Comparison of different process technologies for HCNG production
Parameters Feedstock
SMR
Water electrolysis
Methane pyrolysis
HP-HCNG technology NG/refinery fuel gas/
Naphtha
Water
Methane
natural gas 800-900°C
biogas
Operating
70-100°C (PEM and alkaline electrolysers)
1,100-1,200°C
~600°C
temperature
Catalyst
Ni based
Nil Nil
Nil Nil
Proprietary
Process CO₂
~ 9-11 kg/kg H₂
Nil
footprint Water footprint
4.5 kg/kg H₂ Hydrogen CO and CO₂
9 kg/kg H₂ Hydrogen
Nil
Nil
Product
Hydrogen
H-CNG
Byproduct
O₂
Solid carbon (amorphous)
Carbon nanomaterials
with >90% purity
Table 1
• True zero-emission hydrogen production : Most reported HCNG demonstrations, including those undertaken by public transport authorities and gas utilities in India and abroad, rely on hydrogen sourced from SMR. This means they have significant carbon emissions unless paired with carbon capture technologies. In comparison, HPCL’s process produces hydrogen via catalytic pyrolysis, resulting in zero direct CO₂ emissions. This positions the technology as an authentic low-carbon pathway, rather than one dependent hydrogen production technologies, including SMR and electrolysis, consume significant quantities of water, which is a growing concern in water-stressed geographies. HPCL’s process is entirely water-free, reducing environmental impact and broadening applicability in industrial zones where water availability is constrained or highly regulated. on offsets or post-treatment systems. • No water requirement : Conventional • High-value byproduct integration : The majority of competing methane pyrolysis processes generate amorphous or low-value carbon byproducts; HPCL’s proprietary catalyst and reactor system selectively produce carbon nanomaterials, including MWCNTs. This transforms the carbon residue from a disposal liability into a high-value revenue stream, enhancing the process’s financial attractiveness and supporting a circular economy. • Catalyst and reactor innovation: The catalyst used in HP HCNG technology is synthesised
in-house, creating a self-reliant, cost-effective supply chain. Moreover, the process operates in a custom-designed fluidised bed reactor, with continuous operation, uniform heat distribution, and easy scalability. Summary As industries worldwide are accelerating their efforts towards decarbonisation, there is an urgent need for technologies that are not only sustainable but also practical, scalable, and economically viable. HP HCNG technology offers a solution that meets these requirements. By leveraging catalytic methane pyrolysis at low temperatures and without the need for water, the technology provides a true zero-emission pathway to HCNG production. The integrated generation of carbon nanomaterials, including MWCNTs, adds a valuable commercial dimension, enabling cost competitiveness and market flexibility.
Arun Kuniyil arunkuniyil@hpcl.in
Bhanu Prasad S G bhanuprasad.sg@hpcl.in Pramod Kumar pramodkumar@hpcl.in Sriram S ssriram@hpcl.in V.K. Maheshwari vkmaheshwari@hpcl.in
Refining India
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