An ECOR-ETS Indigenous Innovation for Sustainable Energy and Circular Economy
Methane, especially in its waste or compressed form, poses a significant ecological threat due to its high global warming potential. ECOR-ETS introduces a revolutionary technology platform based on plasma-assisted pyrolysis of methane to produce fuel-grade green hydrogen and tire-grade virgin carbon black in a carbon-neutral, waterless, and energy- efficient manner. This innovation aligns with India’s ambitions under the National Green Hydrogen Mission and reinforces the spirit of Atmanirbhar Bharat.
CURRENT LIMITATIONS IN HYDROGENPRODUCTION
The most prevalent method of hydrogen production—Steam Methane Reforming(SMR)— generates over 10 tons of CO₂ per ton of hydrogen, rendering it environmentally unsustainable. While water electrolysis using renewable power is considered a green alternative, it remains highly energy-intensive, requiring 285 kJ per mole of H₂, and thus economically uncompetitive.
THE ECOR-ETS SOLUTION: PLASMA-ASSISTED METHANE PYROLYSIS
This innovative process decomposes methane directly into hydrogen gas and solid carbon, eliminating any CO₂ emissions.
The process uses:
The technology leverages advanced chemical pathways including poly-cyclic aromatic hydrocarbon (PAH) formation and H-abstraction-acetylene-addition (HACA) to drive over 99% conversion efficiency. Rapid yet controlled gas quenching, real-time gas analytics, and closed-loop impurity separation systems ensure high purity of final products and minimal environmental footprint.
KEY ADVANTAGES
Waterless Process
Eliminates dependency on freshwater—a critical advantage in water-scarce regions.
Energy Efficiency
Requires only ~38 kJ per mole of H₂, making it ~7x more efficient than electrolysis.
Dual Revenue Streams
Produces virgin-grade carbon black in 1:3 H₂:C ratio, usable in tire, rubber any other industrial applications.
Cost Effective
Projected hydrogen production cost of INR 150–200/kg, enabling commercial viability.
COMMERCIAL PROSPECTS
The process is thermodynamically efficient and economically viable, with projected hydrogen production costs of INR 150–200/kg, making it competitive and scalable. Virgin carbon black derived from this process has applications in tire and rubber industries, enabling circular material recovery
PROGRESS AND ROADMAP
ECOR-ETS has already achieved Technology Readiness Level 3 (TRL-3) through proof-of- concept in its in-house lab—the first such validation in India. The next milestone is the construction of a working prototype capable of kilogram-scale production of both green hydrogen and virgin carbon black over the next 12–18 months, targeting TRL-7 with full engineering and process validation.
The technology leverages advanced chemical pathways including poly-cyclic aromatic hydrocarbon (PAH) formation and H-abstraction-acetylene-addition (HACA) to drive over 99% conversion efficiency. Rapid yet controlled gas quenching, real-time gas analytics, and closed-loop impurity separation systems ensure high purity of final products and minimal environmental footprint.
UNIQUE POSITIONING
To the best of our knowledge, no equivalent technology currently exists in India. The closest known example is the OC1 facility by Monolith Industries (USA), though its details remain confidential. ECOR-ETS’s process is not only scientifically distinct, but indigenously developed, resource-adaptable, and designed for scalable deployment in the Indian context.
This transformative technology stands at the intersection of clean energy, circular materials, and climate action. ECOR-ETS is committed to demonstrating India’s leadership in green innovation and welcomes collaboration for sustainable development.
