Techno-Economic Evaluation of Scalable and Sustainable Hydrogen Production Using an Innovative Molten-Phase Reactor

The transition to low-carbon energy systems requires efficient hydrogen production methods that minimise CO2 emissions. This study presents a techno-economic assessment of hydrogen production via methane pyrolysis, utilising a novel liquid metal bubble column reactor (LMBCR) designed for CO2-free hydrogen and solid carbon outputs. Operating at 20 bar and 1100 ◦C, the reactor employs a molten nickel-bismuth alloy as both catalyst and heat transfer medium, alongside a sodium bromide layer to enhance carbon purity and facilitate separation. Four operational scenarios were modelled, comparing various heating and recycling configurations to optimise hydrogen yield and process economics. Results indicate that the levelised cost of hydrogen (LCOH) is highly sensitive to methane and electricity prices, CO2 taxation, and the value of carbon by-products. Two reactor configurations demonstrate competitive LCOHs of 1.29 $/kgH2 and 1.53 $/kgH2, highlighting methane pyrolysis as a viable low-carbon alternative to steam methane reforming (SMR) with carbon capture and storage (CCS). This analysis underscores the potential of methane pyrolysis for scalable, economically viable hydrogen production under specificmarket conditions.