(572o) Techno-economic analysis of catalytic methane pyrolysis for COx-free hydrogen and high-value carbon production

Methane pyrolysis (MP), also known as the thermal decomposition of methane, offers a promising route for producing COx-free hydrogen and advanced nanocarbons from natural gas and biogas. Despite its potential, limited research has focused on the economic and environmental evaluation of MP [1-4]. This project aims to provide a comprehensive assessment of the MP supply chain at an industrial scale.

In this study, we developed a MP process plant concept where we design further into a process plant model (flowsheet) in a process simulation software (Aspen Plus). This will include the necessary upstream and downstream separation processes. The MP reactor models, integrated within the flowsheet, account for catalyst deactivation, incorporating kinetics and deactivation models derived from experiments on nickel-supported catalysts in a fluidized bed reactor [5].

A techno-economic analysis of the conceptual MP plant is performed, estimating its capital and operating costs, net present value, payback time, and the levelized cost of hydrogen at varying carbon-selling prices. Additionally, we assessed the economic impact of different reactor heating methods, including electrical, microwave, and fuel combustion. In this opportunity, we present preliminary results from our techno-economic evaluation which indicate that this process could serve as a crucial bridge between conventional and green hydrogen production.

In future work, we will conduct a life-cycle analysis to evaluate the environmental impact, focusing on the CO2 intensity of the MP supply chain, from the production of fossil and bio-based methane to the applications of hydrogen and solid carbon. Our goal is to identify scenarios that minimize costs and emissions, achieving an optimal balance between both. Finally, we will perform a market analysis to explore the applicability of functional carbon products generated through MP.

References
[1] Kerscher, F., Stary, A., Gleis, S., Ulrich, A., Klein, H., & Spliethoff, H. (2021). Low-carbon hydrogen production via electron beam plasma methane pyrolysis: Techno-economic analysis and carbon footprint assessment. International Journal of Hydrogen Energy, 46(38), 19897–19912. https://doi.org/10.1016/j.ijhydene.2021.03.114

[2] Leal Pérez, B. J., Medrano Jiménez, J. A., Bhardwaj, R., Goetheer, E., van Sint Annaland, M., & Gallucci, F. (2021). Methane pyrolysis in a molten gallium bubble column reactor for sustainable hydrogen production: Proof of concept & techno-economic assessment. International Journal of Hydrogen Energy, 46(7), 4917–4935. https://doi.org/10.1016/j.ijhydene.2020.11.079

[3] Riley, J., Atallah, C., Siriwardane, R., & Stevens, R. (2021). Technoeconomic analysis for hydrogen and carbon Co-Production via catalytic pyrolysis of methane. International Journal of Hydrogen Energy, 46(39), 20338–20358. https://doi.org/10.1016/j.ijhydene.2021.03.151

[4] von Wald, G. A., Masnadi, M. S., Upham, D. C., & Brandt, A. R. (2020). Optimization-based technoeconomic analysis of molten-media methane pyrolysis for reducing industrial sector CO2emissions. Sustainable Energy and Fuels, 4(9), 4598–4613. https://doi.org/10.1039/d0se00427h

[5] Hadian, M., Marrevee, D. P. F., Buist, K. A., Reesink, B. H., Bos, A. N. R., van Bavel, A. P., & Kuipers, J. A. M. (2022). Kinetic study of thermocatalytic decomposition of methane over nickel supported catalyst in a fluidized bed reactor. Chemical Engineering Science, 260, 117938. https://doi.org/10.1016/J.CES.2022.117938