Engineered for
Efficiency and Reliability.
Replacing coal-fired furnaces with microwave plasma.
600°C Operation. Zero Coking. 99% Purity.
The CH₄-to-Si Reactor
Plasma Activation
Microwave plasma efficiently breaks down methane ($CH_4$) into highly reactive radicals at a moderate 600°C, bypassing the energy-intensive 2000°C requirements of traditional furnaces.
Catalytic Reduction
Our nano-engineered Molybdenum Carbide (Mo₂C) catalyst weakens quartz ($SiO_2$) bonds. This proprietary lattice structure prevents "coking" (carbon buildup) that killed previous attempts.
Pure Output & Loop
Yields high-purity silicon. Valuable byproducts ($CO, H_2$) are captured and recycled into the system, generating ~20% of the energy required to run the plasma.
The Molybdenum Advantage.
The core failure of past methane-to-silicon attempts was "coking"—carbon deposits choking the reactor. Our solution? A living lattice.
- C Prevents carbon deposition (coking) via atomic spacing.
- H Operates efficiently at 600°C (vs 2000°C).
- Si Enables continuous, scalable extraction.
Modular by Design.
Traditional silicon plants are massive, fixed liabilities costing $250M+. We changed the form factor. Our containerized units allow flexible deployment directly at the natural gas source.
FIG 2.4: FIELD DEPLOYABLE UNIT
Path to Commercialization
Develop & Optimize
Build and refine a lab-scale plasma-catalytic reactor. (Completed)
Validate Performance
Current Status: Demonstrate energy efficiency (< 5.5 kWh/kg) and silicon purity (>99%).
Prove Scalability
Pilot runs and techno-economic model proving commercial viability (<$1.50/kg Si).