A joint Australia India research effort has shown that agricultural waste can partly replace coal in steel production, offering a potential pathway to reduce emissions in one of the world’s most carbon-intensive industries.
Researchers from Australia’s national science agency, CSIRO, and the Indian Institute of Science conducted a full-scale trial in India using rice husk pellets to generate biomass-derived synthesis gas for iron ore reduction. The test was carried out at a commercial steelworks operated by Jindal Steel in Odisha in partnership with RESCONS Solutions Pvt., a steel technology company incubated at the Foundation for Science, Innovation and Development at IISc.
Steel production accounts for roughly one-tenth of global carbon emissions. India’s steel sector, the fastest growing in the world, currently produces an average of 2.55 tonnes of carbon dioxide for every tonne of steel, above the global average of 1.8 tonnes.
“This trial is a world-first demonstration of how agricultural waste can be harnessed to decarbonise steelmaking at scale. By blending rice husk pellets into commercial gasifiers, we’ve shown that biomass can replace coal without compromising performance. This is a major step forward for sustainable steel production in India and globally,” said Warren Flentje, Senior Experimental Scientist at CSIRO.
During the trial, researchers blended five and ten per cent rice husk pellets into Jindal Steel’s gasifiers. The process produced a steady flow of biomass-derived syngas used to reduce iron ore, while maintaining normal operating performance.
If the method were adopted across India’s steel sector, researchers estimate emissions could fall by as much as 50 per cent, amounting to about 357 million tonnes of carbon dioxide a year.
India’s steel industry is expanding rapidly. Production capacity is projected to reach 300 million tonnes by 2030 and 500 million tonnes by 2047. The sector currently accounts for around 12 per cent of the country’s total emissions, largely because many facilities rely on coal-based processes and direct reduced iron kilns.
Keith Vining, Research Group Leader for Green Metals Production at CSIRO, said the collaboration addressed both industrial emissions and regional resource use.
“India’s steel sector is both a major employer and a source of emissions. Our partnership with the Indian Institute of Science and JSPL has demonstrated that biomass can be a viable alternative to coal, especially in regional areas where surplus agri-waste and coal DRI facilities co-exist. The next phase will focus on increasing biomass replacement rates and assessing impacts on the direct reduction process.”
India generates large volumes of agricultural residues each year. Surplus crop residue biomass has been estimated at more than 228 million tonnes. Much of this material is currently burned in fields, contributing to poor air quality in parts of the country.
Researchers say redirecting some of that waste into steel production could reduce emissions while limiting the need for open burning. Biomass use in steelmaking could lower net emissions by roughly 1.19 tonnes of carbon dioxide for every tonne of crude steel produced.
The project forms part of the India Australia Green Steel Research Partnership supported by the Australian Government. As part of the effort to support wider adoption, the CSIRO and RESCONS team has created an online map showing India’s steel plants alongside regional biomass supplies. The tool is designed to help companies assess where biomass-based production could be viable.
Professor Govind S. Gupta, Managing Director of RESCONS Solutions, said the collaboration reflects an effort to combine research with industrial practice.
“At RESCONS Solutions, we believe in environmentally sustainable solutions that benefit present and future generations. Collaborating with CSIRO and IISc, we are proud to help pioneer the use of biomass in steelmaking, supporting India’s transition to greener industrial practices.”
India’s government has outlined plans to achieve net zero emissions by 2070. Policy discussions include greater use of electric arc furnaces, expanded recycling of scrap steel, carbon capture and storage, green hydrogen and biomass-based fuels.
Damodar Mittal, Executive Director at Jindal Steel, said the trial formed part of the company’s wider shift toward lower emission production.
“This collaboration marks a pivotal moment in our journey towards decarbonisation using green hydrogen and green energy, accelerating our transition to lower-emission steel. By integrating green energy and biomass into our production processes, we are not only reducing our carbon footprint but also setting a new benchmark for the Indian steel industry.”
Researchers say further trials will now examine how the process performs in smaller regional facilities and with additional biomass sources.
A spokesperson from the Indian Institute of Science said innovation in production methods could reshape how steel is made in the decades ahead.
“Conventional steel production is highly carbon intensive, but process innovations like biomass gasification and hydrogen reduction can drastically lower emissions. Our partnership with CSIRO is helping to bring carbon neutrality to steel production by 2050.”
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