Advantages of plasma torches for decarbonizing high-temperature processes

•    No direct CO₂ emissions

Since heating is electric, there are no local CO₂ emissions from burning fossil fuels (provided the electricity is sustainable). XERION´s  plasma torches produce “no greenhouse gases” during heating (“carbon direct avoidance”).

•    High temperature optionality

Plasma can generate extremely high temperatures, which enables many high-temperature processes that are difficult to electrify.

•    Flexibility

Plasma can be used in various atmospheres (e.g., vacuum, protective gas), which is helpful in many specialized industrial processes.

•    Energy efficiency

Depending on the process, plasma heating can be more efficient—especially if green electricity can be used.

Technical Data Torch PLASMA NOVA 100

Industrial Plasma Torch Systems for High-Temperature Applications

The Plasma Torch by XERION Berlin Laboratories GmbH is a high-performance thermal system engineered for demanding industrial processes requiring extreme temperatures, precise control and reliable continuous operation.

Designed for advanced material processing, decarbonized heat generation and plasma-driven thermal applications, our plasma torch systems deliver stable thermal power up to 110 kW and apparent power up to 230 kVA.

Whether integrated into rotary kilns, high-temperature furnaces or research platforms, the XERION plasma torch ensures maximum efficiency, durability and process control.

What Is an Industrial Plasma Torch?

An industrial plasma torch generates extremely high-temperature plasma arcs by ionizing a process gas using electrical energy. The resulting plasma jet reaches temperatures far beyond conventional combustion systems, enabling:

• Rapid heating rates

• Controlled high-temperature reactions

• Clean and precise thermal energy input

• Electrically driven, fossil-free heat generation

Unlike traditional burners, plasma torches provide electrically generated heat without combustion emissions, making them ideal for decarbonized industrial processes.

Key Features of the XERION Plasma Torch

High Thermal Output

• Thermal Power: 110 kW

• Apparent Power: 230 kVA

Compact and Robust Design

• Torch Diameter: 60 mm

• Torch Length: 200 mm

The compact geometry allows seamless integration into rotary kilns, plasma reactors, calcination systems and experimental setups.

Advanced Industrial Control System

• Controller: Simatic S7

• HMI: 17” Industrial Touch Screen

The integrated PLC-based control platform enables:

• Precise power regulation

• Real-time diagnostics

• Process data logging

• Remote monitoring capability

• Seamless integration into SCADA systems

Engineered for Industrial Reliability

Power Electronics

Rectifier Unit

• Dimensions: 2,000 × 1,000 × 2,200 mm

• Weight: 1,200 kg

Oscillator Unit

• Dimensions: 900 × 800 × 800 mm

• Weight: 250 kg

The separated rectifier and oscillator architecture ensures high operational stability and simplified maintenance access.

Cooling System

• Water Cooling

• Minimum Water Pressure: 2.5 bar

• Required Water Flow: 80 l/min

The water-cooled design guarantees thermal stability even under continuous high-load operation.

Applications of Plasma Torch Technology

Our plasma torch systems are ideally suited for:

Plasma-Fired Rotary Kilns

Replacement of fossil burners for decarbonized mineral processing and calcination.

Advanced Material Processing

High-temperature treatment of ceramics, refractories, graphite, lithium compounds and battery materials.

Waste Treatment & Recycling

Thermal decomposition and plasma-assisted conversion processes.

Research & Pilot Plants

Laboratory and demonstration systems requiring precise high-temperature control.

Advantages Over Conventional Burners

✔ Electrically generated heat – no fossil combustion
✔ Reduced CO₂ footprint
✔ Extremely high achievable temperatures
✔ Fast response time
✔ Precise power control
✔ Lower maintenance compared to combustion systems
✔ Future-ready for green electricity integration

Plasma Technology for Decarbonized Industrial Heat

Industrial heat generation is one of the largest contributors to global CO₂ emissions. Electrically driven plasma systems provide a scalable pathway to decarbonization by replacing fossil fuel burners in high-temperature processes.

Combined with renewable electricity, plasma torches enable:

• Carbon-neutral calcination

• Fossil-free mineral processing

• Electrified kiln systems

• Green industrial transformation

Integration Into Rotary Kilns and Thermal Systems

The XERION plasma torch is specifically engineered for integration into:

• Direct-fired rotary kilns

• Indirect heating systems

• High-temperature shaft furnaces

• Continuous thermal processing lines

Thanks to compact geometry and advanced control architecture, retrofitting into existing systems is possible.

Why Choose XERION Plasma Torch Systems?

• German-engineered industrial quality

• Custom integration capability

• Industrial-grade automation

• Decades of high-temperature furnace expertise

• Tailored solutions for R&D and production

We do not offer off-the-shelf plasma devices – we engineer complete thermal solutions.