Summary
At a remote gas-processing site in Western Canada (client anonymized), we deployed a modular molten-bath methane-pyrolysis unit that converts a slipstream of natural gas into high-value carbon and clean hydrogen—cutting flaring and Scope-1 emissions at the source. A single 40-ft unit delivers ~580 t/yr of carbon and ~190–215 t/yr of net hydrogen while avoiding ~2,160 tCO₂e annually, creating a new revenue line instead of a carbon-tax liability.
The problem
The operator faced rising carbon costs and stakeholder pressure tied to routine and upset flaring. Globally, >150 bcm of gas is still flared each year (~390 Mt CO₂e), underscoring both the scale of the issue and the opportunity for site-level solutions.
Site constraints
- Harsh climate (–40…+35 °C design), limited power headroom, and strict hazardous-area compliance.
The solution
We installed Lightmatter’s containerized, four-box system:
- C1 Process & Reactor: Dual molten-tin chambers with PWM ohmic heating decompose CH₄ → C + 2H₂ at ≥1,000 °C and <1 s residence.
- C2 Power & Control: SiC rectifiers with constant-current control; plant-standard MCC/PLC.
- C3 Feed Gas & Pretreat: Block-and-bleed, USM meter, coalescer, analyzer rack; bypassable polishing media as needed.
- C4 H₂ Handling & Cooling: Knockout, blend to low-carbon fuel gas or small onsite power; hybrid dry cooler with PCM buffer.
Safety & compliance
The package follows CSA/CEC electrical codes, NFPA dust/venting, and ISO/IEC functional-safety and cybersecurity practices; pressure equipment meets Canadian CRN requirements.
How it works (in plain English)
Natural gas (85–98 % CH₄) is bubbled through a molten bath. The heat splits methane into solid carbon (captured by cyclone + baghouse) and hydrogen (dried/knocked-out and blended for energy use). As-produced carbon is ≥95 % C, with optional inline polishing to approach battery-grade later.
Implementation approach
- Discovery audit — Data pull on flare/slipstream quality, available utilities, and ESG priorities.
- Planning brief — Tie-in points, blend strategy, and emissions baselining (mass/energy balance closed for 1.4–1.6 t/d C).
- Execution track — Set containers, interconnect spools/trays, dry-run logic, and safety PLC proof tests (SIL-2 trips).
- Performance review — 72-hour acceptance at 1.4–1.6 t/d with conversion, energy, purity, and safety targets met.
Measured outcomes (first unit)
- Carbon production: 1.4–1.6 t/day (as-produced ≥95 % C).
- Hydrogen: ~0.47–0.53 t/day gross; net 190–215 t/yr after self-power options.
- Energy & uptime: ≤6.0 kWh/kg-C specific energy, ≥95 % availability design target.
- Air & dust: CH₄ slip minimized; baghouse vent dust ≤10 mg/Nm³.
- GHG impact: ~2,160 tCO₂e/yr avoided per unit (planning figure, carbon-credit ready).
Economics (illustrative, from plan)
- Revenue baseline: ~$1.6–$1.9 M/yr at bulk carbon pricing + net H₂ + credits, with upside to $4 M+/yr for specialty grades.
- CapEx learning curve: Typical unit ~$1.45–$1.55 M CAD after design optimizations.
ESG & community value
- Direct flare-gas abatement at the source; no solvent loops or amines.
- Pathway to battery-grade carbon via optional thermal polishing and classification.
- Indigenous partnership & local build options align with regional procurement and permitting goals (BC/AB).
Why this worked
- Right-sized, modular: four standard containers simplify siting and scale-out.
- Energy-smart: H₂ LHV (33.3 kWh/kg) lets the unit offset a large share of its own process power, trimming Opex and onsite emissions.
- Designed for real plants: codes/standards alignment, dust hazard controls, and cold-weather HVAC/ventilation.
What’s next
With FOAK performance proven, the operator is evaluating replication (≈1 unit every ~4 months) and a polishing step to qualify carbon for higher-value markets.
Technical appendix (key specs)
- Feed: CH₄-rich slipstream (85–98 % CH₄) with optional desulfurization; residence <1 s at ≥1,000 °C.
- Mass/Energy: 1.5 t/d case → ~500 kg/d H₂; process DC ~250–500 kW; BOP 15–50 kW.
- Solids handling: cyclone → baghouse → sealed totes; explosion-vented per NFPA 654.
