Advancing plasma technologies from lab to industrial scale for a circular chemical industry

Development of a modular plasma reactor for methane pyrolysis.

Paco will present the development of a modular 50-kW plasma reactor for methane pyrolysis — a cutting-edge approach to electrify chemical processes and reduce greenhouse gas emissions.

His work within the “Plasma Conversion of Methane” project focuses on converting methane into valuable products like acetylene and ethylene, while tackling challenges such as soot formation, extreme temperatures, and complex nonlinear physics. By combining multiphysics simulations with experimental validation, the team aims to scale this technology to industrial levels — paving the way for a more sustainable chemical industry.

Turquoise Hydrogen via Methane Plasmalysis – Decarbonizing Industry with Solid Carbon Co-Products
The presentation will introduce Graforce’s methane plasmalysis technology, which produces CO₂-free turquoise hydrogen and high-value solid carbon. Key focus areas include process efficiency, scalability, integration into existing industrial infrastructure, and the economic and environmental advantages compared to conventional hydrogen production. The talk will also highlight market applications for the solid carbon co-product and its role in accelerating industrial decarbonization.

Plasmas for Resource Utilization: Methane Pyrolysis and Iron Making
Plasma-enabled methane pyrolysis and iron ore reduction are two emerging areas of interest in how plasmas can be leveraged for resource utilization. Methane pyrolysis enables the production of hydrogen and solid carbon with energy efficiencies significantly exceeding those of conventional electrolysis. The iron and steel industry is the largest industrial emitter of CO₂. Replacing carbon-based energy carriers with hydrogen and electricity could eliminate these emissions, producing only the environmentally friendly byproduct H₂O. However, thermodynamic constraints present challenges, as reducing iron ore with hydrogen requires temperatures above 900 K. Hydrogen plasmas have recently been proposed as a promising solution to overcome these thermodynamic limitations. In this presentation, we will discuss ongoing research in this area and highlight a collaboration with an industrial partner that led to the development of unique diagnostic tools for probing the fundamental processes underlying plasma–iron oxide interactions.

From the Fertiliser Industry – A Critical Reflection
This presentation offers a thought-provoking journey through the evolution of the nitrogen industry — from its historical roots to the urgent paradigm shift now underway. It explores the agronomic debate between ammonia vs. nitrates, the implications for food security, and the tension between centralized and local production units. Rune Ingels will also address how the industry and authorities have turned away from key innovations, raising the question: what’s next for sustainable fertiliser production? Expect insights into both the technical and societal dimensions of fertiliser production in a changing world.

Plasma Chemistry for the Energy and Materials Transition of the Process Industry

Achieving a carbon-neutral and circular economy requires the use of waste materials and biomass as feedstocks for producing new materials. The energy input for such processes must be carbon-free, relying primarily on intermittent renewable electricity. Plasma technology offers promising solutions to some of the key challenges in this transition. Its compatibility with fluctuating energy sources and its ability to drive efficient and selective reactions with molecules like CO₂, N₂, and CH₄ make it a powerful tool for sustainable innovation. This presentation focuses on the valorization of methane via carbon coupling, showcasing plasma’s potential for the direct production of ethylene (C₂H₄) — a crucial building block in the chemical industry. These insights contribute to a roadmap for industrial-scale implementation of plasma-based processes at Chemelot.

Scaling Up Plasma Technology for Decarbonization of the Chemical Industry

Plasma processes are already widely applied in the high-tech sector, but their use in the chemical industry remains limited. In recent years, however, plasma chemistry has gained renewed attention — driven by the growing urgency to reduce CO₂ emissions and the increasing availability of green electricity. Plasma technology offers the potential to enable fully CO₂-free chemical processes on an industrial scale, powered by renewable energy. As high-temperature fossil-based processes lose relevance, electrified alternatives like plasma chemistry are becoming increasingly attractive. Yet, significant development is still needed, particularly in scaling the technology from lab to industrial scale. This presentation highlights methane valorization as a compelling use case — a “forgotten option” for sustainable chemistry. In 2024, Brightsite announced the spin-out Thoriant, focused on using plasma technology to convert methane into emission-free hydrogen, acetylene, and ethylene.