Hypersonic Technologies is turning methane into hydrogen and carbon black

Chennai-based startup Hypersonic Technologies is developing an innovative process to convert methane and biomethane into both hydrogen and carbon black using a method called staged-plasma pyrolysis. This dual output technology aims to help industries decarbonize while monetizing both hydrogen and carbon black, instead of relying on hydrogen revenue alone.

Founded in 2023 by Jayaraman Kandasamy and Jayakumar Venkatesan, the company's plasma pyrolysis system uses high temperatures to break down hydrocarbons, combining dielectric plasma with microwave plasma in two stages for improved efficiency. By producing hydrogen and solid carbon simultaneously, the process seeks to reduce emissions associated with conventional hydrogen production methods, such as steam methane reforming, which can emit significant carbon dioxide per kilogram of hydrogen produced.

Hypersonic Technologies' prototype is currently at Technology Readiness Level (TRL) 5, validated in a relevant environment, and has received a patent grant and approval through the government-backed NRDC-NETRA programme. The carbon black produced is intended for industrial applications like pigments, and the company is exploring collaborations with established manufacturers.

With immediate challenges including scaling the prototype and securing funding for further development, Hypersonic Technologies is targeting industries such as refineries, steelmakers, cement companies, and fertiliser manufacturers. The startup is seeking government support and has received a Carbon Zero Challenge grant. For industrial adoption, the cost remains a significant factor, with Hypersonic Technologies seeing new facilities as a more viable option for adopting the new technology than retrofitting existing plants.