Microwave Plasma Catalysis Pyrolyzer for Low-Carbon Hydrogen Production

The goal of Maat Energy is the production of low-carbon hydrogen at a cost of < $2.0 / kg H2. Currently, the primary method (> 95%) employed for hydrogen production commercially is steam-methane reforming (SMR). While this process can produce hydrogen at a cost of < $2.0 / kg H2 it has a high carbon intensity. On the other hand, while electrolysis is an environmentally friendly alternative for hydrogen production, the cost of hydrogen generation using electrolysis is typically > $4.0 / kg H2. We propose the development of Microwave Decomposition of Methane (MDM). The MDM process is a novel low-temperature plasma catalysis system for the pyrolysis of methane into hydrogen and carbon black as a value-added byproduct (CH4 ? 2 H2 + C(s)). The electricity required in the MDM process is ¼ that of the electricity required for electrolysis. In addition, the solid carbon produced by the MDM can be used a valuable byproduct Maat Energy has been developing microwave-based plasmas for chemical applications. We will leverage that expertise in order to apply our experience to gain operational advantages of the MDM process. In Phase II we developed novel reactors that eliminate the need for dielectrics in close proximity to the plasma and catalytic means to adjust the plasma temperature. In this program we will scale the technology to commercial scale and will build and test a pre-commercial unit in the field, with support from our industrial partner. Preliminary analysis of the carbon solids produced have been shown it to be a high value carbon black product. We will continue to analyze the carbon solids produced by the process to control its form and value. Our ability to control and reduce plasma temperatures through the use of our catalyst enables this control of carbon structure. If successful, the market would be large, as the US consumes about 10 million tons per year of hydrogen, mostly for refinery and ammonia manufacturing applications. At $2/kg, the potential market is around $20 billion/year. In addition, other applications, such as transportation, can substantially increase the market size.