Techno-economic analysis and experimental pre-study of hydrogen production with improved catalytic process

Background

The transition toward a carbon-neutral energy system demands large-scale production of clean hydrogen. Today, over 95% of global hydrogen is produced via Steam Methane Reforming (SMR)—a process that, despite its technological maturity and low cost, emits substantial amount of CO₂ per kg of H₂ produced. In contrast, water electrolysis, when powered by renewables, offers zero direct emissions but remains limited by high electricity demand and cost. These challenges hinder the global expansion of low-emission hydrogen.

Methane pyrolysis, also referred to as turquoise hydrogen production, has recently emerged as a promising alternative. The process thermally decomposes methane into hydrogen and solid carbon, avoiding CO₂ formation altogether. Compared to electrolysis, it requires significantly less energy input, while producing a valuable solid carbon by-product suitable for industrial use in metallurgy, batteries, and advanced materials. When enhanced with a catalyst, the process can operate at lower temperatures and with improved hydrogen yield, offering both environmental and economic advantages.

Preliminary research conducted at the KTH Heat and Power Technology (HPT) Laboratory, as part of the MERiT+ and CH4Industry initiatives, has shown unexpectedly high hydrogen conversion rates at relatively low temperatures using nickel-based catalysts. This performance is hypothesized to result from thermal and redox activation techniques, improving catalyst activity and stability. Building on these findings, this thesis will experimentally investigate and model the process in order to evaluate its technical feasibility and economic viability as a scalable low-emission hydrogen production method.

Aim of the Thesis

To evaluate the technical feasibility and economic viability of catalytic methane pyrolysis and to define scaling strategies for pilot- and industrial-level hydrogen production.

Option for two MSc students:

• Student A: Experimental investigation of catalyst performance and process optimisation.

• Student B: Techno-economic modelling, cost analysis, and industrial scale-up scenarios.

Specific Objectives

• To experimentally validate the performance of CMP and nickel-based catalysts for methane pyrolysis under controlled temperature and pressure conditions.

• Determine optimal catalyst activation and regeneration methods for sustained performance.

• Develop a techno-economic model for CMP, estimating CAPEX, OPEX, and LCOH across plant scales and configurations

• Compare CMP with SMR (± CCS) and electrolysis, identifying economic break-even points.

• Propose process-scale configurations suitable for integration with existing gas or industrial systems.

Research Questions

• Can catalytic methane pyrolysis (CMP) achieve high hydrogen yield at reduced operational temperatures using optimised nickel-based catalysts?

• How do activation and regeneration methods affect catalyst lifetime and conversion efficiency?

• What is the potential economic competitiveness of CMP compared with SMR and water electrolysis under varying energy and feedstock costs?

• How can laboratory-scale findings inform the design of future pilot-scale methane pyrolysis systems?

Expected Deliverables

• Joint MSc Thesis Report (or two coordinated reports) covering:

• Experimental results and catalyst analysis

• Techno-economic and scale-up evaluation

• Comparative analysis vs SMR and electrolysis

• Oral presentation(s) at KTH.

• Data and findings contributed to CH4Industry documentation and future publications.

Duration

The project should start in Jan-Feb 2026, with a duration of up to 6 months.

Location

KTH, Department of Energy Technology

Supervisors

Examiner