Implementation of Biocoke in industrial scale

Biocoke is a suitable CO₂-neutral substitute for fossil carbon carriers that are commonly used in metallurgy as reducing agents and energy sources. However, due to its higher reactivity and lower bulk density compared to conventional reducing agents such as fossil coke, petroleum coke, or anthracite, the use of biocoke is subject to certain limitations depending on the metallurgical process. In processes where the carbon carrier is exposed to prolonged heating with at least partially oxidizing conditions, the high reactivity of biocoke is disadvantageous, as part of the material is consumed prematurely and is therefore no longer available for the metallurgical reaction.

In a separate success story, it is reported how this behavior was improved and the high reactivity was minimized through a specialized micro-agglomeration process.

In contrast, in processes where the carbon carrier is introduced directly into a molten phase and reacts immediately with the material, the high reactivity is less problematic. In these cases, the main challenge is to ensure that the low-density biocoke remains within the melt, preventing losses due to reactions with the atmosphere at the bath surface.

In collaboration with project partners and external experts in biocoke production, it was possible to define the requirements and parameters needed for biocoke to be suitable for applications in primary and secondary lead metallurgy (battery recycling), as well as to identify optimization steps required to replace as much fossil carbon as possible. These findings were validated at both laboratory scale and technical scale (40–60 kg per batch), yielding satisfactory results. As a result, planning for the first industrial trials was initiated already in the second year of the project.

At the facility of one project partner in Germany (primary lead metallurgy), initial batches were tested at the end of 2025, with further trials scheduled for the first quarter of 2026. For a lead battery recycling facility in Austria, preparatory steps for industrial trials have already begun, and the trial campaigns will be carried out in the coming months.

Impact

For industry, the rapid implementation of CO₂ reduction measures is of critical importance. Environmental regulations and rising CO₂ certificate prices are increasing production costs and negatively affecting market competitiveness. Metal production is a highly international business, and competition from regions outside Europe – where production costs are significantly lower than in Central Europe – must therefore be taken into account.

Building on know-how gained from previous projects, intensive research focusing on optimization and upscaling from laboratory to pilot scale, combined with the involvement of the right industrial partners, enabled rapid development and facilitated the timely implementation of the proposed strategy.