Research database

The achievement of the EU net zero emissions by 2050 passes through the decarbonization of hard-to-abate industries and the sustainable access to critical raw materials. In this context, with about 60 Mt/y of fossil coal and 5 % of the EU GHG emissions, the decarbonization of steel sector is a key challenge. Recently, research projects demonstrated that a biocoal with high stability (charcoal), can be produced by pyrolysis of residual biogenic materials, such as wastewood, and biomass prunings. This biocoal, differently than torrefied biomass, presents low oxygen content and it is thus usable to replace fossil coal in EAF, as well as BF. In addition, circular recycling of biogenic residues like sludge, digestates and green wastes is another opportunity, beyond representing a problem, in EU. A combined process, patented by RE-CORD and licensed to start-up, was developed to obtain a high quality biocoal also from inorganic-rich bioresidues. Despite achievable chemical composition and quality, already demonstrated in previous studies, industrial scale-up of technology to full commercial demo-scale is needed, as well as demonstration campaign to validate the applicability of biocoal to green steel production, and to adapt the existing material handling solutions. This, together with completing the End of Waste classification for the obtained biochar, is key to unlock the market, allowing steelmakers to elaborate commercial contracts and use. Within the THELMA project, a large-scale innovative integrated pyrolysis-leaching demonstration plant will be design, built, commissioned, and operated, so to produce at least 350 tons of biocoal from biogenic residues, such as sludges and green wastes and residues, beyond residual lignocellulosic biomasses. Biocoal will be through various innovative systems and then be tested in both scrap metal, and DRI EAFs, so to determine the effects and adjust the existing technologies. In this project, biocoal compaction, handling, and utilization solutions will be identified and tested at full industrial scale, producing > 1000 ton of green steel. The production campaigns, conducted by two partners (leading industrial steelmakers) will be monitored and assessed by the coordinator, a leading Academia in energy and sustainability technology and assessments, delivering data about the energy performances, process sustainability, and product quality. At the end of the project, the technical and economic impact of using residue-derived biocoal for steel production will be determined at full industrial scale, providing the information essential to bring the biocoal to industrial and commercial application, so to provide a relevant contribution to EU steel sector decarbonization.