(570c) Tuning Particle ALD Catalysts for Methane Pyrolysis

Hydrogen is one of the most essential chemical building blocks to our energy infrastructure, with downstream applications in oil refining as well as production of ammonia, the key component in fertilizer. Today, nearly all hydrogen is produced commercially via steam methane reforming. For every kilogram of hydrogen produced, there are roughly 9 kilograms of CO₂ released to the atmosphere.¹ With an estimated global hydrogen production rate of 75 million metric tons per year¹, over 675 million metric tons of carbon dioxide are emitted via this process. A profitable alternative to produce hydrogen while circumventing greenhouse gas (GHG) is needed. A Catalytic-Chemical Vapor Deposition (CCVD) process to produce hydrogen and carbon nanofibers (CNFs) from methane is a financially promising alternative to steam methane reforming.

Methane, the primary component of natural gas, requires substantial process conditions to overcome the strong C – H bonds. Particle Atomic Layer Deposition (ALD) enables the formation of highly dispersed metal nanocatalysts on a given support which reduce the energy required for methane conversion. Moreover, the highly dispersed catalyst, consisting of abundant metals such as iron or nickel, is essential as this process contains a “sacrificial catalyst”; process contains a sacrificial catalyst; the catalyst, support, and CNFs combine as one product to improve the strength and durability of concrete. In partnership with both the Hubler group in the department of Civil and Environmental Engineering and the National Ready Mixed Concrete Association (NRMCA), we are investigating the CNF/catalyst product to reduce cracking and improve the durability of high purity concrete (HPC).

In this research, abundant transition metals are deposited onto a support via particle ALD. CCVD and catalyst treatment parameters are investigated to maximize carbon and hydrogen yield. CNFs and hydrogen are then generated via CCVD with the particle ALD catalyst. A preliminary technoeconomic analysis is performed to assess the large-scale viability of this catalytic methane pyrolysis technology.

¹Bartlett, J., & Krupnick, A. 2020. “Decarbonized Hydrogen in the US Power and Industrial Sectors: Identifying and Incentivizing Opportunities to Lower Emissions” (Report 20-25). Resources for the Future.