Carbon Neutral Hydrocarbon Pyrolysis With Catalytic Membrane Process
1 October 2026
Affiliation
NUS
Focus topic
Low-carbon H2 & Derivatives
Low-Temperature Catalytic Membrane for Clean Hydrogen Production
Summary
This technology is an integrated catalytic membrane reactor that converts methane and other hydrocarbons into ultra-pure hydrogen and carbon nanotubes (CNTs) at significantly lower temperatures (500–650°C) than conventional methane pyrolysis processes (typically 800–1,400°C). Simultaneous hydrogen removal through a Pd-based membrane shifts the reaction equilibrium, achieving up to 77% single-pass methane conversion at 550°C with 80% hydrogen recovery, while nearly 100% methane conversion is predicted at 700°C with 80% H₂ recovery.
Laboratory studies demonstrated stable methane conversion (>40%) over 35 hours using a catalyst-coated membrane reactor. The process eliminates downstream hydrogen purification, produces high-value metal-free CNTs, and incorporates in-situ catalyst regeneration using CO₂, enabling potential carbon-neutral or carbon-negative hydrogen production. A laboratory-scale integrated prototype reactor has been designed and is currently under commissioning (TRL 3).
Potential industrial interest has been identified from Shell, ExxonMobil Asia Pacific, Sembcorp and Dyna-Mac, although no formal collaboration or licensing agreement has been reported.
What makes this novel compared to best-in-class technology?
Integrated catalytic membrane simultaneously performs methane pyrolysis and hydrogen separation, enabling operation at 500–650°C versus 800–1,400°C for exisiting technologies.
It also enables in-situ CO₂ catalyst regeneration and co-produces high-value carbon nanotubes, reducing energy consumption and downstream hydrogen purification costs.
TRL Level
1-3
Relevant for
Hydrogen production plants, ammonia plants, refineries, petrochemical complexes, methanol plants, industrial gas producers, natural gas processors, steel decarbonisation projects, waste-to-hydrogen facilities
About
Inventors: Sibudjing Kawi
Affiliation: National University of Singapore (NUS), Department of Chemical and Biomolecular Engineering
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