Rethinking Natural Gas: Energy and Materials Without Emissions

Burning natural gas for energy and releasing CO₂? That’s outdated. We see natural gas as a dual resource—delivering both clean energy and valuable materials. Our process naturally eliminates CO₂ emissions as an integrated side effect.

Natural gas is mostly methane (CH₄). Instead of burning it, we transform it through methane pyrolysis—splitting methane into hydrogen (H₂) and solid carbon (C). Then, we process the solid carbon to a platform material for various bulk applications: CARBOSANDS. This process provides clean hydrogen as an energy source while capturing carbon in a stable, solid and valuable form—with CO₂ elimination built into the process.

Let’s move beyond combustion and embrace the future of clean natural gas.

At the heart of our innovation is CARBOSANDS™, our patent-pending technology that transforms solid carbon from methane pyrolysis into a high-performance fine aggregate. With optimized particle size, shape, distribution, and strength, CARBOSANDS™ is engineered for integration into bulk construction materials—from drywall panels to concrete.

But the impact goes even further: If the methane used to produce CARBOSANDS™ is derived from CO₂-based sources, concrete and other building materials could become a massive CO₂ sink, potentially locking away gigatons of atmospheric carbon.

Currently, CARBOSANDS™ is in the research and development phase. We are focused on demonstrating the technology, validating the final product, and assessing its economic potential. Once complete, we aim to turn CARBOSANDS™ into a profitable driver of climate protection. Find out more

Natural gas will become a dual-purpose commodity for transporting and storing energy AND materials.

To protect the climate, we must stop emitting CO₂ .  And ultra-large quantities of CO₂ have to be removed from the atmosphere. Why not transform it and store it as mass-produced, infinitely recyclable building materials? At CARBOSANDS, we are tackling the largest industrial raw material of all: construction sand. Our Solid Carbon Sand is made from carbon-negative methane.

Mankind has developed a global infrastructure for natural gas over the past century. Why not leverage this existing infrastructure for the new, nearly identical substance —carbon-negative methane? Let’s use and renovate the natural gas infrastructure to ensure no methane escapes, ushering in a new era of carbon-negative methane.

CARBOSANDS: A new material made of natural gas

The patent-pending CARBOSANDS technology combines thermal methane decomposition with an innovative Solid Carbon Sand production process. It is engineered to produce Solid Carbon Sand that matches the hardness, particle shape, and grain size distribution of mineral construction sand.

CARBOSANDS Solid Carbon Sand is designed to meet all relevant requirements for construction sand, including compressive strength, tensile strength, modulus of elasticity, creep, and shrinkage. Unlike other technologies such as molten bed or plasma methane pyrolysis, which yield amorphous solid carbon, CARBOSANDS will deliver a high-quality product optimized for construction applications.

We believe the “Highway from DAC to Building” represents the most cost-effective path to simultaneously remove CO₂ from the atmosphere, produce, transport, and utilize energy sustainably, and craft a world built from stunning, innovative materials. Welcome to a new era defined by methane and solid carbon. Join us: Contact

A highway from Direct Air Capture (DAC) to buildings. Let’s establish a process chain that transforms CO₂ to methane as an input to the CARBOSANDS process.

CARBOSANDS technology offers an innovative approach to producing hydrogen as an energy carrier from natural gas while simultaneously generating a building material—solid carbon sand for drywalls and concrete. We are excited to launch this solution now.

A look into the future: CARBOSANDS will become part of a much larger initiative, the “Highway from DAC to Buildings,” which includes assembly units, transport mechanisms, and cleavage units. In the assembly units, a combined energy and raw material commodity is produced: carbon-negative methane. This process involves extracting CO₂ from the atmosphere using Direct Air Capture (DAC) or sourcing it from hard-to-abate industrial processes. This CO₂ is then combined with hydrogen produced from renewable sources like solar and wind energy to methane. Methane can be efficiently transported from assembler locations—where solar and wind resources are plentiful—to cleavage sites in regions with high energy and raw material demand. In the cleavage units, methane is converted into hydrogen, an energy carrier, and solid carbon, a raw material.

This solid carbon will serve as the foundation for new building materials, such as Solid Carbon Sand for concrete. The term “Highway” symbolizes the potential gigaton-scale impact of this innovative process chain.