Methane thermal decomposition is a promising technology for producing CO₂-free hydrogen. This study experimentally examines how temperature (1,000–1,400^oC) and residence time affect methane decomposition in a ceramic tubular reactor. The results show that both the methane conversion rate and hydrogen yield increased with temperature, reaching approximately 95% and 45%, respectively, at 1,400^oC. At lower temperatures (1,000–1,200^oC), residence time had a significant impact, while at higher temperatures (1,300–1,400^oC), temperature became the predominant factor. Additionally, the formation of C₂ hydrocarbons, particularly acetylene (C₂H₂), increased as residence time decreased, negatively affecting both methane conversion and hydrogen yield. Analysis of the solid carbon by-products identified two distinct forms: amorphous, spherical carbon black particles and a semi-graphitic, crystalline carbon film. These findings provide essential data for optimizing the conditions of methane thermal decomposition.

Sustainable Aviation Fuel (SAF) is crucial for achieving carbon neutrality in the aviation sector. Among various production methods, Fischer–Tropsch (FT) synthesis using eco-friendly syngas has garnered significant attention. Two primary routes for producing syngas for FT synthesis—Dry Reforming of Methane (DRM) and Water Electrolysis combined with Reverse Water Gas Shift (WE&RWGS)—are actively being studied. As upstream processes, these routes are evaluated for their potential to provide low-carbon syngas for FT synthesis. However, comprehensive comparisons between these two pathways are limited, despite their importance for future technology planning and decision-making. In this study, we conduct a comparative evaluation of DRM- and WE&RWGS-based SAF production systems using virtual process design, along with life cycle assessment (LCA) and techno-economic analysis (TEA), to assess their environmental and economic viability as future technologies. LCA results indicate that the DRM-based route has more than four times lower environmental impact compared to the WE&RWGS-based system. The majority of the environmental burden arises from feedstock supply (CH₄ and CO₂) and energy inputs. TEA results suggest that while the base case scenario demonstrates limited economic feasibility, future scenarios that incorporate economies of scale and policy incentives show promise for long-term economic viability.

Solid oxide fuel cell is a next generation energy conversion device that can efficiently convert the chemical energy of fuel into electrical energy. Fuel flexibility is one of the advantages of SOFCs over other types of fuel cells. SOFCs can operate with hydrocarbon type fuel. While nickel based composite is commonly used in direct methane fueled SOFC anode because of its great catalytic activity for methane reforming, the direct use of hydrocarbon fuels with pure Ni anode is usually insufficient for facile anode kinetics, and also deactivates the anode activity because of carbon deposition upon prolonged operation. In this report, the Ni based anodes with 20 nm thick catalytic functional layers, i.e., Pt, Ru, and Pt-Ru alloy, are fabricated by using the co-sputtering method to enhance the anode activity and power density of direct-methane SOFC operating at 500℃.