Catalytic cracking of methane to hydrogen and carbon: Scale-up perspective

Decarbonizing natural gas for the production of H₂ and value-added nanostructured graphitic carbons via catalytic decomposition of methane (CDM) presents an attractive alternative to conventional steam-methane reforming. This work is an attempt to establish the practical viability of the CDM process considering the reciprocity of methane conversion, the type and quantity of carbon formation, and the effective lifetime of the catalyst. Effects of the reaction parameters and reactor configurations on the catalyst performance, type of carbon-formation, and the catalyst degradation have been analyzed critically, providing state-of-the-art on laying a foundation for the development of new catalysts with better selectivity and longevity. Finally, a continuous regeneration-recycling system has been modeled by simulating a fluidized-bed reactor for Fe-based catalyst. The energy-exchange efficiency of regeneration/recirculation of catalyst via partial combustion has been established to lay out the guidelines for future development of the CDM process on a commercial-scale.