with plasma technology for decarbonization

Converting industry to climate-neutral process heat is one of the major challenges of the energy transition. High-temperature processes such as cement production or glass melting have traditionally relied almost exclusively on fossil fuels due to their high energy density. Currently, most of this heat is generated by burning fossil fuels such as natural gas or process gases. Achieving climate-neutral production processes necessitates the gradual replacement of these fossil fuels with sustainable energy sources like green electricity or hydrogen.

  • glass melting: 1450°C-1650°C; current energy sources: natural gas, heavy oil, electricity

  • cement production: clinker burning process, calcination, up to 900°C; current energy sources: waste-based fuels, coal

  • sintering: up to 1450°C

  • CFC decomposition: 1400°C

In addition to the use of hydrogen, plasma technology offers a revolutionary method for providing heat at temperatures exceeding 1200°C directly using (green) electricity. In this process, a carrier gas such as water or air is heated to high temperatures by an electric arc. The gas escaping from the burner can be used as a heat exchanger and also allows the generated radicals to act as reactants for targeted chemical reactions. This method not only replaces fossil fuels but also enhances process efficiency and reduces greenhouse gas emissions.

plasma source plasma gas performance area use
PBR water steam, air, oxygen 5-120 kW

disposal of CFC waste

pyrolysis of waste

conditioning of synthesis gas
PBI nitrogen, hydrogen 5-40 kW plasma abatement systems for the semiconductor industry,

methane pyrolysis
PBC methane, hydrogen, methane-hydrogen 50-120 kW hydrogen production,

production of turquoise hydrogen
PlasmaAir has been at the forefront of developing light-pickled plasma torches for over 20 years, leveraging them for various industrial applications. Recent advancements in plasma technology have focused on enhancing application versatility, output capacity, and the variety of plasma gases used, specifically tailored for energy transition applications. For instance, the output for water vapor plasma sources has been significantly increased from 20 kW to over 100 kW, enabling their use in pyrolysis processes, such as the conversion of plastic waste for hydrogen production.

The use of methane and CO2 as plasma gases is gaining traction. Methane pyrolysis (decomposition of natural gas or biogas) serves as a critical component for hydrogen production (turquoise hydrogen), consuming three times less energy than electrolysis. Carbon dioxide, when used as a plasma gas and circulated within the system, can act as a CO2-neutral heat transfer medium, offering a sustainable alternative for processes like pyrolysis or cement production.

PlasmaAir AG provides turnkey plasma systems, including essential accessories such as power supplies and process control systems. The plasma sources themselves can be individually adapted for installation on or in reactors, ensuring seamless integration into existing industrial processes.

Impact on the Energy Transition: The adoption of plasma technology in high-temperature processes represents a significant stride towards decarbonization. By enabling the use of green electricity and reducing reliance on fossil fuels, plasma technology supports the broader goals of reducing greenhouse gas emissions and mitigating climate change. This innovative approach not only aligns with global sustainability targets but also paves the way for more efficient and eco-friendly industrial practices, contributing substantially to the energy transition.

Plasma torch with methane as plasma gas,      50 % electrical and 50 % chemical output