A breakthrough technology developed at RMIT University is poised to transform the production of sustainable bio-oils, offering a cost-effective and environmentally friendly alternative to petroleum-based products used in electronics, construction, and automotive industries.
PYROCOTM, the new technology, employs high-temperature pyrolysis — heating treated sewage (biosolids) in the absence of oxygen — to convert waste into a carbon-rich material known as biochar.
This biochar acts as a catalyst for producing phenol-rich bio-oil, a key ingredient in manufacturing resins, lubricants, and industrial additives.
Developed in collaboration with South East Water, Intelligent Water Networks, and other water authorities, PYROCOTM is now being applied to several circular economy initiatives.
The latest research, conducted with the Indian Institute of Petroleum and published in Renewable Energy, demonstrates that biochar derived from biosolids can effectively replace expensive commercial catalysts in extracting oil from biomass such as Willow Peppermint, a native Australian plant.
The study found that using biochar as a catalyst not only reduces costs but also significantly lowers carbon dioxide emissions by replacing high-emission products.
Experiments produced bio-oil with high concentrations of phenolics (69 per cent) and hydrocarbons (14 per cent), confirming the effectiveness of the biochar catalyst.
Professor Kalpit Shah, Deputy Director (Research) of the ARC Training Centre for the Transformation of Australia’s Biosolids Resource at RMIT, announced that PYROCOTM is nearing commercial readiness.
RMIT and its partners — Aqua Metro, South East Water, and Iota — have secured $3 million in federal funding to construct a commercial-scale demonstration plant (Mark-3) at a South East Water recycling facility next year.
“Our upcoming project aligns with the Global Waste Management Policy and Australia’s National Waste Policy Action Plan.
“Our goal is to prevent PFAS-contaminated biosolids from being disposed of in landfill by converting them into PFAS-free biochar, for its diverse applications,” Shah said.
The initiative is supported by an additional $3 million from South East Water and aligns with the latest PFAS National Environment Management Plan 3.0, reflecting a strong commitment to environmental sustainability and regulatory compliance.
RMIT has filed patent applications for PYROCOTM and selected Iota as its commercialisation partner.
Recent trials at the Melton Recycled Water Plant (Mark-2 unit) have successfully processed biosolids from five different utilities, removing pathogens, PFAS, and microplastics, and paving the way for large-scale deployment.
South East Water Managing Director Lara Olsen highlighted the environmental significance, stating: “We’re tackling a national challenge by harnessing cutting-edge technology with the potential to destroy 99.99 per cent of PFAS in biosolids.
“The PYROCO project reflects our vision of innovating with purpose to protect our environment for future generations.”
Aqua Metro CEO Manish Pancholi added: “We see a unique opportunity for this technology to provide significant decarbonisation, environmental and circular-economy benefits to the water industry and potentially other industries and are looking forward to proving the PYROCO technology at scale.”
According to the International Biochar Initiative, the global market for biochar could reach $3.3 billion by next year, underscoring the commercial and environmental promise of the technology.
The latest RMIT study, conducted with Dr Thallada Bhaskar’s group at the Council for Scientific and Industrial Research – Indian Institute of Petroleum, is published in Renewable Energy.
With its proven ability to convert waste into valuable, sustainable products, PYROCOTM stands at the forefront of Australia’s efforts to build a circular economy and reduce industrial reliance on fossil fuels.
