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Plasma Metallurgy

 

Carbon-Free Plasma Reduction of Metal Oxides is a platform enabling direct, high-temperature reduction of metal oxides using high-enthalpy inductively coupled plasma. This approach supports atmospheric and pressurized operation and is applicable to aluminum, magnesium, and strategic metal oxides with engineered thermal control and rapid reaction kinetics.

Plasma Metallurgy process diagram

Core technological differentiators:

  • Electrode-free RF plasma — chemically clean operation with no electrodes, contamination, or consumables; suitable for high-purity metals and powders.
  • Optimized plasma-forming gases — selected gas chemistry enabling high energy efficiency in plasma generation and oxide reduction.
  • Unprecedented scalability — single-torch power levels up to 15 MW enabled by novel engineering solutions.
  • Ultra-fast quenching — reaction products cooled at rates up to 106 K/s, suppressing back-reactions.
  • Proven scientific and engineering foundation — more than 40 years of experience in plasma technologies, from laboratory systems to industrial-scale devices.

Focus metals — expansion roadmap:

  • Current focus: Al, Mg, Ga, Ti, Tb, Dy
  • Planned expansion: Sc, Ge, and other strategic and critical metals

Why Plasma Metallurgy changes the industry:

  • 100% carbon-free process — the only reaction by-product is water.
  • Lower specific energy consumption compared to conventional carbothermic routes.
  • Direct production from ore without coke, anodes, or blast furnaces.
  • Spherical powders produced directly for additive manufacturing.
  • In-flight alloying and doping in a single processing step.
  • Reaction times measured in fractions of a second.
  • Minimal footprint with no need for large metallurgical plants.

As an example, the entire annual global demand for gallium could be produced on a footprint of approximately 300 m².

Technology status:

  • Passed scientific peer review
  • Under active discussion with global metals producers
  • A future-ready platform for sustainable metallurgy

Key Publications:

 

 

 

 

 

© 2026 Applied Plasma Technologies, Corp.
Address: 4460 Whiting Road, Marshall, VA 20115

 

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