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JOM

https://doi.org/10.1007/s11837-019-03766-4
Ó 2019 The Minerals, Metals & Materials Society

SUSTAINABLE PYROMETALLURGICAL PROCESSING

Use of Biochar for Sustainable Ferrous Metallurgy

LEI YE,1 ZHIWEI PENG ,1,4 LIANCHENG WANG,1


ANTON ANZULEVICH,2 IGOR BYCHKOV,2,3 DMITRII KALGANOV,2
HUIMIN TANG,1 MINGJUN RAO,1 GUANGHUI LI,1 and
TAO JIANG1

1.—School of Minerals Processing and Bioengineering, Central South University, Changsha 410083,
Hunan, China. 2.—Chelyabinsk State University, Chelyabinsk, Russia 454001. 3.—South Ural State
University, Chelyabinsk, Russia 454080. 4.—e-mail: zwpeng@csu.edu.cn

Biochar has been extensively used in ferrous metallurgy in recent years as it


has comparable metallurgical properties to coke and coal, showing great
potential for reduction of the production cost of iron and steel with enhanced
quality and for promotion of environmental protection. This article reviewed
the main applications of biochar in the iron and steel industry, including its
use in coking, iron ore sintering, production of metallized pellets, blast furnace
ironmaking, and electric arc furnace steelmaking. The challenges of using
biochar and corresponding promising measures were also discussed for sus-
tainable development of the industry.

on the use of biochar in ferrous metallurgy are


INTRODUCTION
currently available. The aim of this article was thus
Iron and steelmaking is one of the most important to provide a detailed review of the different appli-
industrial sectors affecting global economic growth. cations of biochar in the iron and steel industry. The
Global crude steel production has increased sharply challenges to its applications and promising mea-
in recent years, reaching 1.6912 Bt in 2018, up by sures were also discussed to guide and facilitate its
4.6% compared with 2017.1 During steel manufac- use in the future.
turing, massive amounts of fossil fuels are con-
sumed and a lot of CO2 is released, causing global PHYSICOCHEMICAL CHARACTERISTICS
warming and other climate problems. Specifically, it OF BIOCHAR AND ITS PRODUCTION
accounts for 20% (474 exajoules) of industrial fossil
It is well known that untreated biomass, whether
fuel consumption2 and produces approximately
from crops or wood, cannot be used directly to
6.7% of total global CO2 emissions.3,4
replace traditional fossil fuels in ferrous metallurgy
The most popular technology used for steelmak-
due to its high moisture content, low carbon content,
ing is the blast furnace-basic oxygen furnace (BF-
and low calorific value.7 Depending on the attri-
BOF) process, which accounts for 64.4% of global
butes of the biomass source, biochar has relatively
iron and steel production.5 As the primary fuels and
complex physicochemical properties. Table I pre-
reducing agents in this process, coke and coal are
sents the properties of crop- and wood-derived
the major carbon sources, emitting huge amounts of
biochars in comparison with those of coke and coal
CO2 to the atmosphere. According to the statistics,
used in iron and steel industry.8–12 Obviously, in
production of 1 ton of hot-rolled coil via the BF-BOF
comparison with crop-derived biochar such as that
route is accompanied by emission of 1.8 tons of CO2,
from wheat straw, wood-derived biochars like those
as shown in Fig. 1.6
from acacia and red gum have higher contents of
In recent decades, great efforts have been made to
fixed carbon and volatile matter but much lower ash
seek efficient, environmentally friendly, and sus-
content. They also have lower contents of alkali
tainable substitutes for coke and coal. As one of the
metals (such as K and Na, which are harmful to
main products of renewable biomass in nature,
ironmaking) than wheat straw-derived biochar.
biochar has attracted much attention as a potential
Compared with coal, biochar, especially wood-
substitute due to its good combustibility and reduc-
derived biochar, exhibits many advantages, such
ing ability. However, no in-depth overviews focusing
Ye, Peng, Wang, Anzulevich, Bychkov, Kalganov, Tang, Rao, Li, and Jiang

Fig. 1. CO2 emissions from an integrated steel mill (BF-BOF route). Reprinted with permission from Ref. 6.

Table I. Comparison between properties of biochar, coke, and coal8–12


Property Biochar Coke10–12 Coal11

Acacia8,9 Red gum9 Wheat straw10,11

Chemical analysis (wt.%)


Fixed carbon 79.6 86.3 74.80 85–88 50–55
Volatile matter 15.9 12.4 4.75 1–3 15–30
Ash 4.3 1.3 20.45 > 10 8–11
Moisture 9.59 8.1 7.5 2–4 7.25
Sulfur 0.07 0.02 0.083 0.7–1.2 0.6–0.8
Calorific value (kcal/kg) 6635 5963 6550 6500–7200 5495–9478
Ash composition
SiO2 30 42.3 30.09 40–50 46–64
CaO 46.2 23.8 4.80 2–10 0.9–4.7
Al2O3 7.2 10.2 1.67 30–35 17.4–29.9
Fe2O3 4.3 4.1 1.01 8–13 7.6–14.6
MgO 1.6 3.6 5.09 1–2 1.1–3.2
K2O 3.6 4.3 32.60 0.6 1.0–3.4
Na2O 0.69 1.7 13.24 0.4 0.2–1.0
Volume porosity (%) 54.4 43.5 – 16.6 –
Surface area (m2/g) 43 28 25.1 4.4 –
Bulk density (g/cm3) 1.79 1.53 1.68 2.01 1.72

as higher calorific value, higher fixed carbon potential to significantly mitigate the CO2 emis-
content, lower contents of impurities (e.g., S),13 sions of the iron and steelmaking industry, as the
higher surface area,14,15 and larger porosity,16,17 gas emitted from biochar is negated by the photo-
making it promising to replace coal in the iron and synthesis of the biomass during its growth cycle,
steel industry. Compared with coke, in general, resulting in zero net impact on the
biochar has relatively lower fixed carbon content environment.18,19
and calorific value. However, it contains much less The unique properties of biochar rely on its
ash and impurities such as S. Unlike coal or coke, production technology. The primary technologies
more importantly, biochar also shows the used to produce biochar include torrefaction,20,21
Use of Biochar for Sustainable Ferrous Metallurgy

slow pyrolysis,20,22 fast pyrolysis,20,23–25 gasifica- shown that the biochar had a negative impact on the
tion,26 and hydrothermal carbonization (HTC),27,28 quality of the resulting coke because of the difficult
producing biochar with different yields and carbon fusion of inert biochar particles into the cell wall of
contents, as summarized in Table II. Among these the blended coal during coking, which weakened the
approaches, slow pyrolysis is one of the most connection of the resulting coke particles.30 To
commonly used methods. By this technique, dried enhance the use of biochar in coking, the most
biomass is pyrolyzed to produce biochar and syngas extensively investigated parameters were the addi-
with heat generation (Fig. 2)29 at  400°C and tion percentage and particle size.33,37–39 It has been
atmospheric pressure over a broad range of time- found that, with increasing addition of biochar, the
scales ranging from minutes to days.30 Because of CSR, CRI, and fluidity index of the coke were
the slow heating speed and long processing time, degraded. It is necessary to limit the addition of
most of the coagulable organic compounds in the biochar to less than 2% to prevent its apparent
biomass are converted into solid carbon (biochar), adverse effects on the quality of the coking product.
light gas, and condensable liquid (mainly water, Additionally, as the particle size of the biochar
carboxylic acid, and aldehyde).31 decreased, the CSR and CRI of the coke deterio-
rated. The suitable particle size range for hardwood-
USE OF BIOCHAR IN FERROUS derived biochar was found to be 2.4–3.4 mm. This
METALLURGICAL PROCESSING finding was mainly attributed to the high ash
content and low density of biochar. Compared with
Coking
coarse materials, fine biochar particles with ash
Coke is an extremely important and the most containing alkali metals and alkaline earth metals,
expensive feedstock for iron and steelmaking, being in particular K, Na, and Ca,40,41 distributed more
obtained from nonrenewable specific-rank coals or uniformly in the coking product (Fig. 3)36 and
blended coal using a high-temperature carboniza- increased the reactivity of coke by catalyzing the
tion process (> 1100°C).31,32 It has multiple roles in Boudouard reaction (C + CO2 = 2CO) at high tem-
the BF during ironmaking,33,34 e.g., as an agent for peratures,41,42 thereby deteriorating the two
reduction of reducible oxides and carburization of indexes. Moreover, because of its much higher
hot metals, as the source of about 80% of the heat surface area than coking coal, biochar had a strong
required by the BF for endothermic chemical reac- physical adsorption capacity. It could adsorb the
tions and melting of metal and slag, as a support for decomposition products from coal, causing an
the descending burden to improve the gas distribu- increase of the softening temperature of the coal,
tion and permeability in the BF, etc. In recent years, which eventually inhibited fluidity development
addition of biochar to blended coal to make coke and coke making.43,44 It is clear that controlling
(also known as bio-coke) has become a research the addition and properties of biochar is of great
hotspot.35 However, complete replacement of coals importance for increasing its use in metallurgical
with biochar still faces difficulties because of the coke production.
quality requirements, including high coke strength
after reaction (CSR, > 60%) and low coke reactivity Iron Ore Sintering
index (CRI, 20–30%), which are required to ensure
Iron ore sintering is a vital process that produces
sufficient permeability in the upper part of the BF
sinter, a major iron-bearing burden (70–80%) for BF
shaft and low pressure loss in the furnace. The
ironmaking,45,46 with many advantages over lump
study by Ng et al.36 examined partial replacement of
iron ore. It can contribute to higher productivity,
coking coal with hardwood-derived biochar. It was

Table II. Comparison of different biochar production technologies30


Technology Typical processing Typical Typical biochar yield on dry Typical carbon
temperature residence time feedstock basis content of biochar

Torrefaction  290°C 10–60 min 61–84% 51–55%


Slow pyroly-  400°C Minutes to days  30% 95%
sis
Fast pyroly-  500°C 1s 12–26% 74%
sis
Gasification  800°C  10–20 s  10% NA
HTC  180–250°C 1–12 h < 66% < 70%
NA not available
Ye, Peng, Wang, Anzulevich, Bychkov, Kalganov, Tang, Rao, Li, and Jiang

Fig. 2. Simplified process flowchart of biochar production via slow pyrolysis with heat generation. Reprinted with permission from Ref. 29.

Fig. 3. Optical microscopy images of coke prepared with addition of (a) 5% fine biochar (< 0.07 mm) and (b) 5% coarse biochar (2.4–3.4 mm).
Reprinted with permission from Ref. 36.

lower coke consumption, and enhanced flexibility in sintering were decreased due to the much lower S
adjusting slag basicity.47,48 In this process, iron ore and N contents of biochar. With a suitable replace-
and auxiliary materials, including fluxes (dolomite, ment percentage of biochar (40%), the emissions of
limestone, and quicklime), return fines (< 5 mm), COx, SOx, and NOx could be reduced by 18.65%,
and solid fuels (e.g., coke breeze), are mixed, 38.15%, and 26.76%, respectively.15 The above-
granulated, and then sintered at high tempera- mentioned benefits in reducing emissions of gaseous
tures.49 The sintering process accounts for 9–12% of pollutants were also accompanied by higher sinter-
the total energy consumption in iron and steel ing productivity but weaker strength of sinter. This
production, which is mainly provided by coke finding was partly attributed to the more porous
breeze,50 and for about 12% of the greenhouse gas structure of biochar, which would sustain more
(GHG) emissions from iron and steelmaking moisture than coke breeze and thus demand more
plants,51 as well as other pollutants including SOx, moisture in the granulation of sintering materials
NOx, dioxins, and fine dust.52 In recent years, before sintering (8.5% versus 7.1%). Consequently,
substitution of biochar for coke breeze in iron ore there was a higher H2O (g) concentration in the off-
sintering has become increasingly attractive due to gas of sintering, which would decrease the maxi-
its potential to reduce production costs and to mum sintering temperature and deteriorate the
relieve environmental pressure.9 Gan et al.15 sintering bed permeability, thereby reducing the
reported that partial replacement of coke breeze sinter quality.54 Another reason was associated
with biochar led to a higher concentration of COx with the burning speed of the solid fuel, which
but lower concentrations of SOx and NOx in the off- would increase as the biochar replacement
gas, as shown in Fig. 4.15 The higher concentrations increased because of the much higher reactivity of
of CO and CO2 in the off-gas were attributed to the biochar than coke at high temperatures (700–
larger biochar addition than coke breeze under the 800°C). It was found that, by replacing over 40%
requirement of the return sinter fines balance and coke breeze with biochar, there was an inconsistent
sinter quality. The addition of biochar had to speed of the flame front and heat front during
increase from 3.62% to 4.17%, due to its higher sintering that reduced the combustion efficiency.15
reactivity compared with that of coke breeze, with a The study by Cheng et al.55 showed that the flame
corresponding percentage of biochar replacement front speed increased with increasing replacement
from 0% to 50%.53 However, the COx emissions were of biochar due to its higher specific surface area and
reduced because of the carbon neutrality of biochar. higher intrinsic reactivity than coke breeze. In fact,
Moreover, the emissions of SOx and NOx during the effect of the replacement percentage of biochar
Use of Biochar for Sustainable Ferrous Metallurgy

Fig. 4. Effects of replacing coke breeze with biochar on the concentrations of pollutants in the sintering off-gas: (a) CO2, (b) CO, (c) SO2, and (d)
NO. Reprinted with permission from Ref. 15.

on the strength of sinter was also proved by the typical types of direct reduced iron (DRI), for
examination of two indexes, namely the duration EAF steelmaking is also attractive because of its
time of melting temperature (DTMT) and melting simple route and great environmental benefits.
quality index (MQI). It was revealed that they Usually, these composite pellets are prepared by
reached their peak values at a replacement per- pelletizing a mixture of iron ore concentrates, non-
centage of biochar of 60%. When the replacement coke carbonaceous materials (e.g., coal), and binder.
exceeded 60%, both indexes decreased sharply, It was found that the composite pellets had a higher
indicating serious deterioration of the sinter reduction degree than the ordinary burden materi-
strength. The results of these studies indicate that als in the BF.56 They could act as microreactors57 at
replacing coke breeze with biochar for iron ore high temperature because the iron ore and carbon
sintering is highly promising in terms of environ- particles are in close contact and the CO produced
mental and economic benefits, despite minor nega- could not escape easily, enhancing the reduction
tive impacts on the sinter strength. In order to process.58 Recently, biochar has also been applied to
substitute more biochar for coke breeze in the replace coal in such pellets. Because biochar is a
sintering process, it is necessary to modify the hydrophobic substance, the mechanical strength of
properties of the biochar, such as its microstructure green and dry biochar-containing iron ore pellets
and chemical reactivity. was found to be slightly lower than that without
addition of biochar. However, the gasification of
Production of Metallized Pellets biochar in the pellets was reported to be dozens of
times faster.59 The studies by Matsui et al.59 and Ye
In addition to traditional BF ironmaking, which
et al.60 demonstrated that good-quality metallized
employs sinter and oxidized pellets as main feed
pellets could be obtained with high reduction effi-
materials, preparation of iron ore–carbon composite
ciencies by using biochar as the main carbon source
pellets for production of metallized pellets, one of
in the composite pellets. In particular, according to
Ye, Peng, Wang, Anzulevich, Bychkov, Kalganov, Tang, Rao, Li, and Jiang

Ye et al.,60 oak-derived biochar could be used to especially true for sustaining smooth and efficient
replace coal completely, and superior iron ore– operation of large modern BFs (> 4000 m3), in
biochar green composite pellets with drop number which the biochar replacing coke should possess
of 3.6 times/0.5 m, compressive strength of 11.1 N/p, good cold and hot strengths to ensure the perme-
and decrepitation temperature of 410°C were ability of the shaft, process stability, production
obtained under the optimal pelletizing conditions. efficiency, and hot metal quality. Hanrot et al.72
After microwave reduction at 1050°C for only reported that top charging of 20 kg/tHM of lump
30 min in neutral atmosphere, the composite pellets biochar with high reactivity could reduce the coke
were successfully converted to metallized pellets consumption in the BF by 30 kg/tHM via decreasing
with total iron content of 89.15% and metallization the thermal reserve zone temperature. In fact,
degree of 95.52%, which served as a good burden for decreasing the thermal reserve zone temperature
steelmaking. These findings show that the use of by 100°C can save up to 19 kg of coke/tHM,56,73,74
biochar for production of metallized pellets as DRI is thereby reducing the CO2 emissions. On the other
viable from the perspectives of energy conservation hand, it may also have a negative effect on the
and environmental protection. productivity of BF.72 It was found that, when the
reserve zone temperature decreased to 850°C, 9%
BF Ironmaking CO2 mitigation was achieved with only 4% loss of
BF productivity. Further decrease of the tempera-
In recent years, biochar has been used directly in
ture to 750°C, however, would achieve 12% CO2
BF ironmaking as a fuel to replace coke and
mitigation with up to 14% loss of the productivity.
pulverized coal (PC).61 It has been found that there
Obviously, injecting/charging biochar into BF
is no apparent technological barrier to use of up to
changes the mass and heat transfers, temperature
200 kg biochar/tHM in BF (HM-hot metal).62 As
profile, and gas distribution in the BF, directly
shown in Fig. 5,63 203 kg O2/tHM and 890 kg CO2/
influencing the ironmaking process. Hence, the
tHM can be released and captured, respectively, if
usage of biochar should be carefully controlled to
biochar is used for ironmaking. The biochar can be
optimize performance.
introduced into the BF by tuyeres injection or top
charging (Fig. 6).64 Tuyeres injection provides a
EAF Steelmaking
flexible choice for biochar utilization in large mod-
ern BFs. In this case, the mechanical strength of the Over the past two decades, production of EAF
biochar is not important. According to simulations steel has increased dramatically, partly because of
of biochar injection into BF based on proper models the low CO2 emissions of the short EAF route (0.4 t
(Fig. 7),65 166.7 kg biochar/tHM could fully replace CO2/t crude steel),75 less than a quarter of that
155 kg PC/tHM with a potential energy saving of typical for the BF-BOF route.76 Coke and anthracite
50.2 GWh/year.66 The maximum injection rate of coal are traditionally used as the carbon source for
biochar was in the range of 200–220 kg/tHM, show- EAF steelmaking due to their high fixed carbon
ing the potential to reduce the net CO2 emissions by contents.77 They mainly play three roles at different
40%. Compared with tuyeres injection, however, top stages of the EAF steelmaking process: (1) as a fuel,
charging of biochar is limited (20%),67,68 due to its to provide heat and to consume excessive oxygen
higher contents of K, Na, and Ca compared with during the melting period; (2) as a slag foaming
coke and pulverized coal (Table I).69–71 This is agent, formed by reaction between the carbonaceous

Fig. 5. CO2 and O2 emissions in biochar-based ironmaking.


Use of Biochar for Sustainable Ferrous Metallurgy

Fig. 6. Tuyeres injection and top charging of biochar into BF. Reprinted with permission from Ref. 64.

Fig. 7. Different submodels, zone-specific reactions, as well as inlet and outlet streams in BF. Reprinted with permission from Ref. 65.

materials and residual oxygen, which protects the reactivities of grape seed-derived and pumpkin
equipment by covering the arcs with electricity seed-derived biochar in EAF steelmaking. It was
conservation; and (3) as a steel recarburizer, to found that these crop-derived biochars could obtain
modify the carbon content in the steel.78 In recent reactivities comparable to those of coal employed in
years, replacement of coke and anthracite with the EAF steelmaking process. Besides, grape seed-
biochar for EAF steelmaking has been a research derived biochar was regarded as a more suitable slag
hotspot due to its great potential for reducing foaming promoter due to its high volatile content.
carbon consumption and CO2 emissions.78 Fidalgo Yunos et al.79 also reported that, compared with
et al.77 studied the thermochemical properties and conventional coke, more violent carbon–slag
Ye, Peng, Wang, Anzulevich, Bychkov, Kalganov, Tang, Rao, Li, and Jiang

interactions occurred when palm shell-derived condensable and gaseous co-products (bio-oil and
biochar was used in EAF steelmaking, as demon- syngas, respectively) with higher calorific value,
strated by the higher CO concentration in its gases. which can be used to produce electricity for driving
However, the relatively high content of ash in relevant processes. There is no doubt that large-
biochar may limit its application in EAF steelmak- scale application of these new technologies will help
ing, because alkali metals, such as K and Na, in the to reduce the cost of biochar production, contribut-
ash can promote the reaction between C and O, ing to its broader application in ferrous metallurgy.
leading to unfavorable burn-off behavior in EAF
steelmaking. Furthermore, because of their high CONCLUSION
specific surface area, biochar fines usually show
This article has reviewed the main uses of biochar
high reactivity. To improve their use in EAF
in iron and steel metallurgy, mainly including
steelmaking, pretreatment, such as agglomeration,
coking, iron ore sintering, production of metallized
is believed to be necessary for control of the
pellets, BF ironmaking, and EAF steelmaking.
reactivity.80
Biochar can be used to partially replace blended
coal when its addition and properties are strictly
CHALLENGES TO USE OF BIOCHAR
controlled. In the sintering process, the replacement
AND CORRESPONDING MEASURES
percentage of biochar for coke breeze may reach
The challenges to use of biochar in the iron and 60%, significantly reducing COx, SOx, and NOx
steel industry are primarily related to eco- emissions. For production of metallized pellets, full
nomics.34,81,82 Currently, the price of biochar varies replacement of coal with biochar in iron ore–carbon
from 130.1 to 236.4 USD/t. In terms of price alone, composite pellets is achievable, as the prepared
biochar cannot compete with coal. However, its composite pellets can be converted to qualified
competitiveness could be improved by implementa- metallized pellets for direct steelmaking at low
tion of carbon taxes or application of advanced temperatures within a short period of time. In BF
biochar production technologies. ironmaking, biochar can be used to replace tradi-
The implementation of carbon taxes is regarded tional carbonaceous materials via tuyeres injection,
as the most advantageous measure at the moment having great potential for energy saving and reduc-
because of the carbon neutrality of biochar. Carbon tion of net CO2 emissions by up to 40%. In EAF
taxes in the range of 47.1–198.7 USD/t-CO2 may steelmaking, biochar may play multiple roles, e.g.,
apply, depending on the country,83 exceeding the as a fuel, slag foaming agent, and steel recarburizer,
value of 30–35 USD/t-CO2 required to ensure thereby improving the steelmaking process. To
roughly equal overall costs of biochar and coal.68 overcome the economic barriers restricting the
In addition, as high-quality metallurgical coke and application of biochar in iron and steel industry,
coal are continuously consumed, the price difference implementation of carbon taxes and use of advanced
between biochar and traditional carbon sources will pyrolysis techniques, such as flash carbonization
decrease. and microwave pyrolysis, are deemed most effective.
From the perspective of technology, reducing It is believed that, with the support of policy and
biochar production costs by employing advanced new technological advances, biochar will have wider
biomass pyrolysis techniques, instead of the tradi- and more efficient applications in ferrous metal-
tion method of pyrolysis in a kiln,8 is another option lurgy in the future.
for enhancing utilization of biochar in ferrous
ACKNOWLEDGEMENTS
metallurgy. Flash carbonization, for example, is a
novel technology that has emerged in recent years. This work was partially supported by the Na-
It was reported that rapid pyrolysis of biomass tional Natural Science Foundation of China under
(< 30 min) can be achieved by flash carbonization Grants 51811530108, 51504297, 51881340420, and
technology at 300°C to 600°C at inner reactor 51774337, the Natural Science Foundation of Hu-
pressure of 1–2 MPa, with typical carbon content nan Province, China under Grant 2017JJ3383, the
and biochar yield of  85% and 37%, respectively.84 Co-Innovation Center for Clean and Efficient
It was estimated that a flash carbonization demon- Utilization of Strategic Metal Mineral Resources
stration reactor (U1.73 m 9 H2.74 m) with output under Grant 2014-405, the Guangdong Guangqing
of 8.4 t/d of fixed carbon will have a very short Metal Technology Co. Ltd. under Grant 738010210,
payback period of 1.3 years, indicating a good the Innovation-Driven Program of Central South
economic profit. Besides flash carbonization, micro- University under Grant 2016CXS021, the Shen-
wave pyrolysis is also considered to be a promising ghua Lieying Program of Central South University
technology. A comparison between conventional and under Grant 502035001, the Fundamental Re-
microwave pyrolysis of biomass to biochar was search Funds for the Central Universities of Central
carried out by Gronnow et al.85 The energy con- South University under Grants 2018zzts798,
sumption of conventional pyrolysis is about three 2018zzts779, 2018zzts220, 2018zzts222, 2019zzt-
times that of microwave pyrolysis. Additionally, s174, and 2019zzts706, the Russian Foundation for
microwave pyrolysis of biomass can produce Basic Research under Grants 18-58-53055 GFENa
Use of Biochar for Sustainable Ferrous Metallurgy

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