Hydrogen is expected to play a larger role in helping industries cut emissions, but conventional production methods can leave a significant carbon footprint. Chennai-based Hypersonic Technologies is working on an alternative that produces hydrogen alongside carbon black, a commercially useful material used in tyres, rubber and pigments.
Founded in 2023 by Jayaraman Kandasamy and Jayakumar Venkatesan, the climate-tech startup uses staged-plasma pyrolysis to convert methane and biomethane into hydrogen and solid carbon. By producing two materials through one process, it aims to help industrial customers offset production costs while reducing emissions.
Kandasamy has more than a decade of experience in Europe, where he worked on plasma technology for aerospace propulsion and explored converting biomass into fuel and hydrogen-rich gases. After returning to India, he founded Hypersonic Technologies to apply this experience to industrial decarbonisation.
“Our main mission is converting methane and biomethane into hydrogen and carbon black using staged-plasma pyrolysis technology,” he says. “The aim is to decarbonise industries, particularly oil refineries, steel, cement, and fertiliser, while also producing carbon black through the same process.”
One process, two outputs
Plasma pyrolysis uses high temperatures to break down hydrocarbons into hydrogen and solid carbon. Hypersonic Technologies combines dielectric plasma with microwave plasma in two stages, which Kandasamy says can improve efficiency and make the process more stable than a single-stage system.
The technology aims to address emissions associated with conventional hydrogen production. Kandasamy says steam methane reforming, a widely used method, can emit around 10 kg of carbon dioxide for every kilogram of hydrogen produced. Carbon black production also generates emissions.
“Both methods have to move towards cleaner, climate-oriented options. That is why this technology is important,” he says. “Methane is available in several places, where it may simply be flared. Instead, we can use it as feedstock to produce hydrogen and solid carbon.”
The company's prototype is at Technology Readiness Level (TRL) 5, meaning it has been validated in a relevant environment. Its lab-scale system at IIT Madras produces around 500 grams of hydrogen per hour, according to Kandasamy. The technology has received a patent grant, and the startup says it has also been validated through the government-backed NRDC-NETRA programme.
The carbon black produced is intended for industrial applications, including pigments, and the company is exploring higher-value grades. Kandasamy says Hypersonic has held discussions with established carbon black manufacturers about possible collaborations, although the technology is still at an early stage.
“We are looking at producing carbon black that can be used for pigments and other applications,” he says. “The advantage is that hydrogen and carbon black can both be monetised, rather than relying on hydrogen revenue alone.”
Moving from the lab to industry
Hypersonic Technologies is targeting refineries, steelmakers, cement companies, and fertiliser manufacturers. It is also exploring commercial models that could include equipment sales, operating partnerships, and payments linked to output.
Its immediate challenge is scaling the prototype. Kandasamy says the company needs around Rs 5 crore to advance from TRL 5 to TRL 7, with plans for a larger pilot plant once funding is secured. The startup is also seeking government support and has received a Carbon Zero Challenge grant.
“We are a deeptech hardware startup, so we need funding to take the technology to the next level,” he says. “Once we establish a plant producing five kilograms of hydrogen per hour and reach the required validation stage, we can pursue orders from refineries and steel companies.”
Kandasamy says industrial adoption will depend largely on cost, particularly because major manufacturers cannot easily replace existing infrastructure. He sees new facilities as a more immediate opportunity than retrofitting existing plants.
“Industries are very sensitive to cost. They cannot replace existing technology overnight because they have already invested in it,” he says. “But when they set up new facilities, they can evaluate alternatives such as plasma pyrolysis.”
For Hypersonic Technologies, the next step is to demonstrate that its process can produce hydrogen and carbon black reliably and economically at a larger scale.
Hypersonic Technologies is part of YourStory's Tech30 cohort—a showcase of India's most promising startups of 2026, unveiled at TechSparks Bengaluru.
Edited by Teja Lele