Biochar Production for Steelmaking

Project Overview
BioCarbon is building a commercial-scale biochar production facility in Bulahdelah, NSW, designed to supply the steel industry with a cleaner alternative to fossil-based coke. The plant will convert low-value waste wood into high-quality biochar lumps and pellets for use as charge carbon in Electric Arc Furnaces (EAFs). Alongside biochar production, the facility will use syngas generated through pyrolysis to produce renewable electricity on site.
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This project represents an important step in Australia’s transition toward low-emissions metals and supports the development of a new domestic renewable carbon supply chain.
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Why This Matters
Steel sits at the heart of Australia’s construction and manufacturing economy, yet traditional steelmaking relies heavily on fossil-derived coke as a carbon source. At InfraBuild's Rooty Hill steelmaking facility, this coke consumption is the second largest contributor to Scope 1 emissions.
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Replacing fossil coke with biochar gives industry a direct pathway to reduce emissions now, without waiting for future breakthrough technologies. By using biomass residues already available in regional NSW, this project transforms a waste stream into an industrial input capable of immediately reducing carbon intensity in steel production.
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What the Project Will Do
Over the life of the project, the Bulahdelah facility will:

• Commercialise two Australian-developed technologies for char production and consolidation
• Process approximately 20,000 tonnes of wood waste annually
• Produce around 8,000 tonnes of renewable carbon products each year
• Supply biochar lumps that can replace more than 90 percent of Rooty Hill’s charge carbon requirement
• Demonstrate consistent, reliable biochar use in EAF steelmaking
• Generate renewable energy from captured syngas to support plant operations
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The outcome will be a proven model for renewable carbon production that can be expanded to support steelmakers across Australia.
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Expected Outcomes
The project is designed to:

• Advance the commercial readiness of next-generation pyrolysis and biochar processing systems
• Demonstrate cost and performance equivalence between fossil coke and renewable carbon
• Enable large-scale adoption of biochar in EAF operations
• Lay the foundation for a broader renewable carbon supply chain
• Support other emerging co-products, including wood vinegar for agriculture and syngas-based renewable heat and power
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Additional Benefits
Beyond supplying renewable carbon, the project will:

• Create new regional employment and technical roles
• Build capability in advanced manufacturing and clean industrial energy
• Expand opportunities for Australian biomass utilisation
• Share lessons, data and performance outcomes to accelerate uptake across heavy industries
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Project Timeline
Start: December 2025
Operational demonstration: 2026 to 2028
Completion: May 2029
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Project Partners

This project is being delivered by BioCarbon in collaboration with the following industry partners:

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• Biomet Pty Ltd 

• InfraBuild (Manufacturing) Pty Ltd

• InfraBuild NSW 

• PyroAg 

• S.A. Relf & Sons Pty Ltd