Economic Viability of Hydrogen Production via Plasma Thermal Degradation of Natural Gas

This study evaluated the economic feasibility of producing hydrogen from natural gas via thermal degradation in a plasma reactor. Plasma pyrolysis, where natural gas passes through the space between electrodes and serves as the working medium, enables high hydrogen yields without emitting carbon monoxide or carbon dioxide. Instead, the primary products are hydrogen and solid carbon. Unlike conventional methods, this approach requires no catalysts, addressing a major technological limitation. A thermodynamic equilibrium model based on Gibbs free energy minimization was used to analyze the process over a temperature range of 500–2500 K. The results indicate an optimal temperature of approximately 1500 K, which achieved a 99.5% methane conversion by mass. Considering the capital and operating costs and profit margins, the hydrogen production cost was estimated at 3.49 EUR/kg. The sensitivity analysis revealed that the price of solid carbon had the most significant impact, which potentially raised the hydrogen cost to 4.53 EUR/kg or reduced it to 1.70 EUR/kg.