Future-fit Waste Management: Where Carbonisation Belongs

Continuous carbonisation technology is emerging as a key building block in a future-fit waste management portfolio, rather than a replacement for existing processes.

As long as humans occupy Earth, managing waste will remain a critical and increasingly complex task. With the global population projected to reach nearly 9.7 billion by 2050 (including about 371 million people in the US and between 35 and 38 million in Australia), the volume of waste generated is accelerating, placing unprecedented strain on landfills, treatment infrastructure and ecosystems. At the same time, PFAS concerns, rising landfill costs, circular economy and net zero commitments, tightening regulations and heightened community awareness are reshaping how councils and utilities approach waste disposal.

From single pathway to portfolio

For wastewater utilities, this pressure is driving a shift away from single pathway solutions like land application towards diversified, future-fit waste management portfolios.

Logan Water was a pioneer in Australia, partnering with Pyrocal to install Australia’s first biosolids carbonisation facility at their Loganholme WWTP. This project provided the regulatory pathway in Queensland for operating approvals and end-of-waste code for land application of biosolids biochar.

“We are pleased to now see Sydney Water adding carbonisation as an extra layer to its existing biosolids and organics toolkit at their North West Treatment Hub,” says Pyrocal CEO Barry Croker.

“By adding carbonisation to the mix, they will be able to turn biosolids into biochar, cutting volumes, reducing haulage costs and creating a more stable, valuable product destined for farmlands and other uses – not our landfills

“Projects like this show how leading utilities are bringing carbonisation into their portfolios; Pyrocal’s CCT systems offer councils and utilities a proven pathway to achieve similar outcomes.”

Science backs the shift

This portfolio approach is reinforced by recent independent research on food organics and garden organics (FOGO) waste. A 2025 study by Habiba Sarwar published in Biomass and Bioenergy, examined FOGO-derived digestate treated via anaerobic digestion followed by high temperature pyrolysis.

The study found that optimised systems can cut biosolids-bound PFAS by more than 90%, with PFAS in the resulting biochar often below detection limits and very low levels in treated offgas when a thermal oxidiser is used.

Although focused on FOGO, the work demonstrates that combining biological processes with downstream carbonisation is a credible part of a multi-pathway, PFAS-aware strategy, not a vendor claim.

Turning expensive liabilities into assets

Already deployed at Loganholme WWTP in Queensland and now being built for the Capital Regional District in British Columbia, Canada, Pyrocal’s Continuous Carbonisation Technology (CCT) is a commercially proven solution that is ready to go.

“Our CCT system gives clients a reliable, flexible solution: it runs year-round, takes multiple organic feedstocks, recovers heat and produces high quality biochar, unlocking new revenue streams, high integrity carbon credits and a host of circular economy benefits,” Croker says.

At Loganholme, volume reduction alone saves the council around AU$1 million per year, converting what was a disposal line item into marketable products and freeing up landfill capacity. Because biochar can qualify as durable carbon removal in voluntary markets, the carbon credits it generates stand up to regulator and community scrutiny, turning a costly waste problem into a de-risked, income generating asset.

social licence and the pfas risk

The conversation around PFAS in the environment is getting louder: consumers are increasingly choosing PFAS-free products while attention is turning to PFAS in drinking water, soils and the food chain – something they have little control over.

“Our CCT system gives clients a reliable, flexible solution: it runs year-round, takes multiple organic feedstocks, recovers heat and produces high quality biochar, unlocking new revenue streams, high integrity carbon credits and a host of circular economy benefits,” Croker says.

Sarwar’s FOGO and pyrolysis study provides independent backing: it shows that well designed pyrolysis systems can achieve high PFAS reduction in solids and that, with robust offgas treatment, emissions remain low. This aligns with testing on Pyrocal’s CCT system, which indicates it can destroy a significant proportion of PFAS and microplastics in biosolids, further strengthening its role within a risk managed portfolio.

PLUG-AND-PLAY with existing infrastructure

Pyrocal’s CCT systems are designed to bolt onto existing treatment sites, integrating with drying, digestion and other upstream equipment.

“It’s a high value outlet for solids without scrapping current assets,” explains Croker.

For any utilities planning 10-to-20-year upgrades, CCT is a modular, scalable, easy-to-maintain building block that can start at one plant and then expand across a region as PFAS policy tightens and biosolids land application rules evolve.

“From feasibility and design to biochar marketing, carbon credits and maintenance support, we offer our clients a comprehensive service that ensures the project is set up for success from day one,” Croker concludes.

The emerging body of research, especially on FOGO digestate, anaerobic digestion and pyrolysis, adds weight to this approach: future-fit waste management will rely on multiple, complementary pathways, with continuous carbonisation providing one of the most flexible and PFAS resilient options in the mix.