Reduction Behavior of Biochar-in-Plant Fines Briquettes for CO₂-Reduced Ironmaking

Blast furnace (BF) ironmaking remains one of the most efficient countercurrent processes; however, achieving further CO₂ emission reductions through conventional methods is increasingly challenging. Currently, BF ironmaking emits approximately 2.33 tonnes of fossil-derived CO₂ per tonne of crude steel cast. Integrating briquettes composed of biochar and in-plant fines into the BF process offers a promising short- to medium-term strategy for lowering emissions. This approach enables efficient recycling of fine residues and the substitution of fossil reductants with bio-based alternatives, thereby improving productivity while reducing energy and carbon intensity. This study investigates the reduction behavior of (i) biochar mixed with pellet fines, (ii) various in-plant residues individually, and (iii) briquettes composed of biochar and in-plant fines. The reduction rate of biochar–pellet fine mixtures was found to depend on biochar type, with pyrolyzed pine sawdust exhibiting the highest reactivity, and pyrolyzed contorta wood chips the lowest. A correlation between reduction rate and the alkali index of each char was established, although other factors such as char origin and physical properties also influenced reactivity. The effect of biochar addition (0, 5, and 10 wt.%) on the reduction of steelmaking residues was also studied. In general, biochar enhanced the reduction degree and shifted the reaction onset to lower temperatures. The produced briquettes maintained high mechanical integrity during and after reduction, regardless of biochar origin. Thermogravimetric and XRD analyses revealed that mass loss initiates with the dehydroxylation of cement phases and release of volatiles, followed by carbonate decomposition and reduction of higher oxides above 500 °C. At temperatures ≥850 °C, the remaining iron oxides were further reduced to metallic iron.