Plasma is often called the ‘fourth state of matter’ after solids, liquids, and gases. Plasma technology utilizes a highly energized, super-heated gas known as plasma, generating extreme heat to process materials at industrial scale.

The main difference is that a coal-fire is a chemical reaction of releasing energy through oxidation of carbon whereas plasma flame is the sustained state of electrically charged particles.

While generating Coal-fired flame, large volumes of carbon dioxide (CO₂), nitrogen oxides (NOx) sulphur dioxide (SO₂), and massive amounts of solid residual bottom ash and fly ash are produced; whereas, flame out of plasma torches generates zero inherent combustion emissions because it does not involve to burn any fuel.

While coal fire generally reaches temperatures between 800°C to 1,500°C, depending on the airflow, boiler setup, and coal quality, Plasma Flame reaches extreme temperatures starting from 3,000°C to well over 10,000°C, making it significantly hotter than any chemical/fuel fire.

This extreme heat generated by thermal plasma torches can melt, vaporize, or chemically reconfigure any known material as well, turn metals, byproducts and rocks into molten state. Such engineered molten matter, upon rapid quenching, form into glass-like slag and, in turn, ground to cement for Ultra-high-Strength Geo-polymer Concrete.

Electricity being the basic input for plasma, it is prohibitive to think of plasma as heat source for processing plants or cement production, availing grid-based electricity. However, owing to the improvements in generation of nuclear power with due safeguards in Small Modular Reactors (SMRs), which is sustainable, cost effective and emission-free, tapping nuclear power for plasma technology has become a plausible proposition with techno-economic-environmental overtones.

Since University of Florida, USA, and Heidelberg Materials, Sweden, have accomplished the pilot plant studies in producing qualitative clinker for cement based on thermal plasma, INSWAREB has given a global call for adopting this manufacturing regime for cement and other process industries, availing SMRs as power source.