Low-Carbon Hydrogen
Supports hydrogen-based direct reduction.
SOLUTIONS / STEEL · LIME · CEMENT
Hydrogen-Based Direct Reduction for Industrial Decarbonization
Produce low-carbon hydrogen, valuable solid carbon, and recoverable process heat to support decarbonized steelmaking, lime, and cement production through Graforce's Methane-Plasmalyzer® technology.
INDUSTRY OVERVIEW
Decarbonizing High-Temperature Industries
Hydrogen-Based Direct Reduction (H₂-DRI) is one of the most promising pathways for reducing emissions in steel production. Graforce enables cost-effective hydrogen production from natural gas or biomethane without process-related CO₂ emissions while simultaneously generating valuable solid carbon and high-temperature process heat.
Solid Carbon
Approximately 3 kg of solid carbon is produced for every 1 kg of hydrogen.
Process Heat
Recoverable heat can be integrated into industrial processes.
Flexible Feedstocks
Compatible with natural gas, biomethane, and flare gas.
GRAFORCE SOLUTION
Methane Plasmalysis for H₂-DRI
Methane is dissociated in a high-temperature plasma reactor into hydrogen and solid carbon. Hydrogen is supplied to the direct reduction process, while solid carbon and process heat are recovered as valuable industrial resources.
Process Diagram
Feedstock
Natural gas or biomethane is prepared for plasma conversion.
Plasma Conversion
Methane is split into hydrogen and solid carbon.
Direct Reduction
Hydrogen supports low-carbon reduction of iron ore.
Heat Recovery
High-temperature process heat is reused in the plant.
INDUSTRIAL BUSINESS CASE
20 MW Methane-Plasmalyzer® Integration for Steel Production
A business case analysis demonstrates the integration of a 20 MW Methane-Plasmalyzer® system (40 × 0.5 MW modules) into a German steel plant to supply hydrogen for Hydrogen-Based Direct Reduction (H₂-DRI). The study highlights the technical performance, hydrogen production capacity, and economic benefits of modular large-scale deployment.
Performance Highlights
20 MWPlant Capacity
40Modules
12,000 t/yearHydrogen Output
6,000 h/yearOperating Hours
PERFORMANCE ECONOMICS & ENERGY
Competitive Hydrogen Production
From approximately 80 kg/h of flare gas feed, the process produces hydrogen-rich product gas and 54.3 kg/h of solid carbon while recovering useful process heat. The plasma reactor operates above 1500°C and delivers a hydrogen concentration of approximately 96.1 mol%.
Performance Strip
€1.69/kg H₂Long-Term Target
€0.53/kg H₂Gross Margin
54.3 kg/h€6.4 Million
€2.47/kg H₂Hydrogen Cost
BYPRODUCT UTILIZATION
Maximizing Industrial Value
Solid Carbon
Sold to foundries and metallurgical industries.
Process Heat
Recoverable heat up to 750°C reused within the DRI process.
Hydrogen
Supplies low-carbon hydrogen for steel production.
ADDITIONAL APPLICATIONS
Energy Recovery from Process Water
Hydrogen-Based Direct Reduction (H₂-DRI) is one of the most promising pathways for reducing emissions in steel production. Graforce enables cost-effective hydrogen production from natural gas or biomethane without process-related CO₂ emissions while simultaneously generating valuable solid carbon and high-temperature process heat.
FAQ
Frequently asked questions
How does methane plasmalysis support H₂-DRI?+
It supplies low-carbon hydrogen for direct reduction while recovering solid carbon and process heat as valuable co-products.
Why is solid carbon valuable?+
Solid carbon can be used as a reducing agent, additive, or industrial material without creating process CO₂ emissions.
Can biomethane achieve negative carbon intensity?+
When renewable biomethane is used and biogenic carbon is permanently bound, the pathway can support negative carbon intensity.
How is waste heat reused?+
High-temperature heat can be integrated into direct reduction and other high-temperature industrial processes.
What is the expected hydrogen production cost?+
Project-specific costs depend on plant size, operating hours, feedstock, electricity, and product revenues.
Project Inquiry
Does Our Technology Fit Your Application?
Ready to Decarbonize Steel Production?
Discover how Graforce's Methane-Plasmalyzer® delivers low-carbon hydrogen, valuable carbon co-products, and high-temperature process heat for next-generation steel, lime, and cement production.