HYPLASMA® TECH · METHANE PYROLYSIS
Clean hydrogen and carbon black, from (bio)methane.
Modular, turnkey production units adapted to industrial operating requirements: the plasma arc splits methane into hydrogen and solid carbon, with no combustion and no direct CO₂.
Up to 3x
Less electricity than electrolysis
per kilogram of hydrogen produced
0 kg CO₂
Direct emissions
no combustion, no oxidation
1–6 barg
Operating pressure
compact, pressurised design
2 sizes
100 kW unit · 2 MW plant
containerised, or a three-floor structure
How it works
CH₄ → 2H₂ + C. No combustion, so no direct CO₂.
The plasma arc splits methane directly into hydrogen and solid carbon. Unlike steam reforming, nothing is burned or oxidised.
1
(Bio)methane in — natural gas, biogas or flare gas, 1–6 barg.
2
Three-phase plasma arc — above 3,000°C; the arc’s motion mixes the gas, no oxygen involved.
3
Hydrogen and solid carbon out — two valuable products, zero direct CO₂.
1
(Bio)methane in — natural gas, biogas or flare gas, 1–6 barg.
2
Three-phase plasma arc — above 3,000 °C; the arc’s motion mixes the gas, no oxygen involved.
3
Hydrogen and solid carbon out — two valuable products, zero direct CO₂.
Inside the unit
From gas skid to carbon filter.
The whole process in one containerised unit: power and control, gas feed, the plasma reactor and the carbon separation.
Control cabinets
Power supply and control of the plasma torch.
Gas skid
Meters the methane, and the inert gas used for start-up and cleaning.
Plasma torch
The three-phase torch on top of the reactor, where methane splits into hydrogen and carbon.
Carbon filter
Separates the solid carbon from the hydrogen; a screw conveyor carries it out.
Control cabinets
Power supply and control of the plasma torch.
Gas skid
Meters the methane, and the inert gas used for start-up and cleaning.
Plasma torch
The three-phase torch on top of the reactor, where methane splits into hydrogen and carbon.
Carbon filter
Separates the solid carbon from the hydrogen; a screw conveyor carries it out.
Technical features
The most cost-effective route to clean hydrogen.
Combined valuable products
Clean hydrogen and high-value solid carbon in a single process, without direct CO₂. Conventional routes rely on separate, energy-intensive processes for hydrogen production and carbon handling.
Competitive cost
Low, stable production costs compared with conventional low-carbon hydrogen. Methane pyrolysis needs far less electrical energy per kilogram of hydrogen than water electrolysis, and the solid carbon co-product adds a revenue stream. Limited maintenance, economical consumables and no AC/DC rectifier keep the architecture simple.
No carbon bill
SMR pays around €0.70/kg H₂ in CO₂ costs at today’s EU ETS price. HyPlasma® emits no direct CO₂, so there’s nothing to pay, and that gap grows as the carbon price rises.
Indirect emissions depend on your electricity mix and gas source.
Low footprint
An optimised, pressurised design: operating at up to 6 barg reduces internal gas volumes and downstream equipment size, so the plant fits existing industrial sites where space is critical.
Competitive cost
What a kilogram of hydrogen costs in Europe.
In 2026, HyPlasma is slightly cheaper than steam methane reforming once SMR’s carbon cost is counted, and 2.4 times cheaper than electrolysis. Select a year to see the values.
SMR pays for the CO₂ it emits; HyPlasma® has no direct CO₂, so its cost does not move with the carbon price. Pick a year, then move the carbon price.
SMR + carbon cost = SMR + carbon price × about 10 kg of CO₂ per kg of hydrogen, the ratio in the figures of the first view.
Sources: European Hydrogen Observatory, ACER, Eurostat, SDES, EDF, NaTran, European Commission, Trading Economics, Burckhardt Compression. HyPlasma®: Plenesys estimate. EU averages, € per kg of hydrogen.
SEE THE REACTION
Methane in. Hydrogen and solid carbon out.
This animation illustrates the methane pyrolysis reaction inside the HyPlasma reactor, resulting in hydrogen and solid carbon.
Specifications
Start at 100 kW. Scale to 2 MW.
Specifications can be adapted to project-specific requirements.
100 kW unit
Containerised · 2 containers
2 MW plant
Three-floor structure · ~100 m²
- POWER
100 kW unit
30–100 kW
2 MW plant
2 MW
- HYDROGEN OUTPUT
100 kW unit
1 to 7 kg/h8.5 to59.5 t/year
2 MW plant
20 to 140 kg/h170 to 1,190 t/year
- SOLID CARBON OUTPUT
100 kW unit
3 to 21 kg/h25.5 to 178.5 t/year
2 MW plant
60 to 420 kg/h510 to 3,570 t/year
- OPERATING PRESSURE
100 kW unit
1–6 barg
2 MW plant
1–6 barg
- GAS FEEDSTOCK
100 kW unit
Natural gas, biogas, flare gas…
2 MW plant
Natural gas, biogas, flare gas…
- ELECTRICAL INPUT
100 kW unit
380/400 VAC · 3-phase · 50 Hz
2 MW plant
380/400 VAC · 3-phase · 3 MVA
- CONSUMABLES
100 kW unit
Graphite electrodes · inert gas for start-up and cleaning
2 MW plant
Graphite electrodes · inert gas for start-up and cleaning
- FOOTPRINT
100 kW unit
2 containersContainerised
2 MW plant
~100 m²3-floor structure
Highlighted rows are the two product outputs: hydrogen and solid carbon.
SECTORS
Two products, two markets.
Hydrogen production
Low-carbon H₂ on site, from the gas you already have.
Carbon production
Solid carbon as a product, not an emission.
Our products
Plasma Torch
The three-phase torch at the heart of every HyPlasma® unit.
Services
Pilot testing
Measured yields and carbon grades on your own gas.