CHAR Technologies is advancing the commercialization of its biocarbon production through a strategic partnership with the Ontario government and industrial stakeholders. Supported by a $2.25 million investment from the provincial Forest BiomassBiomass is a complex biological organic or non-organic solid product derived from living or recently living organism and available naturally. Various types of wastes such as animal manure, waste paper, sludge and many industrial wastes are also treated as biomass because like natural biomass these More Program, the company is optimizing its Thorold Renewable Energy Facility to produce high-quality biocarbon pellets. This initiative aims to utilize up to 180,000 metric tons of forest biomass annually, converting mill byproducts and underused wood into a low-carbon fuel source. The project represents a significant step in diversifying Ontario’s forest sector while providing a sustainable energy alternative for heavy industry.

The primary challenge addressed by this initiative is the technical requirement for biocarbon to serve as a viable “drop-in” replacement for fossil coal in intense industrial processes like steelmaking. Standard raw 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 often lacks the physical durability and energy density required for existing industrial handling systems and long-distance transport. To be integrated into the operations of partners such as ArcelorMittal Dofasco, the material must withstand rigorous storage and transport conditions without degrading. Furthermore, the industry faces the economic challenge of creating stable, value-added markets for forest residuals that would otherwise be landfilled or left as waste.

To resolve these issues, CHAR Technologies is employing its proprietary high-temperature 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 (HTP) technology to produce specialized biocarbon pellets. This process involves heating woody biomass to 900 degrees Celsius in an oxygen-free environment, cracking the material into renewable natural gas and a solid carbon output. The recent funding specifically supports the optimization of pelletization to improve the density and durability of the final product. By refining these physical characteristics, the company ensures the biocarbon can be seamlessly integrated into existing steelmaking infrastructure and safely exported to international markets, including Europe.

The outcomes of this project include the successful commissioning of the first commercial HTP kiln at the Thorold facility, with a second kiln planned to double capacity. The facility is expected to produce 5,000 metric tons of biocarbon annually in its first phase, eventually scaling to 10,000 metric tons while simultaneously generating enough renewable natural gas to heat over 5,500 homes. This development supports ten local jobs and establishes a new supply chain linking the forestry and steel industries. Environmentally, the project is projected to reduce Ontario’s greenhouse gas emissions by up to 30,000 tonnes per year by displacing fossil fuel combustion.