

4.1.2.3 Analytical results of concrete sludge sampled obtained from Company B

Obtainment of concrete sludge

We received samples of concrete sludge during our stay with Company B in Thailand in

August and October, 2016. We received only washing sludge samples when visiting in August.

The sampling points are listed below. We conducted a cross-check during our visit in October.

The cross-check will be described later in detail.

(1) Washing sludge samples

Table 3shows the washing sludge samples obtained from the second clear water reservoir in

August. The calcium concentration is 685.8 mg/l and therefore found to be fully applicable to

this technology. However, Company B reuses the obtained washing sludge for washing mixer

trucks. For that reason, the incentive for applying the water of Company B’s second clear

water reservoir to MCC&U would be low.

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Table 3 Secondary clear water reservoir of Company B

Elements Concentration

(mg/l)

Ca 685.8

Mg 0.02

Si 2.62

S 142.6

P 0.067

Cr 0.10

Pb <0.004

4.1.2.4 Cross-check (Thailand-Japan comparison data)

Purpose

If MCC&U technology is transferred to Company A, Company A will be mainly in charge

of the operation and quality control of that technology. To ensure proper transfer of the

technology, the concrete-waste composition data from Thailand, which is essential to MCC&U,

must be in agreement with the Japanese data. We conducted a cross-check to make sure.

The cross-check in the study means collecting two pieces of the same samples from the

mortar sludge generated from Company B’s K plant and analyzing them in the same procedure

at NC (in Japan) and Company A (in Thailand).

The concrete sludge data to be taken is the following three:

(1) : Solid-liquid ratio of mortar sludge which has just been generated;

(2) : Element composition of the solid content of mortar sludge which has just been

generated; and

(3) : Concentration of heavy metals in the liquid content of mortar sludge which has just been

generated.

How to conduct a cross-check:

We collected mortar sludge, weighing 300 g, discharged from the ready-mixed concrete

(mixer) truck which just comes back to Company B’s K plant from the sites.

The collected mortar sludge was filtrated on the spot and separated into solids and liquids.

The samples separated into solids and liquids were weighed. Their ratio by weight was

calculated to find the solid-liquid ratio of mortar sludge which had just been generated.

Company A and NC each took half of the weighed samples back to their own offices and

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analyzed them in the same method. How we conducted the cross-check is shown below.

Results of cross-check

The cross-check results are as follows. In conclusion, the composition analysis data of the

mortar sludge samples collected from Company B showed the same tendency at NC and

Company A, although there was a slight difference between them.

(1) Solid-liquid ratio of mortar sludge which has just been generated:

The weights of the solids and liquids of the mortar sludge filtered with filter paper are listed

below. The mortar sludge consists of 44.7% solids and 55.3% liquids. It was also found that

the mortar sludge collected from Company B’s K plant was not almost included coarse

aggregates.

Though the solid-liquid ratio of the mortar sludge generated in Japan varies according to the

place of generation, there are some cases close to this ratio. Hence, we have concluded that the

solid-liquid ratio of the mortar sludge obtained in Company B (Thailand) is almost the same as

that in Japan.

Table 4 Solid-liquid ratio of mortar sludge which has just been generated at Company B

No. Item Weight (g) Percentage

(%)

1 Whole mortar sludge 300 －

2 Solid content of mortar sludge 134 44.7

3 Liquid content of mortar sludge 166 55.3

Photo 1 Collection of liquid content of

filtered mortar sludge

Photo 2 Collected samples

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(2) Element composition of the solid content of mortar sludge which has just been generated:

Table 5 shows a summary of the analysis data of NC and Company A. Japan and Thailand

showed the same tendency of the solid content containing large amounts of calcium,

aluminium and iron. The results also indicated that the concentration of calcium, critical to

MCC&U technology, is high.

Table 5 Solid content of mortar sludge which has just been generated

(3) Data comparison of heavy metals in the liquid content of mortar sludge which has just

been generated:

Table 6 shows a summary of the analysis data of NC and Company A. The comparison of

NC and Company A data indicated a tendency of the liquid content containing large amounts

of calcium, potassium and sulphur components. However, the both parties have verified that it

does not contain a large amount of any heavy metal.

Table 6 Liquid content of mortar sludge which has just been generated

Element NC

(mg/L)

Company A

(mg/L)

Ca 1194.9 1556.4

Mg ＜0.0001 < 1

Si <0.01 20.1

S 498.6 484.1

P <0.007 -

Cr 0.51 0.9

Pb ＜0.005 0.515

Element NC

(wt%)

Company A

(wt%)

Ca 32.3 41.6

Mg 0.65 0.58

Si 10.9 5.2

S 0.64 0.64

P 0.16 -

Cr 0.0044 0.008

Pb 0.0020 0.067

19

4.1.2.5 Company B’s ready-mixed plants located within or outside of a 100-km radius of

Company A’s cement plant

The number of Company B’s ready-mixed plants located within a 100-km radius of

Company A’s cement plant is 14, which include Plant K from which we obtained samples.

From the amount of mortar sludge generation of ready-mixed plant K, we also estimated the

amount of mortar sludge generation of the 14 ready-mixed plants within the 100-km radius.

The amount of annual mortar sludge generation of the 14 ready-mixed plants within the

100-km radius was estimated to be approximately 9,400 tons.

There are some Company B ready-mixed plants of outside of a 100-km radius of Company

A’s cement plant. Like the above, we estimated the amount of annual mortar sludge generation

of the ready-mixed plants outside of the 100-km radius to be approximately 44,100 tons.

All Company B ready-mixed plants in all throughout the country, and we estimated that

they generate approximately 53,500 tons of sludge annually.

4.1.2.6 Amount of ready-mixed concrete generation from ready-mixed plants other than

Company B

In order to explore the CO2 reduction potential of MCC&U technology, it is necessary to

grasp the amount of the mortar sludge generation throughout Thailand. From the share of

Company B in the whole output of ready-mixed concrete in Thailand, we estimated the mortar

sludge generated from ready-mixed concrete throughout Thailand to be approximately

214,300 tons.

4.1.3 Study on cement sludge generated from main secondary concrete product plants (within

a 100-km radius of Company A’s cement plant)

4.1.3.1 Main Secondary Concrete Product Companies

(1) Company C

Company C is a manufacturer of concrete spun piles and possesses centrifugal molding

technology. It is situated in the Nonthaburi area.

(2) Company D

Company D is a manufacturer of piles and possess centrifugal molding technology. It is

situated in the Nonthaburi area.

(3) Company E

Company E is a manufacturer of piles, situated in the Pathumthani area. The company

owns two pile manufacturing plants and possesses centrifugal molding technology like

the other two.

20

4.1.3.2 Processing methods and amounts of generation of cement sludge at main Secondary

concrete Product Companies

● Cement sludge processing method of each company

The cement sludge processing methods of the 4 plants of 3 Secondary Product Companies

that we visited for the study have the following features in common. They are:

i. storing cement sludge in ponds (reservoirs);

ii. reusing the supernatant liquid of the reserved cement sludge as washing water in the

plants; and

iii. excavating the reserved and settled solid contents for use in land reclamation on a

periodic basis.

If cement sludge is generated in Japan, we dehydrate it first, and then use the solid content

for land reclamation and neutralize the liquid content with acid. Cement sludge processing

costs very much and causes issues such as high cost of building houses and an increase in

waste volume.

The detailed processing methods used by the companies are itemized as follows:

Company C

a. The cement sludge is discharged through a pipe into the reservoir 0.6 km ahead while

being diluted with new water (not for washing the equipment) so as not to be

solidified.

b. The washing sludge is reused for such purposes as washing the equipment.

c. The solidified cement sludge is currently taken away for free.

Photo3 Cement sludge which has just been generated

21

Photo4 Reservoir (far) and reclaimed land (right)

Company D

a. The cement sludge generated in the centrifugal molding process of piles is treated in

5 treatment tanks arranged in a series (the dimensions of each of the first to fourth

tanks: 3 m by 4 m by 2 m deep; the fifth tank is smaller).

b. The solid content of cement sludge is settled and solidified in the first treatment tank,

and overflow is transferred to the second tank.

c. The solidified cement sludge is removed with a backhoe and stacked in piles at a

frequency of once every 2 days.

d. The dried cement sludge is used for landfill in available locations within the

premises of the plant.

e. The alkaline water in the fifth tank is reused for washing the equipment in the

processing line.

Photo5 Cement sludge treatment tanks (The third tank is on the upper

right; the fourth is in the centre; and the fifth is in the front left.)

22

Photo6 Pile of solidified cement sludge

Company E (First Plant)

a. The cement sludge generated in the First Plant is reused as trapezoidal-shaped

blocks.

b. The trapezoidal-shaped blocks are supplied for free to temples and construction

companies in the neighbourhood, mainly for use as flood countermeasures.

Photo 7 Cement sludge discharged from centrifugally molded products at First Plant

Photo 8 Block produced at First Plant

23

Company E (Second Plant)

a. Two types of blocks are fabricated from the cement sludge generated in the Second

Plant, by adding sand: One of them is pile covers (to prevent falling on the

embedded piles), and the other is interlocking blocks.

b. The cement sludge not used for block production is stored in the yard. The clear

supernatant liquid is reused for washing the equipment. The cement sludge solidified

on the bottom of the yard is periodically excavated and used for land reclamation.

Photo 9 Blocks produced at Second Plant

Photo 10 Cement sludge storage yard at Second Plant

The amount of the cement sludge generated from the companies is as follows:

Table 7 Amount of cement sludge generation

No. Company name Amount of cement sludge

generation per day

Amount of cement sludge

generation per year

1 Company C 11.25 t/day 3,375 t/year

2 Company D 5 t/day 1,500 t/year

24

3 Company E

(First Plant)

2.6-16 t/day 4,800 t/year

4 Company E

(Second Plant)

16 t/day 4,800 t/year

4.1.3.3 Analytical results of concrete sludge sampled obtained from main Secondary concrete

Product Companies

The sampling points of the concrete sludge obtained from the main Secondary Product

Companies are as follows:

Washing sludge samples

Table 8 shows the washing sludge samples obtained in October 2016. The number of the

washing sludge samples obtained during our stay in Thailand in October was three. The

saturated concentration of calcium in calcium hydroxide is 920 mg/L, and the samples of

Company E were saturated. The calcium concentration of samples of Company E was a

relatively high 692.5 mg/L.

Table 8 Element composition of liquid samples obtained in October, 2016 (mg/L)

Elements

Washing sludge at

Company E’s First

Plant

Water combined

with sludge

(washing sludge) at

Company C

Ca 692.5 913.6

Mg ＜0.0001 ＜0.0001

Si ＜0.01 ＜0.01

S 11.4 2.87

P ＜0.007 ＜0.007

Cr 0.145 0.050

Pb ＜0.005 ＜0.005

Cement sludge samples

Table 9 shows the cement sludge samples obtained in August 2016. The samples obtained in

August are 2 types from Company C and 3 types from Company D. The sampling points were

the areas where they were generated, storage, etc.

25

Table 9 Element composition of solid samples obtained in August (wt %)

The calcium content percentages of the cement sludge samples were nearly 30% except for

(4) and (5) of Company D and therefore fully usable with this technology. The samples (4) and

(5) of Company D had smaller calcium content percentages than those of the other companies.

On the other hand, they had more Si components. Therefore, the cement sludge samples of

Company D are considered to contain more pebbles and other materials than the other

companies.

We obtained 7 cement sludge samples during our stay in Thailand in October 2016. Table

10 shows the cement sludge samples obtained in October.

They were three from the First Plant of Company E and two more from the same company’s

Second Plant. In addition, we obtained one each from Company C and Company D. The

calcium content percentages were more than 30% except for samples (4) and (9).

Since samples (4) and (9) had many Si components, they are considered to have shown

relatively smaller percentages of calcium content than those of the other companies.

Company C Company D

Elements

(2) Solid content

of cement sludge

at treatment plant

(3) Cement sludge

which has just

been discharged

(4) Cement

sludge at

treatment plant

pond

(5) Above ground

storage space for

solid content of

cement sludge

(6) Underground

storage space for

solid content of

cement sludge

Ca 32.9 32.3 13.7 14.6 28.1

Mg 0.43 0.54 0.31 0.28 0.50

Si 8.28 8.81 27.1 27.0 13.1

S 0.50 0.66 0.21 0.18 1.06

P 0.024 0.023 0.028 0.030 0.031

Cr 0.005 0.0066 0.003 0.003 0.005

Pb <0.0005 <0.0005 <0.0024 <0.0024 <0.0012

26

Table 10 Element composition of solid samples obtained in October (wt%)

4.1.4 Analyses of SCG’s Cement plant

During our first visit to Thailand in August, a cement plant tour of the Company A was

conducted to collect operational data on kiln exhaust gas containing CO2 and to discuss with a

plant manager and their engineers about an installation of MCC&U facility near by the target

cement kiln.

4.1.4.1 Exhaust gas from target cement kiln

Table 11 shows the operational data on kiln exhaust gas in the Company A’s Cement Plant.

The concentration of CO2 is 24% in the kiln exhaust gas, which is approximately twice as

much as that in the exhaust gas fed from boiler in NC’s MCC&U plant. Therefore, it is almost

certain that the exhaust gas from the cement kiln in the Company A’s Cement Plant can

sufficiently be applied for the MCC&U technology. The high CO2 concentration makes the

MCC (mineral carbonation) reaction possible to react rapidly. When the following technical

barriers on the MCC reaction are removed, it would be considered the MCC technology is

simply applied at the plant.

Elements

(3) Oct. 5 Solid

content which has just been

discharged from First Plant of

Company E

(4) Oct. 5 Solid block

debris at First Plant

of Company

E

(5) Oct. 5 Solid

content around

drainage yard at

First Plant of

Company E

(7) Oct. 5 Solid content

which has just been

discharged from Second

Plant of Company E

(8) Oct. 5 Solid

content around

drainage yard at Second Plant of

Company E

(9) Oct. 6 Solid content

which has just been

discharged from

Company C

(11) Oct. 6 Storage

space for solid

sludge at Company

D

Ca 34.7 22.3 35.5 36.8 36.3 28.4 33.6

Mg 0.90 0.69 0.96 1.03 0.76 0.41 0.57

Si 12.5 24.4 9.29 10.8 8.71 20.5 10.2

S 1.073 0.731 0.432 1.025 0.822 0.485 1.052

P 0.162 0.154 0.160 0.160 0.145 0.149 0.160

Cr 0.0050 0.0039 0.0053 0.0058 0.0041 0.0040 0.0048

Pb 0.0043 0.0035 0.0043 0.0044 0.0030 0.0029 0.0023

27

Table 11 Properties of exhaust gas from cement kiln at the Company A’s Cement Plant

No. Properties Measured value

1 Temperatures of

exhaust gas at the inlet

of a stack

70-80C when feeding of raw materials

105-110C when feeding of none of raw

materials

2 Composition of

exhaust gas

CO2=24%, O2=8.5%, NOx=350 ppm、

SO2=7ppm

3 Gas volume of

exhaust gas at the

outlet

430,000 Nm3/h

4.1.4.2 Barriers on installment of MCC&U

After completing of the JCM feasibility study, the MCC&U bench-scale plant to be installed

is proposed to comprise four 1 m3 reactors (see 4.3 for details). As a result of discussions

with engineers at the plant, the following barriers have been found to install the MCC&U

bench-scale plant at the cement plant:

Installation site occupied by MCC&U facility

It is found that there is open area with approximately 105 m2 (approx. 15 m approx. 7

m) to install the MCC&U bench-scale plant near the cement kiln from which CO2 is

generated. However, the area is too small to install a business scale plant. Furthermore,

since fork lift trucks are currently driven across the area, for instance, two stages

MCC&U plant should be considered.

Water resource

Since a shortage of water resource is one of urgent issues in Thailand, it was requested

to install a recycling system for used water from reactors in the MCC&U plant. To

respond to this request, used water recycling system will currently be designed for the

bench-scale plant. The system, however, requires only water (1 m3) for initial operation of

four reactors in the bench-scale plant.

Exhaust gas temperature

It is required to consider how to feed the exhaust gas from the target cement kiln to the

MCC&U plant. To do this, the optimized rather low temperature of the exhaust gas

should be fed to the reactor.

Though a temperature of the exhaust gas from the cement kiln stack is very low, it is

28

technically difficult to feed the gas to the MCC&U plant. However, in order to remove

dust in the gas, an electrostatic precipitator is generally applied so that the temperature of

the gas is expected to be low. Therefore, the exhaust gas fed to MCC&U plant should

use a low temperature gas through utilization of other equipment such as electrostatic

precipitator from the cement kiln.

CO2 concentration in exhaust gas

A concentration of CO2 in the kiln exhaust gas is as high as 24%. It is approximately

twice of that in the exhaust gas from the boiler fed to MCC&U plant in NC’s Kawashima

plant. A high CO2 concentration has an advantage of rapid dissolving rate of the exhaust

gas into water but on the contrary, a saturation solubility of dissolved calcium

concentration will be expected to increase. Therefore, we have to optimize operational

conditions of the MCC&U plant corresponding to such changes on CO2 concentration.

NOx concentration in exhaust gas

Though NOx in the kiln exhaust gas can be dissolved in solution during the procedure,

nitrates as a solid can’t be removed from the solution since its solubility is very high.

Therefore, it would be a technical problem due to condensation of NOx by recycled

water.

4.1.5 Applicability of concrete sludge at sites to MCC&U

The concrete sludge samples collected during our stay in Thailand in August and October,

2016 had large percentages of calcium contents and therefore are fully applicable to MCC&U

technology. The calcium content percentage of the cement sludge and mortar sludge collected

in Japan was approximately 30%. Since the cement sludge etc., collected in Thailand had

much calcium like that in Japan, it can be reused as the raw material of MCC&U.

Especially, the cement sludge, which is obtained main secondary concrete product factories,

has very suitable quality for MCC&U. Because they are generated by centrifugal molding

technology and not almost including fine aggregates as well as Japan.

As assumed, fine aggregate is seen to be mixed in some of the mortar sludge collected from

Company B and some of the secondary concrete product plants. If fine aggregate is mixed in,

there will be an issue that it does not contribute to the CO2 fixation in MCC&U and may cause

damage to the interior of the plants. However, on a realistic level, it is difficult to remove fine

aggregate from mortar sludge completely if we also consider the incurred cost. Accordingly, a

MCC&U plant requires resistance to wear, which will be caused by friction with fine

aggregate, and pretreatment for removing some of the aggregate. We expect that the cement

29

sludge is able to introduce MCC&U plant without pretreatment if generated in main secondary

concrete product factories.

Besides, concrete sludge (mortar sludge and cement sludge) needs to be transported to a

spot close to Company A which emits CO2, which is later described in more detail.

4.1.6 Study results on other wastes generated throughout Thailand

4.1.6.1 Waste concrete

The waste generated from buildings under dismantling/demolition accounts for 0.5% of the

whole waste generated in Thailand, the volume of which is numerically estimated to be

130,000 tons per year, from data supplied by Company A

We were unable to obtain samples of waste concrete in the study. Hence, we have not

grasped the exact percentage of calcium content in the waste concrete generated in Thailand.

4.1.6.2 Coal ash

A coal fired power plant approximately 700 km away from Bangkok annually generates 2

million tons of fly ash and 1 million ton of bottom ash.

Table 12 shows the chemical components of sample of fly and bottom ash obtained in

February 2017. Ca content in each ash is measured as about 13 wt% and hazardous substances

such as Pb, Cd and Hg were observed as low value. Free calcium (free lime) in each ash is

assumed to be 5.0 wt%. Therefore, it is expected that coal ash (fly ash and bottom ash) is the

most suitable Ca source for MCC&U.

However, the quality of coal ash is depended on that of coal as raw material. For example, if

the coal contains hazardous substances, coal ash is reflected on similar substances. If the coal

ash can actually be procurable, it is necessary to conduct severe quality control as well as

other wastes in general.

Table 12 Element composition of solid samples obtained in February, 2017（wt %）

wt% Fly ash Bottom ash

Ca 12.8 13.5

Mg 1.41 1.54

Si 18.4 19.0

S 0.99 0.38

P 0.08 0.09

Cr 0.006 0.006

Pb < 0.0003 < 0.0003

Al 10.8 11.4

30

Fe 8.75 8.61

K 1.70 1.57

Na 1.12 1.05

Ti 0.22 0.24

Ba 0.09 0.09

Mn 0.07 0.07

As 0.02 0.00

Zn 0.01 0.00

Cu 0.006 0.005

Ni 0.005 0.005

Mo 0.001 0.001

Cd 0.0009 0.0009

Hg < 0.005 < 0.005

Others 43.7 42.6

4.1.7 Study on CO2 fixation using calcium

This chapter describes the CO2 amount which can be fixed with this technology. The

amount of CO2 fixation is described in the following two types: The fixation of CO2 emitted

from the cement kiln, using the waste containing calcium, and the amount of suppression of

CO2 emissions during cement production by adding PAdeCS as a minor additional constituent

of cement in cement. The former falls under the MCC of MCC&U technology, and the latter

falls under the U of the same technology.

4.1.7.1 Amount of CO2 fixation, derived from cement kilns, using waste containing calcium

This chapter estimates the amount of CO2 fixation by calculation, classifying the waste

containing calcium into two: ready-mixed concrete of Company B, and waste from the main

three Secondary concrete Product Companies and others.

Table 13 shows the amount of CO2 which can be fixed with sludge derived from

ready-mixed concrete generated from Company B and the whole country. Only with Plant K

of Company B, 107 tons of CO2 can be fixed annually. If the plants for that purpose are

extended to all plants of Company B, 4,775 tons of CO2 can be fixed annually. If we estimate

the amount of ready-mixed concrete produced throughout Thailand in consideration of

Company B’s share of ready-mixed concrete output, it can be considered that 11,937 tons of

CO2 can be fixed annually.

31

Table 13 Amount of CO2 fixation using sludge derived from ready-mixed concrete,

generated from Company B and the whole of Thailand

No. Item Amount of

CO2 fixation

(t/year)

Remarks

A One of Company B’s ready-mixed

plants (Plant K)

107

B Company B’s 14 ready-mixed plants

within a 100-km radius of Company

A’s cement plant

838 Calculated by using

data supplied by

company A for

reference.

C Company B’s ready-mixed plants

outside of a 100-km radius of

Company A’s cement plant

3,937 Calculated by using

data supplied by

Company A for

reference.

D All Company B’s ready-mixed plants 4,775 Calculated by using

data supplied by

Company A for

reference.

E Derived from ready-mixed concrete,

generated throughout Thailand

11,937 Calculated by using

data supplied by

Company A for

reference.

Table 14 shows the CO2 amounts which can be fixed, derived from sludge of the main three

Secondary concrete Product Companies and other waste. The cement sludge generated from

the main Concrete three Secondary Product Companies can fix 2,600 tons of CO2 annually.

With use of waste concrete, 7,150 tons of CO2 can be fixed annually. We estimated that up to

110,000 tons of CO2 can be fixed annually from fly ash. However, Company A already used

fly ash for other ways. Thus, we investigated the utilization of unused bottom ash for MCC&U

and estimated that 55,000 tons of CO2 can be fixed annually from bottom ash.

32

Table 14 Amount of CO2 fixation derived from sludge of the main three Secondary

concrete Product Companies and other waste

No. Item Amount of

CO2 fixation

(t/year)

Remarks

F Four (4) plants of 3 Secondary concrete

Product Companies

2,600

G Waste concrete 7,150 Calculated by using

data supplied by

Company A for

reference.

H Coal ash

(only bottom ash)

Thermal power station 55,000 Calculated by using

data supplied by

Company A for

reference.

4.1.7.2 Amount of suppression of CO2 emissions during cement production by adding

MCC&U by-products (PAdeCS and calcium carbonate) as minor additional constituent of

cement

If addition of all amounts of by-products (PAdeCS and calcium carbonate) as a minor

additional constituent of cement, they can contribute to the cement resource

recycling/circulation (closed recycle) and to large suppression of CO2 emissions during

cement production. Table 15 shows a summary of the amount of PAdeCS and Calcium

carbonate generation and CO2 emission suppression by the sludge generation sources. We used

0.692 tons per cement ton to be a track record in 2014, which Cement Social Industries (CSI)

in World Business Council for Sustainable Development (WBCSD) announces, as the value of

average CO2 intensity per cement in Thailand. Assuming waste concrete and the mortar sludge

derived from ready-mixed concrete throughout the country can be collected, PAdeCS and

calcium carbonate generated from them would be able to contribute to suppression of

approximately 227,000 tons of CO2 evolution.

About 20% minor additional constituent of cement may be added to cement in Thailand,

and currently Company A uses fly ash etc., Replacement of them by PAdeCS and calcium

carbonate can contribute to suppression of CO2 evolution during cement production.

33

Table 15 Amount of by-product generation and CO2 generation suppression of MCC&U

4.1.7.3 Summary of amount of CO2 fixation and generation suppression

The amount of CO2 reduction are summarized, showing CO2 amount derived from cement

kilns and the amounts of CO2 generation suppression in the production process, the results of

which are shown in Table 16. If it is possible to collect the Ca-containing waste generated

throughout the country, we estimated the large amount of CO2 emission reduction. As the table

indicates, the use of coal ash, especially, contributes greatly to the CO2 emission reduction.

No. Item Amount of

PAdeCS

generation

(t/year)

Amount of

calcium

carbonate

generation

(t/year)

Amount of CO2

generation

suppression

during cement

production

(t/year)

A

Mortar

sludge

One of Company B’s

ready-mixed plants (Plant K)

600 243 583

B Company B’s 14 ready-mixed

plants within a 100-km radius

of Company A’s cement plant

4,703 1,905 4,573

C Company B’s ready-mixed

plants outside of a 100-km

radius of Company A’s cement

plant

22,092 8,947 21,479

D All Company B’s ready-mixed

plants

26,795 10,852 26,052

E Derived from ready-mixed

concrete, generated throughout

Thailand

66,988 27,130 65,129

F Cement

sludge

Main 3 Secondary concrete

Product Companies

7,238 5,910 9,098

G Waste concrete 123,500 16,250 96,707

H Coal ash

(Bottom ash)

Thermal power station 950,000 125,000 743,900

CO2 of total fixation throughout Thailand

(sum E+F+G+H)

1,147,725 174,290 914,834

34

With MCC&U technology, the more there is waste containing Ca or Mg, the more CO2 will

be fixed. If it is possible to collect and transport waste from the whole of Thailand, the amount

of CO2 fixation will be also increased.

Table 16 Total amount of CO2 fixation of MCC&U

No. Item

Fixation of

CO2 derived

from cement

kilns

(t/year)

Generation

suppression of

CO2 during

production

(t/year)

Total

(t/year)

A

Mortar

sludge

Company B

(K ready-mixed plant) 107 583 690

B Company B within 100-km radius

(14 ready-mixed plants) 838 4,573 5,411

C Company B out of 100-km radius

(some ready-mixed plants) 3,937 21,479 25,416

D All Company B ready mixed

plants 4,775 26,052 30,827

E Derived from ready-mixed

concrete, generated throughout

Thailand

11,937 65,129 77,067

F Cement

sludge

Main 3 Secondary concrete

Product Companies 2,600 9,098 11,698

G Waste concrete 7,150 96,707 103,587

H Coal ash

(bottom ash only ) Thermal power station 55,000 743,900 798,900

CO2 of total fixation throughout Thailand

(sum E+F+G+H) 76,687 914,834 991,522

4.1.8 Study on utilization of calcium carbonate

This is extremely significant in terms of the cost of MCC&U plants to sell the calcium

carbonate mainly generated by MCC&U technology. The price of calcium carbonate varies

according to its application. Table 17 lists the applications of calcium carbonate and their

functions in the case of Japan. We were unable to obtain information on the prices.

This chapter discusses the calcium carbonate in use at paper and plastics manufacturing

35

plants introduced by Company A. Concerning the calcium carbonate generated by MCC&U

technology, we explored their application to the plastics plants.

Table 17 Applications and functions of calcium carbonate

Application Functions

Plastics Low cost, and increased strength and fluidity

Rubber Low cost and increased fluidity, increased amount agent

Paints Improved workability of adhesion adjusting material and paints

Paper making (filters) Low-cost augmenting agent

Paper making (coating) Improved quality of whiteness

Agriculture Improved solubility of disinfectant and soil amendments

4.1.8.1 Applications and amount used of the calcium carbonate provided by hearings

The purposes of the calcium carbonate used at 2 of the hearing site’s paper manufacturing

plants (Companies F and G) and its one plastics plant (Company H) are as follows:

Company F: As increasing amount agents and quality remain agents in manufacturing

paper.

Company G: As Adjustment agents for whiteness in manufacturing gypsum.

Company H: As reinforced agents for manufacturing polyvinyl chloride pipes (“PVC

pipes”).

Company A has proposed Company H as an example of applications of the calcium

carbonate which are generated by MCC&U, in consideration of their particle sizes and

convenience of the companies’ delivery destinations. The next chapter describes the

applications at Company H.

4.1.8.2 Applications at Company H

We visited the plant of Company H during our stay in Thailand in October 2016, when we

obtained the following information on use of the calcium carbonate:

a. Company H mixes resin and the calcium carbonate at a high temperature and produces

PVC pipes by extrusion molding. The PVC pipes are colour-coded according to their

application: Blue pipes are water pipes, gray for agriculture, and yellow and white are

electrical conduits.

b. Company H is purchasing the calcium carbonate from 2 companies. The types of the

calcium carbonate are OMYACARB-2B and HICOAT 410BM.

c. The particle sizes of the calcium carbonate in use are 2 - 3 μm.

d. The amount of the calcium carbonate used is 1070 tons per month per plant. Company H

36

has 2 plants.

e. The unit price of the calcium carbonate in use is 3100 - 3200 THB per ton.

f. The calcium carbonate to be supplied to Company H must meet the following 3

requirements:

(1) Coated grade (the surfaces of the calcium carbonate particles shall be coated with fatty

acids);

(2) The acceptable particle sizes of the calcium carbonate are between 1 μm and 2 μm,

and the size shall not vary from them; and

(3) High level of whiteness.

4.1.8.3 How to utilize the calcium carbonate available from this technology in a proper

manner

The major obstacle to application of the calcium carbonate produced by MCC&U

technology to Company H is considered to be the particle sizes to be adjusted. With the

calcium carbonate available by the current manufacturing method in MCC&U processes,

particle sizes are about 10 times larger than those required for Company H. Therefore, we

should explore a method of manufacturing the calcium carbonate of smaller particle sizes from

MCC&U technology in the future. We consider it possible to produce the calcium carbonate

from MCC&U technology, which is equal in quality to the raw material for Company H, by

such means as controlling the particle sizes of CO2 bubbles and changing the set pH values for

neutralization.

It must be noted that CO2 contained in the emissions from a cement kiln is used as raw

material in the calcium carbonate from this technology. If the calcium carbonate is

decomposed, CO2 will be emitted. Hence, use of the calcium carbonate available from this

technology is not suitable under the condition of temperatures as high as about 800 degrees

centigrade or strong acidity. However, the calcium carbonate is unlikely to be decomposed as

long as it occurs in nature. To use the calcium carbonate available from this technology for

industrial purposes, checking the use conditions shall be required by such means as restricting

usage in the form of policy proposals.

4.1.9 Study on utilization of PAdeCS®

PAdeCS is generated from MCC&U technology, and the amount of its generation is always

larger than that of the calcium carbonate. Hence, it is extremely significant in terms of the cost

of MCC&U plants to sell PAdeCS at a proper price.

This chapter describes removals of phosphorus and arsenic, which are under study as the

37

main applications of PAdeCS. The same chapter discusses use of PAdeCS as a minor

additional constituent of cement as a plan to suppress CO2 generation during cement

production and furthermore describes multipurpose functions of PAdeCS.

4.1.9.1 Use for removal of phosphorus, and usage example

Addition of PAdeCS to wastewater (especially wastewater from washing rice) in Japanese

food plants provides multiple advantages. First of all, it can reduce the phosphorus

concentration in wastewater to the reference value or less. Besides, since the wastewater from

washing rice after an elapse of time is acidic, PAdeCS can neutralize it, too. Moreover,

PAdeCS can serve as a fertilizer, which will be the highest value-added application, by

collecting high concentrations of phosphorus contained in wastewater.

We explored the applicability of the Japanese case stated above to the food industry in

Thailand. We visited Company I, one of the leading food companies in Thailand, and obtained

some wastewater samples during our stay in the country in August 2016, and conducted a

study on the applicability of PAdeCS using the case of Company I. Details of Company I and

the obtained information are as follows:

About Company I

Company I is a company belonging to the largest group in Thailand. The plant we visited

produces packed lunches, frozen food and refrigerated food for convenience stores in Thailand.

The company uses parboiled rice for polished rice.

Drainage treatment process of Company I

Wastewater from washing rice at Company I is combined with other wastewater and then

treated in an activated sludge process. The solid content of the drainage water is collected and

utilized as fuel for another plant. Most of the treated wastewater is discharged as effluent, and

the remainder is reused for AC cooling towers and sprinkling.

The water quality standards of effluent into rivers are as follows: The BOD level is 20 ppm

and the COD level is 50 ppm. They have told us that there is no phosphorus level specified for

the effluent water quality standards and therefore they have not measured the phosphorus

concentration of the effluent water or the phosphorus concentration of the wastewater from

washing rice.

We were able to obtain the wastewater collected after the wastewater from washing rice was

combined with other wastewater. The wastewater from washing rice was unavailable for

reasons of the facilities.

The wastewater composition of Company I is shown below in Table 18. The concentration

of P (phosphorus) is 2.0 mg/L. Compared with the phosphorus concentration of the wastewater

38

from the Japanese food plants, which is approximately 100 mg/l, the value at Company I is

extremely low. Thus we found it difficult to produce fertilizer by using the obtained samples

and PAdeCS.

Table 18 Wastewater of Company I

Element

Company I

wastewater

（mg/L）

P 2.0

The reason why the phosphorus concentration of Company I’s wastewater is low is

considered to be because of the parboiled rice manufacturing method which prevails in

Thailand. The parboiled rice manufacturing method means a manufacturing process of

steaming rice covered with hulls, and then drying and polishing it. However, the wastewater

from washing rice to be supplied for meals contains a large amount of phosphorus, which

means that the phosphorus can be removed and fixed by using PAdeCS for recycling. Thus it

is possible to evaluate its utilization for a new application as the raw material of fertilizer.

Phosphorus resources are poor in Thailand, which imports them all. Currently Europe is

advanced in recycling phosphorus resources, which can be an issue to be implemented in

Thailand in the future.

4.1.9.2 Use for removal of arsenic, and utilization

PAdeCS can remove arsenic as well as phosphorus. The arsenic which can be removed by

PAdeCS is present in the soil or liquid.

Company A has proposed that substitution of PAdeCS as an arsenic remover for the

chemicals treating wastewater from Mine J. The wastewater treatment process of this mine

uses ferric chloride 40% solution, which removes arsenic with coprecipitation. PAdeCS is

considered usable as a substitute for ferric chloride.

Table 19 shows a summary of Mine J. The arsenic concentration level in the wastewater

from the mine is 0.2 mg/L, which is reduced down to 0.02-0.04 mg/L by using ferric chloride

40% solution. The regulation value for arsenic in Thailand is 0.01 mg/L.

39

Table 19 Treatment of wastewater from Mine J

No. Item Value

1 Arsenic concentration of wastewater from Mine J 0.2 mg/L

2 Amount of wastewater treated 6,000 m3/day

3 Arsenic concentration level in treated water 0.02-0.04 mg/L

4 Usage of ferric chloride 40% solution 600 t/year

5 Price of ferric chloride 40% solution 3,000 THB/t

4.1.9.3 Use of PAdeCS as minor additional constituent of cement

PAdeCS is also considered to be usable as a minor additional constituent of cement.

According to Japanese Industrial Standards (JISR-5210), up to 5% of cement can be replaced

by regulated materials (blast furnace slug, silica admixture, fly ash and calcium carbonate) as a

minor additional constituent of cement. If 5% of cement can be replaced by PAdeCS, the

usage of the raw material of cement will be reduced, which can contribute to suppression of

CO2 generation during cement production.

Confirming mechanical properties, we obtained the result that PAdeCS is mixed with

cement, it can increase the strength of mortar. We also confirmed the result that if 25% of the

cement used to produce mortar is replaced by PAdeCS, the 7 day strength and 28 day strength

of mortar is increased by 36% and 24% respectively, compared with the mortar not replaced

by PAdeCS.

Reuse of PAdeCS for cement production can not only save resources of the plant, but also

contribute to suppression of CO2 generation during cement production. Besides, this has

another advantage of cyclic use (recycling) of cement, which contribute to formation of a

recycling-oriented society in Thailand.

4.1.9.4 Other applications

PAdeCS has multipurpose functions in addition to removal of phosphorus and arsenic.

Specifically, it is expected to be used for removal of heavy metals, deodorization and

suppression of algal-bloom generation.

Since Thailand has an issue of offensive odours in rivers, PAdeCS is considered

contributive to resolution of offensive odour issues, according to use.

4.2 Summary of study results

The concrete sludge samples that we obtained during our site survey have large

percentages of calcium content and are found to be fully applicable to MCC&U technology.

40

However, only with the amount of the sludge generated from Company B and the main three

Secondary concrete Product Companies, the fixed amount of CO2 is smaller comparatively.

If coal ash and the waste concrete and concrete sludge throughout the country can be

collected, it is contributed to fix CO2 largely. In particular, bottom ash is generated in large

quantities. Therefore if it is usable as a minor additional constituent of cement, that will lead

to suppressing a large amount of CO2 generation. Because of this situation, it is necessary to

continue research on the collection and transportation of waste, such as waste concrete and

coal ash, which are generated relatively far away from the sites.

The optimum application of PAdeCS is to utilize as a minor additional constituent of

cement, from the perspective of CO2 fixation. However, it would be necessary to consider

sale as arsenic remover according to the country and situation of MCC&U installation.

The calcium carbonate which can be obtained from MCC&U may become the raw

materials of PVC pipes produced by Company H if the particle sizes are adjusted and

reduced to smaller sizes than the existing ones for better quality. However, its use should be

refrained from under conditions of high temperatures or strong acidity.

4.3 Program towards commercialization

4.3.1 Summary

The following chart shows the steps to disseminate this technology in Thailand.

We will conduct a feasibility study for fiscal 2016, and then construct and operate a

bench-scale plant, which will be followed by installation and operation of a pilot plant. On

the basis of that plant, we will aim to promote diffusion of the technology to the cement

industry in Thailand.

Fig. 1 Four steps for commercialization

41

4.3.2 Schedule

Table 20 shows the schedule of a bench-scale plant to verify this MCC&U technology.

We will start designing and construction of the bench-scale plant after the feasibility study.

Commissioning is scheduled for around October 2017.

Table 20 Schedule of construction and verification test at bench-scale plant

4.3.3 Deployment of MCC&U plant

The main components of MCC&U bench-scale plant are 4 tanks, among which one tank

plays the role of CO2 fixation. A variety of knowhow is required to increase efficiency in

reaction products of the calcium carbonate and obtain finer particle sizes. The main role of the

other 3 tanks is elution of sludge and storage of liquid. Therefore, they do not require any

complicated installation. Hence, in order to deploy this technology plant in Thailand, it is

important in terms of cost to source tanks and components as simplified functions of the plant

locally. However, the first system to be installed at the local site will be entirely fabricated in

Japan and, after commissioning, transported to and installed in Thailand, where assembling,

commissioning and verification tests will take place. Then the second system will be

fabricated by Thailand.

4.3.4 Sale and application development of by-products

Acquisition of sales channels for calcium carbonate and PAdeCS generated from MCC&U

will lead to a reduction in the cost of the MCC&U plant. Hence, in order to reduce

MCC&U-related costs, it is essential to find a partner and sales channels available for these

by-products. In particular PAdeCS has a variety of functions and can be utilized as material

Oct. Nov. Dec. Jan. Feb. Mar. Apr. May Jun. Jul. Aug. Sep. Oct. Nov. Dec. Jan. Feb. Mar.

1Feasibility Study

(NC, METI)

2Site Survey, Discussion,

etc.

3Study Trip to Japan,

Discussion, etc.

4

Meeting on the installation

of BSP (NC, SCG, Nikko,

others)

5Designing of BSP

(NC, SCG, Nikko)

6Manufacturing of BSP (NC,

Nikko)

7

First Demonstration

Testing(Commissioning)

(NC,SCG)

9Second Demonstration

Testing (NC,SCG)

10Third Demonstration

Testing (NC,SCG)

No. Items2016 2017 2018

◎◎

×

42

effective for control measures against environmental pollution, such as removal of harmful

heavy metals.

4.3.5 Towards improvement in Thai company CSR

Cooperation of ready-mixed concrete companies that supply a large amount of concrete

sludge and those dealing with secondary concrete products is indispensable to this MCC&U

technology. The cooperative companies involved in this technology will be able to reuse their

own waste as the material for CO2 fixation. Thus the cooperative companies will be able to

gain an added value of environmental friendliness for their products. The merchandise

provided with such added value will have a competitive advantage in the market.

43

5. MRV Methodology

5.1 Concept

The study proposes a draft JCM methodology to calculate the amount of GHG reduction

by CO2 fixation using MCC&U technology. The calculation method was developed based on

CO2 contained in the exhaust gas from a waste heat power generation plant is captured and

fixed by mainly calcium (Ca) with a minor portion by magnesium (Mg) in concrete sludge

and waste concrete at MCC equipment to form carbonates (CaCO3 and MgCO3). Therefore,

the major component that reacts with CO2 was considered to be calcium (Ca). Furthermore,

additional CO2 emission reduction can be expected by using carbonates and PAdeCS,

environmental remediation agent as minor additional constituent for cement as the “U” part

of MCC&U. However, use of such by-products as minor additional constituent for cement is

one of several potential applications. It also depends upon the future company's policies of

Company A and the market price of other products that by-products can substitute. In the

study, CO2 fixation by Ca and Mg and minor additional constituent are considered for the

development of the draft JCM methodology. To calculate the amount of GHG reduction for

CO2 fixation, a method of deducting from the generated material is applied by referring to

the approved methodology of JCM ID_AM001 (Power Generation by Waste Heat Recovery

in Cement Industry). The amount of CO2 fixation is calculated from the measured weight of

the generated carbonates (CaCO3) and MgCO3 as shown in the following chemical formulae:

(Chemical formulae) Ca2+

+ CO32- → CaCO3

Mg2+

+ CO32- → MgCO3

5.2 Methodology

JCM methodology mainly consists of (1) eligibility criteria; (2) calculation of GHG

emission reductions, reference emissions and project emissions; (3) parameters fixed ex ante

and (4) MRV. Details of the above components are as follows:

(1) Eligibility criteria

In JCM methodology, checking against a list of the eligibility criteria enables the

methodology users to easily determine the project's eligibility to the specific JCM

methodology. The main points to consider in the eligibility criteria for MCC&U technology

are summarized as follows:

44

Table 21 Eligibility criteria

Criteria Main point Rationale for setting

Eligibility

criteria 1

The project newly installs mineral

carbon capture (MCC) facilities. MCC

facilities capture CO2 that would have

been released to the atmosphere and

store it into carbonates using concrete

wastes, fly-ash or bottom ash.

・MCC technology enables CO2

reduction by utilizing a wide variety of

wastes. In order to ensure the amount of

CO2 fixed and the properties of

by-products, the waste used in this

methodology is limited to concrete

wastes, fly ash or bottom-ash.

・In the section “Definitions” of JCM

methodology, use highly-versatile

expressions in the definition of “Mineral

carbon capture technology”. Also, clarify

that the waste is solid (waste concrete) or

liquid (including mortar sludge) in the

definition of “concrete waste”, and limit

the ash to the ash from power plants in

the definition of “fly ash” and "bottom

ash".

Eligibility

criteria 2

Carbonates generated by the MCC

facility shall be treated by either one of

below methods:

i) To be stored within the project site;

ii) To be incinerated in a kiln as

feedstock for cement production within

the project site;

iii) To be mixed into cement as minor

additional constituent within the project

site; or

iv) To be sold or donated to a

third-party.

This methodology accounts only the

GHG emissions reductions treated

under the condition of iii) or iv). The

by-products stored under the condition

i) are treated either under the condition

of iii) or iv) can also be accounted for

the GHG emission reduction

calculation.

In the case of by-products treated under

the condition iv), its sale/donation

destination, application and applied

conditions shall be confirmed by the

product specification sheet, invoice or

other documentation to the third party.

Carbonates as by-products of MCC are

expected to be treated under 4 different

conditions. Though carbonates that fix

CO2 are stable substances, fixed CO2

may be partially released if exposed

under the conditions other than

mentioned in the eligibility criteria 3.

Therefore, this methodology is

applicable only to the activities where

the applications of the carbonates are

traceable.

45

Eligibility

criteria 3

Calcium carbonate produced by the

MCC facility shall meet all the

requirements mentioned below:

- Being under 825 degree-Celsius

environment in atmospheric pressure, in

case of applying in industrial processes

- Apply to water body with pH

conditions of more than 7, in case of

mixing in

・The objective of these criteria is to

clarify the requirements for keeping

CO2 fixed to carbonates and avoiding

to be released again to the atmosphere.

Details are as follows:

・Carbonates may decompose slightly,

even at normal temperature if placed

under special conditions such as a

vacuum. Hence, “in atmospheric

pressure” is specified (for the

temperature setting, refer to Perry’s

Chemical Engineers’ Handbook 8th

Edition).

・If calcium carbonate are immersed in

a strong to weak acid solution, fixed

CO2 may be partially released.

Therefore pH is specified as over 7.

In particular, Eligibility criteria 2 and Eligibility criteria 3 are regarded as critical elements

in preventing CO2 emissions (leakage) from the carbonates generated from this project.

(2) Calculation of GHG emission reductions

In JCM methodology, GHG emission reductions in the project are a difference between the

reference emissions and project emissions. JCM ensures environmental integrity by setting

either the reference emissions or project emissions conservatively. Setting "conservatively"

means setting the net emission reductions by JCM project activities on the conservative side,

by calculating the reference emissions so as to be under the normal (BaU) emissions or

calculating the project emissions so as to be more than the actual emissions. Fig. 3 shows the

relationship among the BaU emissions, reference emissions and project emissions.

Source: JC’s Guidelines

Fig. 3 Relationship among BaU emissions, reference emissions and project emissions

46

GHG emission reductions under JCM are calculated in the following equation:

ERp = REp - PEp

ERp : Emission reductions for the period p [tCO2/p]

REp : Reference emissions for the period p [tCO2/p]

PEp : Project emissions for the period p [tCO2/p]

(2)-1 Calculation of reference emissions

Reference emissions in JCM should be considered on the basis of the equipment not being

implemented without JCM. As described above, the amount of CO2 fixed by using MCC&U

technology is determined from the amount of CO2 fixed from the exhaust gas of the waste heat

power generation plant that are (A) sold or donated to a third party or (B) mixed into cement

as minor additional constituent within the project site. In other words, to find CO2 emission

reductions, (A) the amount of CO2 fixed is calculated from the measured weight of the

carbonates generated and (B) the amount of CO2 emissions reduced by replacing the clinker

against minor additional constituent mixed into cement. Since the main components of the

generated material are carbonates, the purity of the generated carbonates is used to calculate

the amount of fixation.

The purity of the generated material of the MCC&U equipment is not always constant

throughout the generation process. However, the lowest value of purity written in the

by-product's specification as quality assurance, such as “purity of more than X%” or “X%

purity guaranteed” can be used to ensure the environmental integrity of the GHG emission

reductions of MCC&U.

Minor portion of Mg can also be found in feedstock of the MCC, namely waste concrete,

fly ash and bottom ash in Japan; however, this may vary according to country by country. As

all samples tested in the study show that Mg's concentration is less than 1%, a default of 1 % is

inserted in the draft methodology. Mg content is highly likely to be affected by the purity of

carbonates. Hence, this default value needs to be revisited when this methodology goes

through JCM approval process. To set a default value, it is desirable to verify the generated

carbonates by employing X-ray analytical instrumentation (XRF) or any of the following

methods:

Thermal analysis; or

Determining the amount of CO2 generated after dissolving carbonates in acid

In consideration of the above description, the reference emissions are calculated in the

47

following equation:

REp Reference emissions for the period p [tCO2/p]

QPJ-sell,p Quantity of the material generated by the Project and sold or donated to a third party

for the period p [t/p]

Fpurity,p Purity of CaCO3 in the generated material (Lower limit of purity that guarantees the

quality of product) [--]

FMg,p Amount of Mg contained in the generated material (default value) [--]

QPJ-mix,p Quantity of the material generated by the project used as minor additional constituent

for the period p [t/p]

EFcement The GHG emission factor for the cement sector（tCO2/t-cement）

Note: CaCO3 = 100 g/mol､MgCO3 = 84.3 g/mol､CO2 = 44 g/mol､Ca=40 g/mol、Mg=24.3 g/mol

In case the GHG emission factor for cement manufacturing cannot be calculated in an

accurate manner, it is possible to use other publicly available emission factors, such as an

average GHG emission factor for the cement manufacturing for Thailand by the World

Business Council for Sustainable Development (WBCSD)-Cement Sustainability Initiative

(CSI). The statistical data are usually open to public after 1 or 2 years of delay. For this reason,

chose the most conservative data from the past 3 years to ensure the environmental integrity

(for instance, the least figure between 2012 and 2014 from WBCSD-CSI in

688kgCO2/t-cement in 2012).

(2)-2 Calculation of the project emission

Project emission means the emission caused by newly added activities in implementing this

project. In this methodology, the following emission resources are studied as the project

emissions:

CO2 required for plant operation (B1)

CO2 emissions during transportation of Ca/Mg sources, such as concrete wastes, fly ash

and bottom ash from outside of the site (B2)

B1 is calculated from the electricity consumption and electricity emission factor of an

MCC&U plant. In JCM methodology, if both system power supply and in-house power

generation are used, there is a rule to use the electricity emission factor which is lower.

However, since the project site uses an emission-free waste heat recovery power generation

system as an in-house power plant, the electricity emission factor of the system power supply

)()}3.24/44*()100/44*{( ,-,,,- cementpmixPJpMgppuritypsellPJp EFQFFQRE

48

announced by TGO is used for the project.

B2 is calculated from the fuel consumption by transportation from the site where concrete

wastes, fly ash or bottom ash is generated, or a ready-mixed concrete plant to MCC&U plant,

and the fuel emission factor of the transportation vehicles. To specify the amount of fuel

consumption, the following two options are examined:

Option (1) : Directly measurement of fuel consumption

Option (2) : Calculation from the transportation distance and loading capacity

Option (1) is for the case in which a transportation vehicle is dedicated for this project and

monitoring can be achieved by cross-checking against receipts for fuel purchase for each

vehicle (represented by “i”). In Option (2), a unit of ton-km (loading capacity - transportation

distance) is used transport vehicles. TGO has prepared an inventory of life-cycle emission

factors based on the measured data, which specifies the emission factors per ton-km of

transportation vehicles by type. The project emissions is estimated assuming that, it is based

on the assumption that a ready-mixed concrete truck with loading capacity of 16 tons is used

to transport concrete sludge.

If the ton-km method is used, it would take a lot of trouble to monitor each vehicle as in

Option (1). We also reviewed the method of using the individual parameters of loading

capacity and transportation distance, which makes it difficult to manage the data. Hence, we

have decided to represent a transporting activity, instead of a vehicle, by “j” and fill out the

drivers’ log with loading capacities, transportation distances and ton-kms for the purpose of

simplifying the management of monitoring data.

The study has made it clear that fixing CO2 is possible, using the fly ash that will be

transported from the power plant located 700 km away in addition to the concrete sludge from

Company B. GHG emission reductions using the above raw materials (fly ash and bottom ash)

are calculated for estimating potential reduction in the study as potential reductions, not as

GHG emission reductions for use in economic analysis. Calculation of the potential reductions

using fly ash is based on the assumption of using a truck with 11 ton loading capacity, where it

is assumed that the truck goes to MCC&U plant at 100% loading capacity and comes back at

0% loading capacity (empty).

The emission factors in the case of using the diesel fuels of trucks according to the same

database are as follows:

49

Table 22 CO2 emission factors of transportation vehicles

Unit

Emission factor of

ready-mixed concrete

truck

(diesel fuel)

Emission factor of

11-ton truck

(diesel fuel)

Vehicle type code specified

by TGO

192-195 104-107

Loading capacity t 16 11

Empty car* kgCO2/km 0.6277 0.4346

50% loading capacity kgCO2/tkm 0.0913 0.1015

75% loading capacity kgCO2/tkm 0.0621 0.0712

100% loading capacity kgCO2/tkm 0.0468 0.0543

*The basic unit of empty cars is set so that the factors are multiplied only by transportation distances due to zero loading capacity.

Source: TGO (2016)

In the study, the emission reductions are estimated based on the assumptions that the

loading capacity of the transportation from the ready-mixed concrete plant to MCC&U plant is

3.5 tons per vehicle and that 2.0 m3 of neutralizing water per vehicle will be transported on the

way back (return) (for the project emissions from the transportation, refer to the following

chart). It is anticipated that the loading capacities do not always agree with the inventory of

the emission factors in the above life cycle as in this assumption, in which case the emission

factor with a larger amount of emissions shall be applied from a conservative perspective.

Fig. 4 Schematic diagram of project emissions by transportations assumed in the project

Construction

site

MCC Equipment

Receiver tank

Neutralizing

water

Add 2 tons of water to concrete sludge.

=> Transport a total of 3.5 tons per vehicle.

Bring back 1.5 tons of

concrete sludge (residue).

Ready-mixed

concrete plant

Site (Cement Plant)

Transport 2 tons of neutralizing water

to the ready-mixed concrete plant.

CO2 PAdeCS Generated

Feed 10 tons of water for

dilution only on the first

day of operation.

Range of project emissions

Fixed

50

In consideration of the above description, the project emissions are calculated in the

following equation:

Option (1) In the case of calculation based on measured fuel consumption:

PEp Project emissions for the period p [tCO2/p]

ECPJ,p Electric energy consumed by the project for the period p [MWh/p]

EFelec Emission factor of electricity consumed by the project [tCO2/MWh]

FCPJ,i,p Fuel consumption by the project vehicle type i for the period p [kL/p]

EFfuel,i Emission factor of diesel fuel used by project vehicle type i [tCO2/kL]

i Vehicle No.

Option (2) In the case of calculation based on transportation distance and loading capacity:

PEp Project emissions for the period p [tCO2/p]

ECPJ,p Electric energy consumed by the project for the period p [MWh/p]

EFelec Emission factor of electricity consumed by the project [tCO2/MWh]

DWPJ-out,j,p Loading capacity and transportation distance by transportation No.j by the project

vehicle for the period p (outward) [tkm/p] [km/p in case of an empty car]

EFDW-out,i Emission factor per ton-km of transportation No.j by the project vehicle (outward)

[tCO2/tkm] [tCO2/km in case of an empty car]

DWPJ-return,i,p Loading capacity and transportation distance by transportation No.j by the project

vehicle for the period p (return) [tkm/p][km/p in case of an empty car]

EFDW-return,i Emission factor per ton-km of transportation No.j by the project vehicle

(return) [tCO2/tkm] [tCO2/km in case of an empty car]

j Transportation No.

(3) Predetermined data and parameters (ex ante parameters)

In JCM methodology, you need to identify the data and parameters to be predetermined

and clarify the source of the data to be used, which are summarized in the following table.

1

,,,, )()(i

ifuelpiPJelecpPJp EFFCEFECPE

1

,,,,,,, )()(j

jreturnDpjreturnPJjoutDpjoutPJelecpPJp EFDWEFDWEFECPE

51

Table 23 Ex ante parameters

Parameter Estimated value by

calculation Unit Description of data Source

EFcement 0.688 tCO2/

t-cement

GHG emission factors for

cement manufactured/t-Cement

production)

Use either publicly available data by Thai government or chose from the 3 years from the most recent data available from WBCSD-CSI.

FMg,p 0.01 -- Amount of Mg contained in the

generated material

Value to be determined

by the methodology

EFelec 0.5897 tCO2/MWh Emission factor of system power

supply

Thai Greenhouse Gas

Organization (ver.

2015)

EFfuel,i 2.644 tCO2/kL Emission factor of diesel fuel

Thailand Energy

Situation (2015), IPCC

(2006)

EFD-out,j 0.0000913 tCO2/tkm

Emission factor per ton-km of

transportation No.j by the

project vehicle (outward) (j:

ready-mixed concrete truck; the

value of 50% loading capacity)

T GO, based on the

assumption that be

predetermined because

the loading capacity

seldom exceeds 50%.

EFD-return,j 0.0000913 tCO2/tkm

Emission factor per ton-km of

transportation No.j by the

project vehicle

(return) (j: ready-mixed concrete

truck; value of 50% loading

capacity

TGO be predetermined

because the loading

capacity seldom

exceeds 50%.

(4) MRV

In JCM methodology, the parameters other than predetermined should be monitored. The

following table shows the monitoring methods of the parameters:

Table 24 Parameters to be monitored

Parameter Unit Description of data Monitoring method

QPJ,-sell,p t/p Quantity of the material generated

from the project for the period p

Measure the weight, using a scale,

or apply the weight stated on a

document such as the shipping

document of shipment or receipt.

Fpurity,p -- Purity of CaCO3 in the generated

material

Check the lowest purity value

stated in the quality warranty of the

product.

ECPJ,p MWh/p Electric energy consumed by the

project for the period p

Measure the electric energy, using

an electricity meter. Install an

electric power board so that the

52

power consumption by MCC&U

technology may be checked at a

time in one place.

QPJ-mix,p t/p

Quantity of the material generated

by the project used as minor

additional constituent for the

period p

Measure the weight using a scale

(need to ckeck how internally

products are measured)

DWPJ-out,j,p tkm/p

Loading capacity and

transportation distance by

transportation No.j by the project

vehicle for the period p (outward)

Drivers’ log (Refer to

JCM_VN_AM001, ver02.0.)

DWPJ-return,j,p tkm/p

Loading capacity and

transportation distance by

transportation No.j by the project

vehicle for the period p (return)

Drivers’ log (Refer to

JCM_VN_AM001, ver02.0.)

5.3 Estimation of reduction potential by calculation

In the study, GHG emission reductions were estimated by calculation as stated above in 5.2,

assuming that MCC&U technology will be introduced at the project site. The amount of CO2

fixation using MCC technology will be determined according to the amounts of collected raw

materials such as concrete sludge, waste concrete, fly ash and bottom ash. In Chapter 4, the

amount of CO2 fixation is calculated on the assumption of 100% purity in accordance with the

information of the specified raw materials. In order to find GHG emission reductions in the

project, the project emissions also need to be considered. To calculate the project emissions,

they will be greatly affected by the distance between the procurement sources of the raw

materials and the location of MCC plant, and the loading capacity per transportation. To

clarify their relationship, an example calculation is shown below.

This calculation is based on the following assumptions:

(1) Concrete sludge:

Collected from Company B plants (14 plants in all) located within a 100-km radius of the

cement plant where MCC technology will be introduced. The total amount of concrete sludge

treated is estimated as 21,960 tons per year, assuming the sludge generated from Company B’s

plant as 9,407 tons per year with water added for transportation.

(2) Transportation distance and loading capacity:

The average distance is assumed to be 50 km one way. Water is added to a ready-mixed

concrete truck returned from a construction site. The diluted concrete sludge is then

transported to the cement plant. The loading capacity outward is 3.5 tons per vehicle

(assuming concrete sludge of 1.5 tons and dilution water of 2.0 tons). The return trip from the

cement plant to the ready-mixed plant carries neutralized water of 2.0m3 per vehicle. The

frequency of transportation is estimated as 6,272 times per year, which is calculated by

53

dividing 21,950 tons by 3.5 tons.

(3) Purity of calcium carbonate:

95%

(4) Power consumption:

Electricity of 12 kWh is consumed per ton of concrete sludge.

Table 25 GHG emission reductions at the project site

(in the case of using concrete sludge from Company B's plants located within a 100-km radius)

Parameter Estimate value

by calculation

Unit Description

ERp 517 tCO2/p Emission reductions for the period p

REp 830 tCO2/p Reference emissions for the period p

QPJ-sell,p 1,905 t/p Quantity of the material generated from the project for

the period p

Fpurity,p 0.95 -- Purity of CaCO3 in the generated material (Lower limit

of purity that guarantees the quality of product)

FMg,p 0.01 -- Amount of Mg contained in the generated material

(default value)

QPJ-mix,p 0 t/p Quantity of the material generated by the project used as

minor additional constituent for the period p

EFcement 0.688 tCO2/

t-cement GHG emission factor for the cement sector

PEp 313 tCO2/p Project emissions for the period p

ECPJ,p 264 MWh/p Electric energy consumed by the project for the

period p

EFelec 0.5897 tCO2/MWh Emission factor of electricity consumed by the

project

DWPJ-out,i,p 1,097,600 tkm/p

Loading capacity and transportation distance by

transportation No.j by the project vehicle for the

period p (outward) [tkm/p]

DWPJ-return,i,p 627,200 tkm/p

Loading capacity and transportation distance by

transportation No.j by the project vehicle for the

period p (return) [tkm/p]

EFD-out,j 0.0000913 tCO2/tkm

Emission factor per ton-km of transportation No.j

by the project vehicle (outward)

( j: ready-mixed concrete truck; the value of 50%

loading capacity)

EFD-return,j 0.0000913 tCO2/tkm

Emission factor per ton-km of transportation No.j

by the project vehicle (return)

( j: ready-mixed concrete truck; the value of 50%

loading capacity)

j 1 - 6,272 ― Transportation No. (1 - 6,272)

54

The following table shows a summary of the calculated GHG emission reduction potential

throughout Thailand using the draft JCM methodology, in prospect of the potential

dissemination of MCC&U technology.

Table 26 GHG emission reduction potentials throughout Thailand*

Raw material GHG emission

reductions Reference emissions

Project emissions

Ready-mixed concrete throughout Thailand

7,376 11,831 4,455

- Company B within 100-km radius (14 ready-mixed plants)

517 830 313

- All Company B ready-mixed plants 2,431 3,901 1,470

Cement sludge from main secondary products

2,089 2,577 488

Waste concrete － － －

Bottom ash 7,376 11,831 4,455

Total 9,465 14,408 4,943

*Base on the assumptions: Purity is 95%. The estimated percentage for Company B's plants within the 100-km radius is targeted to

calculate the project emissions. Use of 11-ton trucks, not ready-mixed concrete trucks, is assumed for raw material transportation. The

amount of waste concrete is estimated by based on the information from Company A. Bottom ash is assumed to be procured only from

a power plant 700 km away from the site of the study project.

Table 27 GHG emission reduction potential for the whole Thailand

including by-products used as minor additional constituent)*

Raw materials

GHG emission reductions

MCC only

MCC+U (Incl. GHG emissions

reduction by by-products)

Total

Ready-mixed concrete throughout Thailand

7,376 64,753 72,129

- Company B within 100-km radius (ready-mixed14 plants)

517 4,546 5,063

- All Company B ready-mixed plants

2,431 25,901 28,332

Cement sludge from main secondary products

2,089 9,184 11,134

Waste concrete － 96,148 96,148

55

Bottom ash － 739,600 739,600

Total 9,477 909,546 952,406

*As per the JCM guidelines, reference emission is calculated based on estimating the most conservative data to ensure the

environmental integrity. Use either publicly available data by Thai government or chose from the 3 years from the most recent data

available from WBCSD-CSI.

The amount of CO2 fixed by the waste concrete, fly ash and bottom ash as shown above

table is the result of estimation based on the data supplied from Company A, and not the data

for the entire Thailand. Hence, GHG emission reduction potential is expected to be further

increased. Moreover, if additional GHG emission reduction potential by substitution of

by-products for cement is added, the annual GHG emission reductions are highly likely to be

several million tons CO2eq.though it depends upon the project emissions according to

transportation distance.

56

6. Analyses of economic effects and impact on Thailand

6.1 Analysis of economic effect

As in the case of Japan where MCC&U technology has already introduced, the investment

for installation of a 60m3-capacity MCC reaction tank for manufacturing calcium carbonate

and PAdeCS is expected to be approximately 200 million yen. The study analyzes the

economic effects expected if the reaction tank of almost the same size is exported to

Thailand, and the concrete sludge is treated after transportation from the ready-mixed

concrete plants located within a 100-km radius of the site used for calculating the estimation

of GHG emission reductions in Chapter 5.

According to the calculation result of the financial analysis with estimated operating

revenues for Company B's 14 plants within a 100-km radius of the project site, the internal

rate of return (IRR) is 23.8%, which indicates a possibility that the investment can be

recovered within 4 years after commencement of the operation.

The following parameters will significantly affect the economic potential of MCC&U

business: (1) initial investment amount of equipment; (2) selling prices of by-products; and (3)

transportation distances of carrying raw materials such as concrete sludge including mortar

sludge and waste concretes. Other parameters including raw material transportation fuel costs

and electricity price can be considered, though they are considered not to significantly affect

the economic potential. Therefore, no price increase is considered for them. The sensibility

analysis on the following parameters is summarized as below: (1) initial investment amount of

equipment, (2) selling prices of by-products, and (3) transportation distances of raw materials.

Impact of local procurement to the initial investment costs under (1) was done in 12 different

assumptions stages of local procurement of some equipment. Since we were not able to obtain

detailed information on the cost of transportation from Japan, which was applicable to the

sensibility analysis, the cost used here is based on a scenario of importing all the equipment

from Japan.

Table 28 Results of sensibility analysis (1)*

Deviation from the reference value (IRR=23.8%)

Deviation -30% -25% -20% -15% -10% -5% Reference

value 5% 10% 15% 20% 25% 30%

Initial investment

amount 13.8% 10.8% 8.2% 5.8% 3.7% 1.8% 23.8% -1.6% -3.1% -4.5% -5.8% -7.0% -8.2%

PAdeCS selling

price -11.2% -9.2% -7.3% -5.4% -3.6% -1.8% 23.8% 1.7% 3.5% 5.1% 6.8% 8.5% 10.1%

Calcium carbonate

selling price -2.5% -2.1% -1.7% -1.3% -0.8% -0.4% 23.8% 0.4% 0.8% 1.2% 1.7% 2.1% 2.5%

Raw material

transportation

distance

1.6% 1.3% 1.1% 0.8% 0.5% 0.3% 23.8% -0.3% -0.5% -0.8% -1.1% -1.4% -1.6%

57

Conditions that cause IRR to be less than 20%

Deviation -30% -25% -20% -15% -10% -5% Reference

value 5% 10% 15% 20% 25% 30%

Initial investment

amount - - - - - - - - - 19.3% 18.0% 16.8% 15.7%

PAdeCS selling

price 12.7% 14.6% 16.6% 18.4% - - - - - - - - -

Calcium carbonate

selling price - - - - - - - - - - - - -

Raw material

transportation

distance

- - - - - - - - - - - - -

s

Fig. 5 Results of sensibility analysis (2)

As previously described, the reference value IRR is 23.8%, which indicates a high rate even,

in a developing country where the investment risks are high in general. If the initial investment

cost can be further reduced by 15%, IRR is expected to be improved to nearly 30%. As for the

estimated prices of by-products in the study, PAdeCS, double amount of carbonate produced,

can be sold at 1.7 times higher than carbonates. Therefore, if the price becomes 10% less than

currently estimated, IRR would be under 20%. Hence, we view determination of the sale

destinations and prices of PAdeCS as imperative in proceeding with this project in the future.

The impact of the raw material transportation distances and carbonates as by-products are

minor compared with the variations of the initial investment amount and the PAdeCS price.

The former two parameters show only differences of about 1.6% and 2.5% from IRR

respectively even when there is a deviation from plus or minus 30%.

0%

5%

10%

15%

20%

25%

30%

35%

40%

45%

50%

-30% -20% -10% 0% 10% 20% 30%

IRR

deviation

Initial investment cost Selling price of PAdeCS

Selling price of carbonates Transportation distance to carry feedstock (one way)

58

Use of PAdeCS and carbonates as additives to cement is also under study in the study, in

which case it would be necessary to compare the amount of proceeds from sale of PAdeCS

with the amount of a reduction in cost in the case of substituting PAdeCS for cement, and

furthermore take into consideration extra cost due to such expenses as sales personnel cost to

secure sales channels for PAdeCS, which is not included in the economic analysis of the

study.

In addition, the import duties on MCC plant are not considered in the study because we

assume the application of a preferential treatment system such as the exemption of import

duties that the Thai Government applies to environmental technologies. Besides, only fuel

costs are allocated to the transportation cost, and estimation by calculation do not include

personnel or administrative costs. Therefore, with a rise in these costs, IRR would fall by

several percent. Thus it is considered important to determine details of those costs in order to

disseminate and promote MCC&U technology in Thailand.

6.2 Impact analysis on Thailand

Fig.6 Schematic diagram of collecting Ca sources

Assuming that all mortar sludge (A-1 and A-2) generated from the ready-mixed concrete

plants within the 100-km radius is collected, the amount of the sludge will be 9,407 tons.

Hence, GHG reduction potential expected from these Ca sources would be 838-ton CO2

fixation annually.

On the other hand, the cement sludge (B-1) generated in a centrifugal molding process at a

secondary concrete product manufacturing plant within the 100-km radius totals 14,475 tons

59

annually. Therefore, GHG reduction potential expected from these Ca sources would be

2,600 tons annually.

Hence, CO2 emission reduction (the amount of CO2 fixed) by carbonating the concrete

sludge (A-2 and B-1) with MCC&U technology is expected to be 838 -2,600 tons annually.

One of efficient collection measures of concrete sludge in the study suggested that a concrete

agitating vehicle goes through near MCC&U plant to discharge the surplus concrete.

6.3 Repercussion effect

[Potential for deployment in Thailand]

Since the annual consumption of ready-mixed concrete in Thailand is approximately

19,490,000 tons (A-1, A-2 and A-3), surplus ready-mixed concrete is estimated to be

approximately 214,000 tons. As a result, CO2 reduction potential is approximately 19,100

tons. On the other hand, an aggregation of the concrete sludge (B-1&2) generated in the

centrifugal molding process at a secondary concrete product manufacturing plant is 14,475

tons annually. Therefore, GHG reduction potential expected from these Ca sources would be

5,900 tons annually. The amount of the concrete sludge discharged outside of the 100-km

radius was not able to be identified.

The above estimated values exclude CO2 emissions from the sludge transportation.

Therefore, we need to explore an optimum location to construct MCC&U plant in the future

while considering the location of the cement plant. Moreover, if MCC&U business plans

proposed under the study is shared with other cement companies in Thailand, it is expected

that MCC&U technology will be a good practice to contribute to NDC and be recognized by

the government and the cement industry as a low carbon technology which will lead to a

significant reduction of GHG, and eventually will enable acceleration of the deployment of

the technology.

Furthermore, if Thailand implements a “programme-type JCM” linked to NDC through

the results of the study, it will be possible to develop a cross sectoral business network

throughout the worldwide cement industry, where large-scale GHG reductions can be

expected. Additionally, this will help further contribute to a development of a circular

economy, as demonstrated by reuse of by-products and or utilization of recycled phosphorus

resource.

[Potential for deployment in other countries mainly in Southeast Asia]

Company A diversifies a cement business in ASEAN region and approximately 7 million

ton of cement is produced outside of Thailand. Therefore, it will be possible to introduce

MCC&U technology in plants in the Southeast Asia region. Besides, it will also be fully

60

possible for Company A's subsidiary companies to conduct various research & development

and technological studies on this technology, and provide technical guidance/assistance to

neighbouring countries.

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7. Issues

7.1 Issues on commercialization

1) Laws and regulations on disposal of such wastes as concrete sludge are not clearly found

Thailand during this project. Therefore, comparing to Japan, the country's incentives are very

low. However, it is anticipated that the health hazard caused by environmental or mine

pollution will become prominent in the future so that the existing regulations and criteria will

tighten and the legal compliance will become more rigorous. To meet these future

regulations, it is critical to start environmental projects at an early date, and the

administrative guidance must also take the first move.

2) It is hard to say that concrete sludge (mortar sludge and cement sludge) in large quantities

is generated from ready-mixed concrete plants and secondary concrete product plants.

Besides, since concrete sludge is self-hardening due to a hydration, it is difficult to provide a

stable supply to the MCC&U plants. However, if the quality of PAdeCS as a minor

additional constituent of cement is ensured, that will directly lead to suppression of CO2

emissions, and eventually provide economic effects, such as local production for local

consumption and closed recycling of resources. We also will discuss about information

exchange and joint research agreement with research institutions such as university and so

on.

3) To have the calcium carbonate used by Company A, a new manufacturing or quality

control method should be fully explored. It is necessary to find a new customer separately

or focus on developing a new application (for instance, nano-particle products) of calcium

carbonate in Thailand.

4) Concerning the environmental remediation agent derived from PAdeCS as a by-product,

we were not able to obtain full information in the study, and therefore, unable to estimate

the selling price at the site and its market potential.

5) Regarding a deployment of the phosphorus resource recycling business, we were able to

obtain a sample of wastewater containing phosphorus only from one site and therefore

further additional samples will be required in the future. We also have to survey on the

source origin, etc. separately.

6) Ca-containing wastes are required to transport to near Company A’s cement

manufacturing plant, which is a source to generate CO2. In consideration of CO2 emissions

generated during transportation, it is assumed that Company A should be as close as

62

possible to a site that generates waste. Therefore, it would be favourable to deploy MCC&U

technology around the district where Company A’s cement plant is located.

Substances which are not self-hardening such as demolished waste concrete and fly ash can

be transported by dump truck or railway. However, concrete sludge is self-hardening and

therefore shall be transported by concrete agitating vehicle or by such means as vessel dump

truck while adding water and taking measures for reducing the self-hardening properties.

Regarding fly ash generated far away from Company A, it is required to review the method of

collecting and transporting the wastes.

7.2 JCM Issues

Calcium carbonate generated by using MCC&U technology may be newly decomposed

into CO2 and causing additional CO2 to be discharged, depending on certain conditions, such

as being stored at a high temperature or exposed to acidic solution.

Besides, a default value of Mg contained in concrete sludge was used to calculate the

amount of CO2 fixed due to a slight amount of Mg contained in concrete sludge in Japan. It

is required to review whether or not the same method is applicable to Thailand.

7.3 Solutions to extracted issues

1) Development of law

In cooperation with Company A, the study team will share information with the related

authorities of the Thai Government and provide policy proposals (For details, refer to

chapter 9).

2) Towards large-scale GHG reduction

We aim at a large-scale GHG reduction by use of fine powder generated from

demolished waste concrete as well as sludge and searching for waste containing Ca and

Mg through the future pilot project. It is necessary to bridge the gap between reality and

the target in the future by exploring a method of collecting sludge from plants far away

(A-3 and B-2), or a method of generating carbonates through reuse of fine powder

generated from demolished waste concrete (C-1 & 2), and by searching for industry

wastes containing Ca and Mg (D-1 & 2). If the situation calls for this, we need to eye

the possibility of reviewing the distribution and construction of small MCC&U plants.

3) Exploitation of new applications of calcium carbonate

Since the study has revealed that if calcium carbonate can be produced on a nano

particle level, it will be applied for new applications, the conditions for the production

will be found through the future pilot project, and the market research for that purpose

63

will be conducted.

4) Business deployment of environmental remediation agent

We should start by comparing conventional methods and getting results in Japan to

conduct market research through the future pilot project. Future tasks will include

proactive development of application of the MCC&U technology and taking action to

resolve the unresolved issues incurred with the occurrence of environmental burdens,

and furthermore proposals to lead to market renovation.

5）Issues on JCM methodology

CO2 capture and store using the technology will be evaluated as the stable amount of

CO2 fixed if the applications and storage procedures are restricted by applying the

eligibility criteria discussed in the methodology. Hence, a review, under consultation

with Company A, is required on whether additional restrictions on use are needed other

than what the eligibility criteria covered in Section 5.2.

64

8. Invitations and training reports

8.1 Objective

We invited a Thai Government official and person working at a private company to inspect

MCC&U technology commercialized in Japan. They also inspected a case of GHG reduction

in operation in Japan and improved their understanding of JCM and MCC&U technology.

We also invited the overseas students of doctoral course in Tokyo Institute University to

introduce our Kawashima factory and the MCC&U technology. They are from

Chulalongkorn University and have major of civil engineering.

8.2 Schedule

The invitation schedule is as follows.

Table 29 Invitation schedule

8.3 Specific report of study

8.3.1. Taiheiyo Cement Corporation Saitama Plant

This plant is situated in Hidaka, Saitama Prefecture and has received industrial waste since

the early 1970s. An AK (Applied Kiln) system, which receives and disposes of general waste,

started operation in 2002 and began recycling the domestic waste generated in the city into

cement resources.

For the AK system, the company has converted an unused cement kiln into a waste

recycling kiln. The system ferments waste through biodegradation reaction. Approximately

15 thousand tons of municipal waste annually generated throughout Hidaka is received by

the plant, which changes all of it into cement resources. Thus Hidaka does not need any

garbage incineration facilities.

The party visited the plant and had a technological exchange with the staff there about the

Date Time Visit Purpose Place

AM (8：00-10：00)

Mitsubishi UFJ Morgan Stanley Securities

Co., Ltd

METI

・Outline of study tour

・NC, TGO and SCG meetingTokyo

PM (13:00-16：00Taiheiyo cement corporation

Saitama factory

・Cement recycling technology tour of household garbage etc

・About environmental conservationSaitama

AM (10：00-11：45) ・Factory Outline Description Other

PM (12：30-16：00・MCC&U Plant for study

・Factory tour

Dec.1st AM (9：00-12:00)Nippon concrete industries Co.,LTD

(Head office)

・Report of cross check result、exchange of opinions

・Outline of MCC&U bench-scale-plantTokyo

Nov.29th

Nov.30thNippon concrete industries Co.,LTD

Kawashima factoryIbaragi

Study tour to Japan in November.

65

AK system that recycles waste.

8.3.2. NC East Japan Concrete Industries Co., Ltd. Kawashima Plant

On November 30, 2016, the party visited a plant, located in Chikusei, Ibaraki Prefecture,

which produces secondary concrete products and has an MCC&U plant on the premises.

They were able to enhance their understanding of MCC&U technology through a briefing of

the plant, and a tour of MCC&U plant, and the whole manufacturing plant.

66

9. Policy proposals

The following four policies can be proposed for the introduction of MCC&U technology:

1) Defining contribution of MCC&U to Thai NDC

2) Developing an industrial standard including definition of minor additional constituent

3) Introducing regulations on disposal of concrete sludge; and

4) Adding environmental remediation agent produced from reuse of waste to the green

procurement list developed by the Thai government

9.1 Defining contribution of MCC&U to Thai NDC

At present, there is only a draft JCM methodology to account GHG emission reduction for

MCC&U, though the GHG accounting methodology will be eventually developed based on

feedbacks from a wide variety of stakeholders. In order to define the actual contribution of

MCC&U to Thai NDC, it is necessary for the Thai government to make a political decision to

include GHG emission reduction by MCC&U as part of the NDC, by reflecting it in the Thai

national GHG inventory. For instance, it may be useful to develop a list of clean technologies

whose contribution is recognized in the Thai NDC. Innovative technologies like MCC&U can

be proposed to be added to the technology list as well.

9.2 Developing an industrial standard including definition of minor additional constituent

According to JIS R 5210 (Portland cement) in Japan, high purity of calcium carbonate can

add to the Portland cement as a minor additional constituent. If PAdeCS is also defined as the

minor additional constituent, further GHG reduction would be expected and its demand will be

increased in Thailand. For instance, if the total amount of minor additional constituent as the

components of Portland cement is allowed to be 5% or less like the case of JIS R 5210, this

will enable additional 5% reduction in the production volume of the cement, and

simultaneously reduce 5% of CO2 emissions intensity per cement. Therefore, PAdeCS should

be included in a definition of the minor additional constituent in the industrial standard in

Thailand.

9.3 Introducing regulations on concrete sludge disposal

As shown in 1) of 7.3.1, it would be very important to facilitate policy dialogues between

Japan and Thailand concerning waste management on disposal of industrial wastes. In Japan,

concrete sludge should be disposed in accordance with regulation of “Waste Management and

Public Cleansing Law” which requires appropriate treatment manner. Cooperation based on

information exchanges between related authority of Japan and Thailand, including the effects

due to the introduction of these regulations, would encourage appropriate disposal treatment of

67

concrete sludge and eventually drive promotion of introducing MCC&U technology.

It is also proposed to establish a technical review committee for standard composed of

industry, academia and government members to develop a new industrial industry standard in

Thailand and to provide policy proposals that contribute to CO2 reductions by establishing a

high quality management system.

9.4 Adding environmental remediation agent produced from reuse of waste to the green

procurement list developed by the Thai Government:

Utilization of a green procurement list can be considered as a method of making

environmental remediation agents (by-products of MCC&U technology) more competitive in

the market in the future. The Thai Government has developed and announced a green

procurement list similar to the Japanese practice. If the list includes such environmental

remediation agents made from recycled wastes instead of natural resources, it may encourage

the demand for by-products of MCC&U technology.