Plasma Torch Specifications — Hardware Options
PyroGenesis (Montreal, Canada) — NASDAQ: PYR
The leading plasma torch manufacturer for military and industrial applications. Supplier to US Navy and US Air Force.
APT-HP (Atmospheric Plasma Torch — High Power)
The most relevant torch for The Claw.
| Specification | Value |
|---|
| Power range | 200 kW to 2 MW (scalable) |
| Temperature | Plasma plume exceeds 5,000°C |
| Arc type | Non-transferred DC Arc, button style, vortex stabilized |
| Gas types | Air, N₂, others available |
| Electrode life — Cathode | Up to 1,000 hours |
| Electrode life — Anode | Up to 500 hours |
| Length | 40 inches to 6 feet (1–1.8 m) |
| Diameter | 6 inches (0.15 m) |
| Weight | 75 kg |
| Environmental | Reduces GHG by up to 250 tonnes CO₂e per GW-h |
| Emissions | Eliminates SOx, VOC, and heavy metal emissions |
| Safety | Electrically isolated torch cover, lockout system, fully automated |
Applications: Iron ore pelletization (patented), steel tundish heating, cement pre-calciner, MSW gasification, incinerator ash vitrification, asbestos vitrification, radioactive waste disposal
Maintenance planning: At 24/7 operation, cathode replacement every ~42 days, anode replacement every ~21 days. This is manageable with spare inventory.
APT (Atmospheric Plasma Torch — Standard)
| Specification | Value |
|---|
| Power range | 50 kW to 500 kW |
| Temperature | Plume exceeds 5,000°C |
| Applications | Waste-to-energy, ash vitrification, steel tundish, titanium melting, nanomaterials |
Suitable for prototype-scale Claw (5 TPD or less).
RPT (Reverse Polarity Torch)
- In use since 1991 — longest operational track record
- Applications: spherical metallic powder production, high-purity metals, gas heating, carbon nanotubes
- Not directly relevant to waste processing but demonstrates PyroGenesis long-term reliability
MINIGUN
- Smallest torch — thermal spray coating, small-scale R&D, university research
- Relevant for: lab-scale testing of ocean plastic feedstock before committing to larger hardware
Power Scaling History (US Defense Client)
| Year | Power Rating | Event |
|---|
| 2019-2020 | 900 kW | Completed torch tests for RISE Energy Technology Center AB (Sweden) |
| 2022 | 2.5 MW | Intermediate scale-up |
| Aug 2023 | 4.5 MW | Contract signed: $4.13M CAD (~$3.13M USD) |
| Jan 2026 | 4.5 MW | Delivered to US aeronautics/defense client; $1M milestone payment |
| Oct 2024 | 20 MW | Ordered — "the largest plasma torch ever produced commercially" (in development) |
The technology is actively scaling. From 900 kW in 2020 to 20 MW ordered in 2024 — a 22x power increase in 4 years.
InEnTec PEM (Plasma Enhanced Melter)
Technology Origin
- Spinoff from MIT's Plasma Science and Fusion Center (PSFC) (1995)
- Incorporated NASA's segment-constricted arc heater design (originally patented 1965 for spacecraft heat shield testing)
Specifications
| Specification | Value |
|---|
| Operating temperature | 1,800 to 27,000°F (1,000 to 15,000°C) |
| Units deployed | 13 PEM systems worldwide |
| PCB destruction | 99.99999999% (10 nines) |
| Organic conversion | Nearly 100% of incoming organics → syngas |
| Hazardous output | Zero — only non-hazardous vitrified glass |
| H₂ production efficiency | ~half the energy of electrolysis (improving to ~quarter) |
Advantage Over Standard Plasma Torches
The PEM (Plasma Enhanced Melter) is not just a torch — it's an integrated reactor system. The plasma enhances a conventional melting process rather than being the sole heat source. This means:
- Lower total electricity consumption per tonne
- More even heat distribution
- Better suited to continuous operation
- Proven 20+ year track record
Partnership with SeaChange Ocean Solutions
InEnTec is the technology partner for SeaChange's plan to deploy a mobile PEM on a ship for at-sea ocean plastic processing. This is the closest real-world validation of The Claw's concept.
Westinghouse Plasma (Historical Reference)
Now owned by Sunshine Kaidi (China) via AlterNRG acquisition. Previously the world's most widely deployed plasma torch for waste gasification.
Key Specs (Historical)
- Used in Utashinai plant (Japan) — 4 torches per gasification island, 2 islands
- Power consumption claim: 2-5% of total energy input for the torch
- Electricity output: ~815 kWh per ton MSW sent to grid (claimed)
- 80% of feed energy recovered in syngas
Current Status
Effectively dormant. AlterNRG/Westinghouse reported ~$5.6M revenue in 2025. The Tees Valley disaster ($1B write-down) killed commercial credibility. Technology IP exists but is not actively commercialized.
Not recommended for The Claw — PyroGenesis and InEnTec are the active, proven suppliers.
Torch Selection for The Claw
Prototype Phase (1-5 TPD)
| Option | Torch | Power | Cost Estimate | Rationale |
|---|
| A | PyroGenesis APT | 200-500 kW | ~$500K-1M | Proven military pedigree, scalable |
| B | InEnTec PEM | Integrated system | ~$2-5M for complete system | Proven 20+ year track record, marine partnership exists |
Recommendation: InEnTec PEM for the prototype. They're already building a ship-based system with SeaChange. The technology is purpose-built for this application. Reach out for a partnership conversation.
Full Scale (50-100+ TPD)
| Option | Configuration | Power | Rationale |
|---|
| A | Multiple PyroGenesis APT-HP (2 MW each) | 4-10 MW total | Modular — add torches as capacity grows |
| B | Custom PyroGenesis (4.5 MW+) | 4.5-20 MW per torch | Fewer units, higher power each |
| C | InEnTec PEM array | Multiple integrated units | Proven system, lower per-unit power |
Electrode Replacement — Operational Planning
Plasma torch electrodes are consumables. They wear out and need regular replacement.
PyroGenesis APT-HP
| Component | Lifespan | At 24/7 Operation | Annual Replacements |
|---|
| Cathode | ~1,000 hours | ~42 days | ~9 per year |
| Anode | ~500 hours | ~21 days | ~17 per year |
For a station with 4 torches:
- ~36 cathodes per year
- ~68 anodes per year
- Supply vessel delivery schedule: Monthly electrode resupply is sufficient
Implications
- Need onboard electrode inventory (1-2 months supply minimum)
- Need trained technician (or detailed procedure for torch swap)
- NOT a show-stopper — comparable to replacing drill bits on an oil rig
- Electrode procurement from PyroGenesis is a standard supply chain