New system will save 350 tonnes of argon annually, delivering 1,000 tonnes of Scope 3 CO₂ reductions each year

UK, January 2026 — Metalysis, the global leader in the production of advanced metal and alloy powders, has further strengthened its sustainability credentials with the installation of a world-leading argon recycling system that will deliver significant carbon and resource savings across its operations.

The company has contracted UK-based clean technology specialist Gas Recovery and Recycle Limited (GR2L) to install ArgonØ™, the world’s most advanced argon recycling system. Once operational, the system will recycle 95% of argon used, saving 350 tonnes of argon annually and delivering direct Scope 3 carbon savings of approximately 1,000 tonnes of CO₂ per year.

Argon plays a critical role in Metalysis’ patented FFC solid-state electrolysis process, where it creates an inert atmosphere that protects metal and alloy powders from contamination by oxygen, nitrogen and hydrogen. The gas is used across all reactor generations — from Gen 1 research-scale units producing grams per run, to Gen 4 reactors producing tens of tonnes annually.

By recycling exhaust purge argon rather than sourcing newly processed gas, Metalysis significantly reduces the upstream emissions associated with argon production and transport. Each tonne of argon purchased typically carries 2–4 tonnes of embedded Scope 3 CO₂, while the ArgonØ™ system itself operates with less than 10% of the energy footprint of conventional gas recycling technologies.

Sustainability built into the process

The investment builds on Metalysis’ long-standing commitment to embedding sustainability at the core of materials production. Its proprietary Metalysis FFC process was originally developed as a lower-energy alternative to traditional titanium melting technologies and is already around 50% more energy efficient for producing powders used in additive manufacturing.

Unlike conventional melt-based processes, the FFC method reduces metal oxides in the solid state, avoiding energy-intensive melting steps while enabling the production of metal, alloy and high-entropy powders across 49 elements of the periodic table.

Metalysis’ materials portfolio supports sustainability not only in production, but also in end-use applications. The company supplies:

• Capacitor-grade tantalum powders
• Aluminium-scandium alloys for semiconductors and lightweight structures
• Refractory alloys such as niobium-hafnium (C103)
• Advanced high-entropy alloys designed for extreme environments with improved performance-to-weight ratios

These materials contribute to energy efficiency, durability and performance improvements across aerospace, defence, clean energy, electric vehicles and advanced electronics.

Expanding clean technology collaboration

For GR2L, the partnership marks a strategic expansion beyond its traditional markets in solar photovoltaics and microelectronics into advanced manufacturing and materials processing.

ArgonØ™ systems recover, purify and recycle exhaust argon from industrial processes, enabling manufacturers to significantly reduce gas consumption, operating costs and emissions.

Leadership perspective

Nitesh Shah, CEO of Metalysis, commented:
“Argon recycling represents another important milestone in Metalysis’ sustainability journey. Our process is already highly energy competitive compared to conventional melting technologies, and our lightweight alloys help reduce emissions for our customers. Saving argon — and the associated Scope 3 CO₂ — further cements Metalysis as a responsible and future-focused manufacturing business.”

Strategic importance

Beyond sustainability, Metalysis plays a critical role in strengthening UK and allied supply chains by providing domestic oxide reduction capabilities for critical and rare materials, reducing exposure to geopolitical and supply risks.

Since 2019, the company has also emerged as a global leader in space resource utilisation, working with the European Space Agency (ESA) and the UK Space Agency to extract oxygen from lunar regolith. Metalysis’ technology — selected by ESA for all its oxygen extraction programmes — enables oxygen capture using an oxygen-evolving anode, supporting future propulsion and life-support systems for lunar missions.

About Metalysis
Metalysis is a global leader in the production of metal powders, alloy powders and high-entropy materials for space, aerospace, defence, clean energy, advanced electronics, AI, EVs, 5G and industrial applications. Using its patented FFC solid-state electrolysis process, Metalysis reduces metal oxides across 49 elements of the periodic table to create high-value materials with lower energy and carbon intensity.

More information:
? www.metalysis.com
? https://www.linkedin.com/company/metalysis