Promising results for methane pyrolysis for carbon black and hydrogen production
Carbon black is a solid-state carbon nanomaterial used in a wide range of products, primarily as a reinforcing filler in tyres and other rubber products. The project Methane Pyrolysis for Carbon Black and Hydrogen Production has investigated the possibilities of manufacturing carbon black via methane pyrolysis in conjunction with hydrogen production. We asked project manager Fredrik Weiland at RISE a few questions.
The project has utilised RISE's carbon black pilot plant in Piteå to decompose methane (CH4) into hydrogen (H2) and carbon black (C(s)). The scanning electron microscope (SEM) images were taken of carbon black produced specifically within this project. An electrified process, powered by a plasma torch, ensures temperatures high enough (>1400°C) to decompose CH4 and form carbon black.
What did you investigate in the project?
This was a feasibility study aimed at investigating the possibilities of manufacturing carbon black via methane pyrolysis at RISE's carbon black pilot plant in Piteå. The objective was to determine the yields of hydrogen and carbon black, as well as to examine how the quality of the carbon black was affected by various operating conditions.
The conclusions were as follows:
- It is possible to produce carbon black via methane pyrolysis using the ‘furnace black’ process.
- The material properties and structure of the carbon black are governed by the reactor's operating conditions.
- The carbon black from the feasibility study was classified as approximately the N300–N500 series (according to ASTM standardised classification for rubber carbon black grades).
- High hydrogen (H2) yield, but also a relatively high concentration of acetylene (C2H2) and traces of unconverted methane (CH4).
- Indications of insufficient residence time at high temperatures for certain samples in this study (non-optimised operating conditions).
- Electrification using a plasma torch is applicable – providing a significant CO2 reduction compared to traditional processes.
How can the results be used moving forward?
The feasibility study provided valuable results, paving the way for promising future work. We are currently working to secure funding and identify interested industrial partners for a larger-scale follow-up project.
The long-term objective of the project is to contribute to technological developments that enable climate-efficient hydrogen production, while allowing the solid carbon nanoproduct from methane pyrolysis to replace other fossil-based carbon black within the chemical industry (CCU).
Partners in the project: RISE, Borealis and Scandinavian Enviro Systems. On the project page below you can read more and access the final report.
Methane pyrolysis for carbon black and hydrogen production
