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PyroGenesis Converts Plasma Gas to Battery-Grade Carbon Black and Hydrogen

PYRGF
  • PyroGenesis successfully produced battery-grade carbon black & hydrogen using a proprietary plasma torch system powered by natural gas or methane.
  • The process converts hydrocarbon feedstock directly into solid carbon & H2 without requiring secondary raw materials, additives, or combustion.
  • Independent testing confirmed the carbon black exceeded battery-grade requirements for ash content, metallic purity, surface area, & tapped density.
  • This achievement marks the first instance of using hydrocarbons as both plasma-forming gas & primary feedstock in a DC plasma torch for this application.
  • The project involved a $1 million Phase 1 contract for designing & delivering a customized pilot-scale reactor & testing infrastructure.
  • President & CEO P. Peter Pascali stated the method is cleaner, simpler, & emission-free compared to conventional furnace or thermal black production.
  • The simplified DC plasma platform is expected to lower capital costs, construction expenses, & logistics related to raw material storage.
  • Next steps include developing additional material outputs, advancing toward commercial-scale production, & integrating the produced hydrogen into the gas grid.
  • The global carbon black market was valued at approximately US$24.5 billion in 2025 & is projected to reach US$36.1 billion by 2033.