6–9 Oct 2025
Palaexpo Veronafiere
Europe/Rome timezone
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Design of a sustainable iron ore smelting system using biochar-based direct reduction and CO₂ sequestration to lower steel’s carbon footprint in Marcegaglia site at Ravenna port

8 Oct 2025, 15:40
20m
Margherita I (Palaexpo Veronafiere)

Margherita I

Palaexpo Veronafiere

Veronafiere, Viale del Lavoro 8, 37135 Verona
Oral Presentation CO2 mitigation in iron and steelmaking Direct Reduction & Alternative Ironmaking

Speakers

Prof. Carlo Mapelli (Dipartimento di Meccanica - Politecnico di Milano)Dr Gianluca Dall'Osto (Dipartimento di Meccanica - Politecnico di Milano)

Description

Steel production is a major contributor to global CO₂ emissions, primarily due to the reliance on coking coal in conventional iron ore reduction processes. This study proposes an innovative system for the direct reduction of iron ore through a smelting process utilizing biochar as a renewable reducing agent, coupled with efficient CO₂ capture to minimize the carbon footprint of steelmaking.
Biochar, produced via biomass pyrolysis, offers a carbon-neutral or even carbon-negative reduction pathway. In the proposed system, iron ore is smelted in a high-temperature reactor where biochar acts as both a reductant and a source of renewable carbon. The process leverages the high reactivity and low impurities of biochar to facilitate efficient iron oxide reduction while minimizing slag formation. The resulting CO₂ emissions are then captured using post-combustion sequestration techniques, such as amine scrubbing or mineral carbonation, ensuring near-zero emissions.
Preliminary assessments indicate that this approach could reduce CO₂ emissions by up to 80% compared to traditional blast furnace methods. Additionally, the integration of biochar—derived from agricultural or forestry waste—enhances circular economy principles by valorizing biomass residues. The reactor design, biochar properties, and CO₂ sequestration efficiency will be faced to enable the industrial scalability. This system presents a viable transitional pathway toward greener steel production, aligning with global decarbonization goals while maintaining cost-effectiveness and material performance.

Primary authors

Dr Aldo Fiorini (Marcegaglia) Dr Alessandro Ferraiuolo (Marcegaglia) Prof. Carlo Mapelli (Dipartimento di Meccanica - Politecnico di Milano) Davide Mombelli (Dipartimento di Meccanica - Politecnico di Milano) Dr Gianluca Dall'Osto (Dipartimento di Meccanica - Politecnico di Milano) Dr Sara Scolari (Dipartimento di Meccanica - Politecnico di Milano)

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