Integration of methane cracking and direct carbon fuel cell with CO₂ capture for hydrogen carrier production

Hydrogen fuel production from methane cracking is a sustainable process compared to the ones currently in practice due to zero greenhouse gas emissions. Also, carbon black that is co-produced is valuable and can be marketed to other industries. As this is a high-temperature process, using solar energy can further improve its sustainability. An integrated solar methane cracking system is proposed where hydrogen and carbon products are sent to fuel cells to generate electricity. The CO₂ exhaust stream from the carbon fuel cell is captured and reacted with hydrogen in the CO₂ hydrogenation unit to produce liquid fuels – Methanol and dimethyl ether. The process is simulated in Aspen Plus®, and its energy and exergy efficiencies are evaluated by carrying out a detailed thermodynamic analysis. In addition, a sensitivity analysis is performed on various input parameters of the system. The overall energy efficiency of 41.9% and exergy efficiency of 52.3% were found.