Innovative catalyst and its regeneration for clean hydrogen production via methane pyrolysis - InnoHyppy
From waste aluminium to cleaner hydrogen: InnoHyppy combined catalyst innovation, regeneration, and by-product valorisation into a circular methane pyrolysis concept.In the InnoHyppy project, experts from Lithuania, Latvia, and Slovenia joined forces to advance both the fundamental understanding and practical application of Fe/Ni-based materials for the development of innovative catalysts loaded on γ-Al₂O₃ support produced from waste aluminium and by enabling cleaner and more efficient hydrogen production via methane pyrolysis. The project focused not only on the development of catalyst systems, but also on strategies to extension catalyst lifetime. Additionally, regeneration approaches and the sustainable use of process by-products as secondary raw materials were explored. Specifically:i) The project results demonstrated that waste aluminium can be effectively converted into high-purity γ-Al₂O₃ via a hydrolysis reaction, while simultaneously producing hydrogen, and that the resulting material can be successfully used as a catalyst support for methane pyrolysis applications; ii) an innovative catalyst system was developed, where Fe ensured stability and durability, while Ni nanoclusters enhanced activity; reaching higher methane conversion performance at lower temperatures; iii) the developed catalyst achieved hydrogen yields of up to 82% at reaction temperatures of 700 °C;iv) a novel plasma-based regeneration approach for coked catalysts enabled up to 38% carbon removal, demonstrating the potential for catalyst reuse and and extension of operational lifetime;v) the carbonaceous by-products of methane pyrolysis were successfully valorised and demonstrated as suitable materials for working electrodes applicable in pesticide detection technologies.These achievements contributed to the development of an integrated dual clean hydrogen production technology via hydrolysis for support production and methane pyrolysis by avoiding critical raw materials, lowering the carbon footprint, improving process efficiency, and promoting circular use of waste-derived materials. All project results were published in 9 scientific articles, resulted in 1 national (Lithuanian) patent, and were presented at 15 scientific conferences. Moreover, InnoHyppy project achievements were actively disseminated through radio broadcasts, lectures for students, and the wider public, interviews, and other outreach activities. The success of the InnoHyppy project encouraged the consortium to expand the concept further and explore new opportunities for continued development, fostering stronger collaboration, advancing innovative hydrogen technologies, and accelerating the transition toward sustainable energy solutions.
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