Methane pyrolysis for carbon black and hydrogen production
Methane pyrolysis has recently emerged as an attractive enabler for climate-neutral hydrogen production as the process does not result in any CO2 emissions. The aim of this feasibility study project is to study thermal methane pyrolysis on a larger scale through experiments in a pilot plant (<30 g/min) for carbon black production at RISE in Piteå.
In thermal methane pyrolysis, the methane molecule is simply broken down into hydrogen gas and solid nanoparticulate carbon [CH4(g) + heat => 2H2(g) + C(s)]. This enables easy separation of the carbon which can then be stored (CCS) or utilized for other products (CCU). Methane pyrolysis technologies are still in the early stages of development and there is a lack of knowledge regarding both reactor design and optimal operating conditions. Through a Formas-funded project, RISE has conducted laboratory-scale experiments (0.3 g/min). The project results were promising and the carbon nanomaterial showed great similarities to carbon black. There is thus great potential for profitable business models through the simultaneous production of both hydrogen and high-value carbon nanoproducts, i.e. carbon black. At the same time, the demand for other fossil-produced carbon black is reduced, which reduces the global climate impact.
Purpose
The purpose of this feasibility study project is to study thermal methane pyrolysis on a larger scale through experiments in a pilot plant (<30 g/min) for carbon black production at RISE in Piteå. The pilot reactor is based on the design that is most common in the carbon black industry, the so-called 'furnace black' process. Unlike today's commercial processes where combustion of natural gas is used to generate the high reactor temperature (1400–1600 °C), the carbon black pilot is electrified and heated via a plasma burner, which means that the process can be completely free of CO2 emissions. The ambition is to carry out some initial tests in the pilot plant with the aim of quantifying the product yields, as well as thoroughly characterizing the carbon black produced. The hope is that the project results will form the basis for a larger research application in the area. In this way, the consortium hopes to be able to take significant steps on the road to commercialization.
Goals
The overall goal of the project is to, in the long term, contribute to technology development that enables climate-efficient hydrogen production while the solid carbon nanoproduct from methane pyrolysis can replace other fossil-produced carbon black in the chemical industry (CCU).
The concrete goals of the project proposal are to:
- Quantify the yields of hydrogen and carbon black from plasma-driven methane pyrolysis at pilot scale.
- Carefully characterize the obtained carbon black products from a couple of different industry-relevant operating conditions in order to investigate the possibilities of replacing some of the carbon black qualities that Borealis, for example, purchases from external suppliers.
- In case the results turn out to be promising, provide suggestions for further activities towards commercialization and identify suitable funding opportunities.
Participating parties
RISE, Borealis, Scandinavian Enviro Systems
Time Period
2025-03-01 – 2025-12-31
Total Budget
353 000 SEK
Read the final report (in Swedish)
Contact the Operational Area Manager
