Intermediate temperature catalytic methane splitting for a swift energy decarbonization

ongoing

Project ZeroCarb will develop, optimize, and operate an intermediate-temperature catalytic methane splitting (IT-CMS) reactor, with the balance of plant, in a relevant environment (TRL6), using biomethane as feedstock and green electricity. This project follows 112CO2 (GA 952219), which developed the fundamentals for the IT-CMS. It is generally accepted that this reaction, also known as methane decomposition or pyrolysis, will play a critical role in the swift and cost-effective energy transition. Due to this great potential, several different processes have been proposed, and new and existing companies are investing in this technology. IT-CMS technology displays, however, critical advantages over all other technologies: i) avoids the use of special reactor’s envelop materials, since it runs at 750 °C and 1 bar, and is catalytic; ii) when fed with biomethane it produces H2 with a negative CO2 footprint and renewable graphitic carbon; iii) the produced metal-free carbon nanofilaments (mostly MWCNT) are shaved off chemically using H2; iv) the reactor is more energy efficient since it uses a fixed bed; v) the catalyst is activated steel foil, commercially available, which reduces the CAPEX tremendously; vi) the reactor module is expected to display a high power density, ca. 1.5 kW L-1, and energy efficiency > 80 %, and a catalyst high stability >> 8500 h; and vii) low CAPEX plant, significantly cheaper than an SMR plant. ZeroCarb targets the development of a demonstration unit producing 2 kgH2 h-1 (ca. 67 kWH2e) and 6 kgC h-1, based on an activated steel foil packed in a plate and frame module. HyCarb aims to bring this technology into the market and meet industry standards or regulations. The business model will be validated with the two industrial partners, CapWatt for hydrogen exploitation (for refineries and synthesis of ammonia/methanol) and BeDimensional as an off-taker of high-purity carbon (for electrically conductive inks/pastes and electrochemical devices).