The Australian Renewable Energy Agency (ARENA) has announced significant funding to support BlueScope Steel in investigating decarbonization pathways for the Port Kembla Steelworks in New South Wales. This initiative, conducted in partnership with the University of Wollongong and Future Fuels CRC, focuses on “Smart Carbon Usage,” a strategy designed to transition away from heavy reliance on fossil fuels in traditional metallurgy. By integrating technical expertise in process modeling and pneumatic conveying, the project aims to establish the feasibility of substituting renewable carbon sources into high-emissions industrial processes.

The primary challenge addressed by this Australian study is the inherent carbon intensity of the integrated blast furnace-basic oxygen furnace (BF-BOF) steelmaking route, which typically requires large volumes of pulverized coal. Traditional coal and coke provide essential heat energy, act as a reducing agent, and support the iron-containing load within the furnace. However, the sector’s global greenhouse gas emissions—estimated at roughly eight percent—necessitate a shift toward alternative fuels that do not compromise the structural stability or chemical efficiency of existing furnace operations.

The proposed solution involves a series of industrial plant trials where biocharBiochar is a carbon-rich material created from biomass decomposition in low-oxygen conditions. It has important applications in environmental remediation, soil improvement, agriculture, carbon sequestration, energy storage, and sustainable materials, promoting efficiency and reducing waste in various contexts while addressing climate change challenges. More is injected into the blast furnace via tuyeres to partially replace coal. This “Smart Carbon Usage” pathway leverages the high heating value and porous structure of metallurgical-grade biochar, which can be produced from sustainably managed forestry and agricultural wastes. Researchers are optimizing the slow pyrolysisPyrolysis is a thermochemical process that converts waste biomass into bio-char, bio-oil, and pyro-gas. It offers significant advantages in waste valorization, turning low-value materials into economically valuable resources. Its versatility allows for tailored products based on operational conditions, presenting itself as a cost-effective and efficient More process to ensure the biochar maintains the necessary reactivity and strength required to survive the high-temperature environment of a large-scale furnace.

Initial outcomes of these trials and the associated feasibility study include technical proofs of concept for blending up to 15% renewable carbon into coal injection systems without reducing productivity. The project is expected to provide critical data over its 13-month duration, helping to de-risk future industrial-scale deployments of biochar in metallurgy. These findings contribute to Australia’s broader goal of reducing industrial emissions and strengthening its position as a sustainable leader in the global steel supply chain.