Modelling and simulation of hydrogen production via natural gas plasma pyrolysis

Abstract Plasma pyrolysis is a cutting‐edge technology that produces hydrogen and solid carbon from methane without emitting carbon dioxide. In this study, we developed a process simulation model in Aspen HYSYS to analyze the behaviour of this technology at the commercial scale. Methane pyrolysis reactions were modelled using a non‐isothermal equilibrium approach, coupled with a kinetic model from the literature. The model was validated using experimental data from laboratory‐scale studies and then extended to represent the commercial‐scale process using natural gas as feedstock. The effects of temperature, pressure, and plasma gas volume on process performance were examined. While analysis of simulation results suggested that the process temperature required to maximize hydrogen yield with minimum by‐products like soot should be close to 3000°C, the commercially applicable temperature is known to be lower, around 2000°C. The estimated specific energy requirement (SER) of the process under commercially relevant conditions (20.12 kWh/kg H 2 ) was found to be in good agreement with that reported by the only known industrial facility (21.54 kWh/kg H 2 ).