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<p>Approximately 50% of the hydrogen produced globally is derived from the steam reforming of methane (SMR), which is associated with significant environmental impacts amounting to 10.5 tons of CO<sub>2</sub> equivalent per ton of hydrogen produced, thus exacerbating the challenges of global warming. An alternative approach to producing clean hydrogen involves methane pyrolysis utilizing metals, and salts. The present review paper showed different aspects of methane cracking (pyrolysis) of molten metal via the bubble-catalyst technique. The direct cracking of methane utilizing supported nickel catalysts has emerged as a viable alternative pathway for hydrogen production from natural gas. Moreover, economic analyses indicate that this approach is financially advantageous, particularly when the solid carbon produced can be reclaimed and utilized. Techno-economic studies showed that methane pyrolysis yields a 14% cost decrease at 100&#xa0;Nm<sup>3</sup>/h capacity vs. SMR with carbon capture and 25% against electrolysis. Also, selling carbon byproducts at $500/ton offsets 30–40% of manufacturing expenses, a capability lacking in blue/green hydrogen routes. A significant benefit of utilizing molten metal bubble columns lies in the ability to achieve continuous carbon separation, as the low-density solid carbon naturally rises to the surface of the molten liquid. Although problems with carbon markets and scalability still exist, the combination of interface engineering, computational design, and renewable integration sets molten metal pyrolysis as the pillar of turquoise hydrogen generation.</p>

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Bubble-Catalyst Interface Engineering in Methane Cracking of Molten Metal: A Review of Process Strengthening and Carbon Material Regulation

  • 期刊论文

  • 发表日期：

    2026年5月26日

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  • Lu Wang,
  • Qi Li,
  • Junkun Hu,
  • Yangdong He,
  • Wenhan Wang,
  • Shanhong Guo,
  • Yongda Cao

摘要

Approximately 50% of the hydrogen produced globally is derived from the steam reforming of methane (SMR), which is associated with significant environmental impacts amounting to 10.5 tons of CO2 equivalent per ton of hydrogen produced, thus exacerbating the challenges of global warming. An alternative approach to producing clean hydrogen involves methane pyrolysis utilizing metals, and salts. The present review paper showed different aspects of methane cracking (pyrolysis) of molten metal via the bubble-catalyst technique. The direct cracking of methane utilizing supported nickel catalysts has emerged as a viable alternative pathway for hydrogen production from natural gas. Moreover, economic analyses indicate that this approach is financially advantageous, particularly when the solid carbon produced can be reclaimed and utilized. Techno-economic studies showed that methane pyrolysis yields a 14% cost decrease at 100 Nm3/h capacity vs. SMR with carbon capture and 25% against electrolysis. Also, selling carbon byproducts at $500/ton offsets 30–40% of manufacturing expenses, a capability lacking in blue/green hydrogen routes. A significant benefit of utilizing molten metal bubble columns lies in the ability to achieve continuous carbon separation, as the low-density solid carbon naturally rises to the surface of the molten liquid. Although problems with carbon markets and scalability still exist, the combination of interface engineering, computational design, and renewable integration sets molten metal pyrolysis as the pillar of turquoise hydrogen generation.