Low-carbon hydrogen production via electron beam plasma methane pyrolysis: Techno-economic analysis and carbon footprint assessment

Electron beam plasma methane pyrolysis is a hydrogen production pathway from natural gas without direct CO₂ emissions. In this work, two concepts for a technical implementation of the electron beam plasma pyrolysis in a large-scale hydrogen production plant are presented and evaluated in regards of efficiency, economics and carbon footprint. The potential of this technology is identified by an assessment of the results with the benchmark technologies steam methane reforming, steam methane reforming with carbon capture and storage as well as water electrolysis. The techno-economic analysis shows levelized costs of hydrogen for the plasma pyrolysis between 2.55 €/kg H₂ and 5.00 €/kg H₂ under the current economic framework. Projections for future price developments reveal a significant reduction potential for the hydrogen production costs, which support the profitability of plasma pyrolysis under certain scenarios. In particular, water electrolysis as direct competitor with renewable electricity as energy supply shows a considerably higher specific energy consumption leading to economic advantages of plasma pyrolysis for cost-intensive energy sources and a high degree of utilization. Finally, the carbon footprint assessment indicates the high potential for a reduction of life cycle emissions by electron beam plasma methane pyrolysis (1.9 kg CO₂ eq./kg H₂ – 6.4 kg CO₂ eq./kg H₂, depending on the electricity source) compared to state-of-the-art hydrogen production technology (10.8 kg CO₂ eq./kg H₂).