Hydrogen and Carbon Production by Methane Catalytic Cracking

A special issue of Processes (ISSN 2227-9717). This special issue belongs to the section "Energy Systems".

Deadline for manuscript submissions: closed (15 October 2025) | Viewed by 1732

Special Issue Editors


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Guest Editor
Chemical and Petroleum Engineering, Khalifa University of Science and Technology, Abu Dhabi P.O. Box 127788, United Arab Emirates
Interests: gas processing; adsorption; catalysis; mineral processing; gasification; pyrolysis; combustion; microwave application; solid waste; waste water; air pollution; process modeling and simulation

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Guest Editor
Department of Chemical Engineering, King Fahd University of Petroleum & Minerals, Dhahran 31261, Saudi Arabia
Interests: catalysis and reaction engineering–in the areas of oxidative cracking/dehydrogenation of hydrocarbons; catalytic cracking of hydrocarbons, oil to chemicals; chemical looping; blue hydrogen; ammonia decomposition to hydrogen; biomass/heavy oil gasification; pyrolysis of waste materials
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Special Issue Information

Dear Colleagues,

The energy transition from fossil fuels is occurring at an unexpectedly rapid pace. Green hydrogen is the agreed path forward to facilitate this transition. Mega projects are being planned for the decades ahead, and hence, the necessary infrastructure and logistics need to be developed to achieve the free availability of hydrogen in the market. The only feasible way of hydrogen production in the industry is steam methane reformation (SMR), which is energy-intensive and involves substantial carbon emissions. As an alternate way of facilitating a smooth transition from fossil-based hydrogen to green hydrogen, methane can be catalytically cracked to hydrogen and solid carbon without carbon emissions at atmospheric pressure, thermodynamically demanding only one-fifth the energy used in SMR. However, the economic feasibility of this process largely depends on the development of a catalyst that can offer high conversion and stability, as well as the development of suitable separation processes.

The topics of interest for this Special Issue include, but are not limited to, the following:

  1. Development of a catalyst that offers high conversion and stability for methane cracking
  2. Characterization and quantification of carbon nanostructures formed through the cracking of methane
  3. Separation of carbon nanostructures from the catalyst
  4. Kinetics and mechanism of the methane cracking reaction
  5. Separation of hydrogen and methane
  6. Regeneration and recycling of the catalyst
  7. Techno-economic feasibility of the methane cracking process
  8. Application of the carbon nanostructures formed through methane cracking

Prof. Dr. Chandrasekar Srinivasakannan
Prof. Dr. Mohammad Mozahar Hossain
Guest Editors

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Keywords

  • methane
  • hydrogen
  • catalytic cracking
  • carbon nanostructures
  • green energy

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Published Papers (1 paper)

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Research

14 pages, 3452 KB  
Article
The Investigation of Methane Pyrolysis and Its Carbon Products Utilizing Molten Metal/Molten Salt Composite Reactors
by Xichen Su, Jiashu Liao, Xiangyang Luo, Xuncheng Ouyang, Jianjun Wei and Fujun Gou
Processes 2025, 13(11), 3549; https://doi.org/10.3390/pr13113549 - 4 Nov 2025
Viewed by 987
Abstract
Methane pyrolysis for turquoise hydrogen production faces dual challenges of reactor clogging and carbon contamination, particularly the difficulty in extracting high-purity carbon from molten media. While most existing studies focus on two-phase systems, carbon products are inevitably contaminated by the medium. This work [...] Read more.
Methane pyrolysis for turquoise hydrogen production faces dual challenges of reactor clogging and carbon contamination, particularly the difficulty in extracting high-purity carbon from molten media. While most existing studies focus on two-phase systems, carbon products are inevitably contaminated by the medium. This work presents a novel dual-layer bubble column reactor (Cu0.45Bi0.55 alloy/NaCl salt) operating at 900–1100 °C. The system achieved continuous operation for over 72 h without clogging. Crucially, the selected NaCl salt offers distinct advantages: its low cost, non-toxicity and high water solubility facilitate effective carbon separation strategies. This configuration reduced metal contamination in carbon from 52.4 wt% to below 4.0 wt%, with post-treatment achieving ultralow metal content below 1.5 wt%. Moreover, the molten salt environment induced valuable structural modifications in the carbon. This work provides an economically viable process for co-producing clean hydrogen and high-value carbon, addressing key technical barriers in molten media reactors. Full article
(This article belongs to the Special Issue Hydrogen and Carbon Production by Methane Catalytic Cracking)
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