Nicoleta Voicu on Using Plasma Conversion to Produce Valuable Products for the Chemical Industry

What is your background, and how did you come to work at TNO?

“That’s quite a long story! I started my academic journey studying physics in Romania. During my Master’s studies I received an Erasmus scholarship in the Netherlands, where I later pursued a PhD at the University of Groningen . During  my PhD, I relocated  to Cambridge with my professor’s team. Working in  Cambridge, by the Cavendish laboratories was an incredible and inspiring experience that broaden my perspective on science and collaborations.

After returning to the Netherlands, I worked for Canon and DSM, with DSM providing exposure to a diverse range of market applications, segments, and business units. At DSM, the research department had scientists from 28 different countries, which was a fantastic opportunity to engage with diverse perspectives. My roles ranged from research and application development to building strategic partnerships for DSM Advanced Solar emerging business  It was a great learning experience and I had the privilege of working with amazing colleagues, from scientists to application and business developers, all of whom helped shape my career.

Later, I started my own company focused on growing flowers sustainably for local events. It’s now bio-certified and operates with a high degree of independence, which I’m proud of. However, I realised last year that I truly missed being involved in science. This brought me to TNO, where I now work as project manager for the NXTGEN project, together with a brilliant team of colleagues and partners. Interestingly, reducing the carbon footprint has been a common thread in both my own business and my work at TNO, which makes the experience particularly meaningful.”

What exactly is your project in the NXTGEN Hightech Energy domain?

“Our goal is to electrify chemical processes using (green) electricity, producing raw materials for the chemical industry without CO₂ emissions. Globally, we are one of the few working on plasma technology in this way.

This project aims to demonstrate the applicability of innovative high-tech plasma generation methods, such as direct current (DC) and microwave technologies, which currently operate at scales ranging from 1 to 50 kW. The challenge is scaling them further while improving energy efficiency under the demanding conditions of large-scale chemical processes, with targets ranging from kiloton to megaton outputs per year.

Through the NXTGEN project, we began scaling up in 2023 by developing equipment enabling the use of plasma technology on a large scale. Specifically, we are working to valorise methane—a common byproduct in the chemical industry that typically has a high CO₂ footprint. Using plasma chemistry, we aim to convert this methane into high-value products like acetylene, hydrogen, and ethylene. These products have significant applications, such as in the production of plastics, fertilisers and other valuable chemicals.

What makes this exciting is that our equipment transforms byproducts from production processes into something valuable and economically viable. For instance, while companies often face penalties for CO₂ emissions from burning methane, our solution allows them to convert this methane into products like ethylene, which has a massive market. This creates a financial opportunity where the income from high-value products can offset penalties, ultimately driving a more sustainable and profitable process. That’s the market potential we’re exploring and developing within the NXTGEN project.”

Why is this technology particularly interesting for the Netherlands, and what gives us a strong position to succeed in this field?

“The Netherlands is uniquely suited for this technology because of its strong, interconnected ecosystems. On one hand, we have an advanced high-tech equipment development sector; on the other, we have a well-established chemical sector. Both of these ecosystems exist within close proximity, allowing us to collaborate effectively.

We also benefit from the Brightsite partnership( Maastricht University, TNO , Sitech Services), partnerships with research institutes like DIFFER and partnerships with the high-tech and chemical industry. These collaborations span the entire value chain, from low TRL (Technology Readiness Level) organisations to equipment manufacturers and industrial partners who can serve as first adopters of the technology. This combination of talent, expertise, and infrastructure is not only unique but critical to the success of our project. By bringing together these diverse fields of application, we can create innovative high-tech solutions that address global challenges.”

How do you expect the technology, materials, and equipment to find a place in the market?

“Our primary customers will be large chemical companies or industries where methane is a byproduct, and there is interest in valorising it into products like acetylene or ethylene. The plasma technology has additional potential applications, such as plastic recycling or nitrogen fixation, so we’re also working to diversify its application range. This adaptability increases its attractiveness in the market.

In terms of commercialisation, the chemical industry typically operates on a licensing model. The technologies, equipment, and processes developed will follow this model. Companies can benefit by either reselling the output products or reusing them in their own operations. This structure enables a scalable and sustainable pathway for integrating the technology into the industry.”

Aside from funding, why is being part of the NXTGEN Hightech programme so important?

“While funding is crucial, the most important aspect of being part of NXTGEN Hightech is the collaborative element. No single organisation has the capability or ambition to develop every component independently. Each partner in this project brings unique capabilities and skills, making the collaboration essential for success.

For example, our partners contributing and optimizing specialised plasma equipment, which forms a critical part of the process. Their involvement as a potential strategic partner is invaluable, as there are very few suppliers of plasma torches, which are essential for processing methane gas. Similarly, expertise in developing chemical processes adds significant value, ensuring that the technology aligns with industry requirements.

We also work with partnerswho are critical for equipment manufacturing and licensing. Licensing comes with specific conditions that require an experienced partner to manage effectively. This collaborative ecosystem ensures that every stage of development—from pilot to demo—benefits from diverse expertise while addressing fundamental research questions through the involvement of universities and research institutes.

Additionally, organisations like Brightsite and VoltaChem are pivotal. Brightside supports the transition of the chemical industry to renewable energy and feedstocks, offering critical knowledge and connections. VoltaChem helps us with the business model, ensuring we can implement the technology effectively.”

From your experience, what is your best advice for other NXTGEN projects?

“The most important aspect of a successful project is maintaining strong collaboration and connecting partners as early as possible. This includes not only consortium members but also new partners. Onboarding everyone quickly and aligning their expectations from the start is key.

Building strong relationships within the consortium is often underestimated but incredibly impactful. While most of us are based in the Netherlands, we don’t interact daily. Workshops and events are essential for fostering these relationships, making it easier to communicate and address challenges collaboratively. Once partners know each other, reaching out with questions or ideas becomes much more efficient.

Ultimately, it’s about creating an environment where everyone feels aligned and valued. Strong collaboration leads to better outcomes, and ensuring all partners are on the same page from the beginning is vital for long-term success.”