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The Future of Hydrogen Chapter 2: Producing hydrogen and hydrogen-based products Box 3. Emerging technologies to produce hydrogen Methane splitting offers a potential new way to produce hydrogen from natural gas. Various technologies have been developed since the 1990s. The main technology is based on alternating- current three-phase plasma, and uses methane as a feedstock and electricity as an energy source. It produces hydrogen and solid carbon, but no CO2 emissions (Fulcheri, 2018). Methane splitting requires high-temperature plasma and significant thermal losses reduce its efficiency advantage, but it uses three to five times less electricity than electrolysis for the same amount of hydrogen produced. It has very low CO2 formation and creates solid carbon in the form of carbon black. It requires more natural gas than electrolysis, but could create additional revenue streams from the sale of carbon black for use in rubber, tyres, printers and plastics. The US firm Monolith Materials operates a pilot methane splitting plant in California and is building an industrial plant in Nebraska; the Nebraska plant will ultimately be run on low-carbon electricity and sell hydrogen to the Nebraska Public Power District, which plans to convert a 125 MW coal plant to burn hydrogen instead of coal. Although the total efficiency would be lower than using the natural gas directly in the power plant, the emissions from gas combustion would be avoided and the hydrogen would effectively be a “store” of input electricity for the power network. Global demand for carbon black is expected to increase from 12 Mt to 16 Mt in the next five years, which would have significant accompanying CO2 emissions using current technology. Producing under 5 MtH2/yr of hydrogen via methane splitting could substitute all this demand and avoid these emissions. Markets for other exotic forms of solid carbon – carbon nanotubes, carbon fibres, graphene – are one to two orders of magnitude smaller than that for carbon black, but could grow rapidly with the expansion of batteries or carbon-reinforced concrete (Dagle et al., 2017). Other solid carbon markets may provide other options (Hanson, 2018). Meanwhile, alternative process designs for SMR are being explored. While natural gas would still be required as feedstock, other energy sources could be used to produce the necessary steam, and this could facilitate the capture of the more concentrated “process” CO2 stream. Electricity is a potential candidate for the production of the necessary high-temperature steam (Bazzanella and Ausfelder, 2017), while concentrating solar heat could be used in areas with the right kind of solar resources. If even higher levels of solar concentration could generate temperatures of around 800–1 000°C, solar energy could be used directly to split water into hydrogen and oxygen without the need for natural gas and CO2 storage. The technology for these higher solar concentration levels, however, is still at laboratory scale. Sources: Fulcheri (2018), “Direct decarbonization of methane by thermal plasma for the co-production of hydrogen and carbon nanostructures”; Dagle et al. (2017), “An overview of natural gas conversion technologies for co-production of hydrogen and value- added solid carbon products”; Bazzanella and Ausfelder (2017), “Low carbon energy and feedstock for the European chemical industry”; and personal communication with Rob Hanson, 2018. PAGE | 41 IEA. All rights reserved.PDF Image | The Future of Hydrogen 2019
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