The thermocatalytic decomposition of methane is a promising method for hydrogen production. To determine the cause of carbonaceous catalyst deactivation and to produce high-value carbon, methane decomposition behavior and deactivated catalysts were analyzed. The surface properties and crystallinity of a commercial activated carbon material, MSP20, used as a methane decomposition catalyst, varied with the reaction time at a reaction temperature of 900 °C. During the initial reaction, MSP20 provided a methane conversion of ≥ 50%; however, the catalyst exhibited rapid deactivation as crystalline carbon grew at surface defects; after 15 min of reaction, approximately 33% methane conversion was maintained. With increasing reaction time, the specific surface area of the catalyst decreased, whereas crystallinity increased. The R-square value of the conversion–crystallinity relationship was significantly higher than that of the conversion–specific surface area relationship; however, neither profile was linear. The activity of the activated carbon catalyst for methane decomposition is mainly determined by the complex actions of the specific surface area and defect sites. The activity was maintained after an initial sharp decline caused by the continuous growth of crystalline carbon product. This study presents the application of carbonaceous catalysts for the decomposition reaction of methane to form COx- free hydrogen, while simultaneously yielding porous carbon materials with an improved electrical conductivity.

To investigate the effect of the catalyst and metal–support interaction on the methane decomposition behavior and physical properties of the produced carbon, catalytic decomposition of methane (CDM) was studied using Ni/SiO2 catalysts with different metal–support interactions (synthesized based on the presence or absence of urea). During catalyst synthesis, the addition of urea led to uniform and stable precipitation of the Ni metal precursor on the SiO2 support to produce Ni-phyllosilicates that enhanced the metal–support interaction. The resulting catalyst upon reduction showed the formation of uniform Ni0 particles (< 10 nm) that were smaller than those of a catalyst prepared using a conventional impregnation method (~ 80 nm). The growth mechanisms of methane-decomposition-derived carbon nanotubes was base growth or tip growth according to the metal–support interaction of the catalysts synthesized with and without urea, respectively. As a result, the catalyst with Ni-phyllosilicates resulting from the addition of urea induced highly dispersed and strongly interacting Ni0 active sites and produced carbon nanotubes with a small and uniform diameter via the base-growth mechanism. Considering the results, such a Ni-phyllosilicate-based catalyst are expected to be suitable for industrial base grown carbon nanotube production and application since as-synthesized carbon nanotubes can be easily harvested and the catalyst can be regenerated without being consumed during carbon nanotube extraction process.

Direct decomposition of methane over three types of carbon black (N330-p, N330-f, and HI-900L) was carried out in a fluidized bed quartz reactor. Properties of carbon black before and after reaction were measured and found to be related with surface structure and weight gain. For N330-p and N330-f, some carbon deposit on the surface was considered to be the reason for the increase of BET surface area and pore volume with weight gain. Carbon deposits on the surface and the conglutination of some aggregates may explain the slight increase of particle size. Properties of HI-900L changed much more significantly with weight gain. It is supposed that the increase of aggregate size of HI-900L were due to some unknown oily components. The corresponding agglomeration might be the reason for the decrease of BET surface area with weight gain, as compared with the increase of that for the case of N330 black.