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Plasma Metallurgy

 

Carbon-Free Plasma Reduction of Metal Oxides is a patented, umbrella plasma technology for the direct, carbon-free reduction of metal oxides. The platform is applicable to virtually all metal oxides — from light metals such as Al and Mg to heavy and rare-earth metals including Tb and Dy.

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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