Hydrogen production for industrial processes via methane pyrolysis

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Methane pyrolysis as a novel hydrogen production technology shall enable the supply of industry with a low-cost, low emission energy carrier. Project idea description​- The problem we would like to solveThe 1st challenge is the decarbonization of industrial process heat, which is the third important energy sector. So far, there is no convincing concept available for its decarbonization apart from the use of biogas, which, however, does not have the necessary volume potential by farThe 2nd challenge is the reduction of electricity demand and imports during winter. The transition of the energy system will lead to a shift towards electrification of mobility and building heating. This will happen in parallel to phasing-out of nuclear power and expansion of photovoltaics. Recent calculations by the Swiss Federal Office for Energy expect a strongly increasing domestic electricity undersupply of more than 10 TWh each winter in the decades to come.The 3rd challenge finally is to generate negative CO2 emissions. Negative emissions will be necessary on a large scale (up to 12 Mt/y) after 2040 to offset remaining emissions. - Our proposed solutionHydrogen is a viable option for the decarbonization of industrial process heat, but as a consequence of the above challenges the production capabilities i) should not emit any CO2 as part of the production process and ii) should not require large amounts of electricity and iii) can offer H2 at a low price. Methane pyrolysis complies with these requirements by decomposing the primary energy carrier methane into solid carbon and gaseous hydrogen. Besides hydrogen for energetic use, a second, marketable product is created –solid carbon. Moreover, the methane pyrolysis allows for CO2 negative emissions if renewable methane (biogas or synthetic methane) is the input. The proposed solution enables rapid large-scale transition to a decarbonized industrial sector and a gradual pathway to negative emissions avoiding lock-in effects. - Who are our customers and how will they profit from our solutionOur customers are industrial companies that run processes at elevated temperatures. Up to now, these processes are fueled by natural gas. The customers could replace their fuel by hydrogen, which could be produced in a methane pyrolysis plant on-site. By doing so, the customers can reduce their CO2 emissions significantly and actually move towards net zero. - How does our project idea affect energy savings or CO2 emissionsOur project idea does affect CO2 emissions by separating the carbon from methane before energetic use. This prevents the largest share of emissions and results in solid carbon.If run with biogas or renewable methane, the process leads to negative CO2 emissions. This is the case because the CO2 necessary for the renewable methane production is taken from other emission sources and in the end is converted to solid carbon, which in contrast to gas is stable and can be stored long term. Going even further, this carbon can be a valuable product as additive in the construction sector (asphalt, cement) or as fertilizer in agriculture. Current status and previous activities - What has been tried before. What was not successful. What have we learnedCurrently our partner companies XGas, Plustherm, and Empa are working on a prototype of laboratory scale. We have successfully performed thermal methane pyrolysis, reaching a concentration of hydrogen of 99% in the product gas. Currently, the challenges are to enable a continuous process, and to design heat recuperation and solid-gas separation units downstream of the reactor. Resources needed - What are our planned work packages1. Definition and development of a proper business model for the methane pyrolysis plants2. Pre-studies for upscaling of the prototype to a demonstrator plant, with hydrogen production capacity of 10 kg/h.3. Identification of suitable separation and heat recuperation concepts and realization of such a concept on laboratory scale. - How can the Energy Lab help youEnergy Lab could help us by identifying and introducing potential customers and developing a business model.

Project Idea Metadata

• Project Idea Name: Hydrogen production for industrial processes via methane pyrolysis
• Date: 3/2/2022 8:35:43 AM
• Administrators:
  • Julia Gerber

Project Idea Description

Project idea description​

- The problem we would like to solve

The 1st challenge is the decarbonization of industrial process heat, which is the third important energy sector. So far, there is no convincing concept available for its decarbonization apart from the use of biogas, which, however, does not have the necessary volume potential by far

The 2nd challenge is the reduction of electricity demand and imports during winter. The transition of the energy system will lead to a shift towards electrification of mobility and building heating. This will happen in parallel to phasing-out of nuclear power and expansion of photovoltaics. Recent calculations by the Swiss Federal Office for Energy expect a strongly increasing domestic electricity undersupply of more than 10 TWh each winter in the decades to come.

The 3rd challenge finally is to generate negative CO2 emissions. Negative emissions will be necessary on a large scale (up to 12 Mt/y) after 2040 to offset remaining emissions.

- Our proposed solution

Hydrogen is a viable option for the decarbonization of industrial process heat, but as a consequence of the above challenges the production capabilities i) should not emit any CO2 as part of the production process and ii) should not require large amounts of electricity and iii) can offer H2 at a low price. Methane pyrolysis complies with these requirements by decomposing the primary energy carrier methane into solid carbon and gaseous hydrogen. Besides hydrogen for energetic use, a second, marketable product is created –solid carbon. Moreover, the methane pyrolysis allows for CO2 negative emissions if renewable methane (biogas or synthetic methane) is the input. The proposed solution enables rapid large-scale transition to a decarbonized industrial sector and a gradual pathway to negative emissions avoiding lock-in effects.

- Who are our customers and how will they profit from our solution

Our customers are industrial companies that run processes at elevated temperatures. Up to now, these processes are fueled by natural gas. The customers could replace their fuel by hydrogen, which could be produced in a methane pyrolysis plant on-site. By doing so, the customers can reduce their CO2 emissions significantly and actually move towards net zero.

- How does our project idea affect energy savings or CO2 emissions

Our project idea does affect CO2 emissions by separating the carbon from methane before energetic use. This prevents the largest share of emissions and results in solid carbon.

If run with biogas or renewable methane, the process leads to negative CO2 emissions. This is the case because the CO2 necessary for the renewable methane production is taken from other emission sources and in the end is converted to solid carbon, which in contrast to gas is stable and can be stored long term. Going even further, this carbon can be a valuable product as additive in the construction sector (asphalt, cement) or as fertilizer in agriculture.

Current status and previous activities

- What has been tried before. What was not successful. What have we learned

Currently our partner companies XGas, Plustherm, and Empa are working on a prototype of laboratory scale. We have successfully performed thermal methane pyrolysis, reaching a concentration of hydrogen of 99% in the product gas. Currently, the challenges are to enable a continuous process, and to design heat recuperation and solid-gas separation units downstream of the reactor.

Resources needed

- What are our planned work packages

1. Definition and development of a proper business model for the methane pyrolysis plants

2. Pre-studies for upscaling of the prototype to a demonstrator plant, with hydrogen production capacity of 10 kg/h.

3. Identification of suitable separation and heat recuperation concepts and realization of such a concept on laboratory scale.

- How can the Energy Lab help you

Energy Lab could help us by identifying and introducing potential customers and developing a business model.

Methane pyrolysis as a novel hydrogen production technology shall enable the supply of industry with a low-cost, low emission energy carrier.