Mitigating climate change requires the development of technologies that combine energy and transport sectors. One of them is the production of sustainable fuels from electricity and carbon dioxide (CO₂) via power-to-liquid (PtL) plants. As one option for splitting CO₂, plasma-based processes promise a high potential due to their flexibility, scalability, and theoretically high efficiencies. This work includes a modeling and techno-economic analysis. A crucial element is the process of the joint project PlasmaFuel, in which two plasma technologies are included in a PtL plant to produce synthetically sulfur-free marine diesel. The results are divided into three scenarios, which differ in the use of different boundary conditions and thus represent different degrees of technology development. The evaluation results in process efficiencies from 16.5% for scenario 2018/20 to 27.5% for scenario 2050, and net production costs between EUR 8.5/L and EUR 3.5/L. Furthermore, the techno-economic potential is mapped in order to open up development steps in the direction of costs below EUR 2.0/L. The present work allows statements regarding system integration and the industrial use of the plasma-based process.; moreover, conclusions can be drawn towards the most important levers in terms of process optimization.

This work presents advancements in a rotating glow-to-arc plasma reactor, designed for stable gas conversion of robust molecules like CO₂, N₂, and CH₄. Plasma-based systems play a critical role in Power-to-X research, offering electrified, sustainable pathways for industrial gas conversion. Here, we scaled the reactor’s power from 200 W to 1.2 kW in a CO₂ plasma, which introduced instability due to uplift forces and arc behavior. These were mitigated by integrating silicon carbide (SiC) ceramic foam as a mechanical restriction, significantly enhancing stability by reducing arc movement, confining convection, and balancing volumetric flow within the arc. Using high-speed camera analysis and in situ electronic frequency measurements, we identified dominant frequencies tied to operational parameters, supporting potential in operando monitoring and control. Arc-rotation frequencies from 5 to 50 Hz and higher frequencies (500 to 2700 Hz) related to arc chattering reveal the system’s dynamic response to power and flow changes. Furthermore, refining the specific energy input ($SEI$) to account for plasma residence time allowed for a more precise calculation of effective $SEI$, optimizing energy delivery to target molecules. Our findings underscore the reactor’s promise for scalable, efficient gas conversion in sustainable energy applications.