Environmental and economic assessment of biochar production systems from agricultural residues

The agricultural sector urgently requires scalable solutions to reduce greenhouse gas (GHG) emissions from residue management. Biochar offers a promising carbon removal pathway, but its adoption is limited by technical, regulatory, and economic barriers. A key constraint is the lack of system designs that can accommodate multiple feedstocks while complying with land application regulations. This study designs and evaluates an integrated biochar production system that enables the separate processing of straw and manure through parallel pyrolysis lines, while optimising internal energy use. Environmental and economic assessments were conducted using a case study of the University of Leeds Research Farm, under a cradle-to-grave system boundary. The results show that the system can produce 300 t of biochar annually, sequester 350 t CO₂e, and reduce manure management emissions by 75%, with an additional 30 t CO₂e avoided through surplus heat utilisation. The carbon abatement cost is estimated at £226 per t CO₂e, primarily driven by capital (38%), operational (32%), and electricity (30%) costs. Sensitivity analysis highlights that straw availability, determined by both yield and crop rotation, is the primary factor influencing system performance. Among the mitigation strategies for addressing heat shortfalls, procuring external straw is identified as the most effective option. This study presents a novel and adaptable system framework for on-farm biochar deployment, addressing key barriers to implementation. The findings provide quantitative insights into the trade-offs between cost, carbon removal, and design decisions, and offer a foundation for scaling biochar use across the agricultural sector.

The online version contains supplementary material available at 10.1007/s42773-025-00527-2.