Under the global push for carbon neutrality, Europe is facing an industrial trilemma: achieving climate-neutrality while securing its strategic autonomy and industrial competitiveness. The metallurgical industry, as the backbone of European industry, consumes about 50–60 million tonnes of metallurgical coal annually. CO₂ emissions from this sector account for approximately 8% of total EU GHG emissions. Therefore, its decarbonization is key to meeting Europe’s climate goals. In this context, biochar, as a renewable carbon source, is emerging with unique value and great potential in the European metallurgical industry.
Biochar, produced through controlled pyrolysis of sustainable biomass, gained recognition for its carbon removal potential through soil application. In recent years, its industrial applications have expanded, particularly in steel and metal smelting. Biochar has become a credible substitute for coal in industrial processes. It meets the chemical and structural requirements for elemental carbon in metallurgy while reducing fossil carbon emissions at the source.
Silicon plays a central role in photovoltaic cells, semiconductors, high-performance alloys, and silicones. In Europe, traditional silicon smelting relies on imported hard coal, which has relatively low fixed carbon content of around 55% and poor reactivity compared to biochar. Consequently,
Currently, European silicon production still relies on imported charcoal and coal, a model that is not sustainable. Developing localized, modern biochar production can secure supply, lower upstream emissions, and strengthen Europe’s position in the global low-carbon metallurgy market.
The European ferroalloy sector is central to the continent’s metallurgical value chains, supplying critical inputs such as ferrosilicon, silicomanganese, ferromanganese, and ferrochromium to the steel and foundry industries. These alloys serve distinct functions in steel refinement, including deoxidation, desulfurization, and the enhancement of specific material properties. All the alloy require carbon-based reductants in high-temperature EAF smelting processes. This makes the sector particularly relevant for the use of biochar to minimize fossil emissions.
| Ferroalloy (name) | Data on Fossil Reference Material | Data on Biochar Substitute Material | Biochar Substitution Radio | ||||||
|---|---|---|---|---|---|---|---|---|---|
| Type | Price €/t | Consumption | Type | Substitution rate | Consumption | 2030 | 2040 | 2050 | |
| Ferrosilicon | Washed Coal | 350 | 1,2 | Lump | 0,71 | 0,85 | 50% | 100% | 100% |
| Silicomanganese | Coke | 340 | 0,47 | Briquette / lump | 1,11 | 0,52 | 30% | 90% | 100% |
| Ferromanganese | Coke | 340 | 0,462 | Briquette | 1,2 | 0,55 | 20% | 70% | 100% |
| Ferrochromium | Coke | 340 | 0,511 | Briquette | 1,2 | 0,61 | 30% | 80% | 100% |
Steel is a cornerstone of modern economies. Elemental carbon remains essential across all steel production routes. Biochar, as a renewable, reactive carbon carrier, supports decarbonization in both transitional and future process chains as described below. Demand for biochar in the European steel sector is projected to reach 620,000 tonnes in 2030, increasing to about 4.1 million tonnes by 2050 and stabilizing in subsequent years.
During the transitional phase of gradually phasing out the traditional BF-BOF route (until 2050), biochar can contribute to emissions reduction in three ways:
In the future mainstream EAF route, biochar plays a more critical role:
To meet the stringent operational demands of metallurgical processes, biochar must achieve high fixed carbon content (>75%) and exhibit consistent quality across multiple physical and chemical parameters. The generally low ash content and low levels of trace elements such as sulphur, iron, phosphorus, boron, etc. are advantageous. When it comes to particle size, density, and mechanical strength, biochar can be designed or agglomerated to fit the specific needs of diverse uses.
| Product Category | Description | Size | FC (%) | Use Cases |
|---|---|---|---|---|
| Biocarbon Lumps | High reactivity for Si / FeSi | 10–60 mm | 80–82% | Silicon/FeSi |
| Medium volatiles | 10–60 mm | 82–85% | Ferroalloys, EAF (semi-open) | |
| Closed furnaces | 10–60 mm | >85% | Ferroalloys, EAF (closed) | |
| Biochar Fines | For injection or agglomeration | 3–8 mm | 80–90% | EAF, BF, injection |
| Briquettes | Roller-pressed or stamped | Variable | 75–85% | General processes |
| Pellets | Extruded with binders | <20 mm | 75–85% | Engineered for process compatibility |
| Extruded Lumps | High-density engineered format | >20 mm | >85% | Closed furnace ferroalloys |
| E-coke | Biochar-anthracite blend | Variable | >85% | EAF/BF/BOF transition |
| H-coke | Coke with biochar share | Variable | >85% | Hybrid with traditional coke |
Demand for biochar in Europe’s metallurgical industry is entering a phase of rapid growth. This growth will not happen automatically. To realize the full potential of biochar, Europe must act now to validate its uses, streamline regulatory pathways, and support investment in industrial-scale production. Overall, by 2040, biochar production capacity will need to reach 20.6 million tonnes to meet the metallurgical sector’s demand for renewable carbon, generating a net carbon effect equivalent to 400 million tonnes of CO₂ (i.e., the circular carbon benefit of biochar). The figure below summarizes these projections across all industrial applications, including silicon and ferroalloys, steel (both BF–BOF and EAF routes), as well as other metallurgical and chemical processes and responsible carbon use.
The application of biochar in the European metallurgical industry is not only a technological replacement but also a paradigm shift in the industry. It aims to institutionalize recycling and climate-friendly carbon emission mechanisms, making them the cornerstone of European industry policy. This has far-reaching and lasting significance for future sustainable development.