Hypersonic Technologies Splits Methane into Hydrogen and Carbon Black with Plasma Reactors

Chennai-based Hypersonic Technologies is working on an alternative to carbon-intensive hydrogen production: staged-plasma pyrolysis that converts methane and biomethane into hydrogen and solid carbon black — a commercially useful material used in tyres, rubber, plastics, paints and pigments — with no direct CO2 emissions. The startup was founded in 2023 by Jayaraman Kandasamy and Jayakumar Venkatesan.

The chemistry advantage is two-sided. Conventional steam methane reforming can emit around 10 kg of CO2 for every kilogram of hydrogen produced, while carbon black manufacturing also generates emissions. By producing two saleable outputs from one process, Hypersonic aims to offset production costs for industrial customers. Kandasamy, who has more than a decade of experience in Europe working on plasma technology for aerospace propulsion, targets oil refineries, steel, cement and fertiliser — industries where flared methane can become feedstock.

The technology is at Technology Readiness Level (TRL) 5, validated in a relevant environment: its lab-scale system at IIT Madras produces around 500 grams of hydrogen per hour. It has received a patent grant and been validated through the government-backed NRDC-NETRA programme, and held discussions with established carbon black manufacturers about collaborations.

The immediate challenge is scaling. The startup needs around Rs 5 crore to advance from TRL 5 to TRL 7, with a larger pilot plant planned once funding is secured — aiming at 5 kg of hydrogen per hour before pursuing refinery and steel orders. It has received a Carbon Zero Challenge grant and is seeking government support, weighing equipment sales, operating partnerships and output-linked payment models.