PyroGenesis Successfully Produces Battery-Grade Carbon Black and Hydrogen Using Plasma Torch Technology

PyroGenesis Inc. announced the successful production of battery-grade carbon black and hydrogen from its proprietary DC plasma torch system. The process uses natural gas and methane as both the plasma-forming gas and primary hydrocarbon feedstock, converting them directly into carbon black and hydrogen without secondary raw material inputs or additives.

The resulting carbon black exceeded battery-grade requirements across key specifications including ash content, metallic purity, surface area, and tapped density, as verified by independent testing. PyroGenesis claims to be the first company to successfully employ hydrocarbons as both plasma-forming gas and primary feedstock in a DC plasma torch for this application.

The achievement stems from a $1 million pilot-scale project initiated in September 2024. The plasma-based process differs from conventional carbon black production methods, which rely on combustion or thermal decomposition of heavy hydrocarbon residues. The PyroGenesis approach is described as combustion-free, emission-free, and additive-free.

Carbon black represents a significant industrial commodity, comprising 25-30% of vehicle tire composition and serving applications in rubber, plastics, coatings, and battery systems. The global carbon black market was valued at approximately $24.5 billion in 2025 and is projected to reach $36.1 billion by 2033.

Next steps include developing additional materials output, advancing toward commercial-scale production, and integrating the produced hydrogen into gas grid infrastructure.

Originally reported by Hydrogen Central. Read the full article →