112CO2 · Project

Clean Hydrogen from Natural Gas Without Any CO2 Emissions

energyTestedTRL 5

Right now, making hydrogen from natural gas releases a lot of CO2 — it's like squeezing juice but leaving a mess behind. This project cracked a way to split methane into pure hydrogen and solid carbon, with zero exhaust gases. Think of it as getting the clean fuel out while the carbon stays behind as a harmless solid you can actually sell. They built a special reactor that runs at relatively low temperatures and proved it works for thousands of hours.

By the numbers

100%

Selective reaction — methane splits into only carbon and hydrogen, no CO2

> 0.45 gH2/gCat/h

Target catalyst activity for hydrogen production

10,000 h

Target catalyst stability lifetime

3,000 h

Prototype tested under real conditions

500 h

Initial proof-of-concept experiment completed before project start

~600°C

Operating temperature of the membrane reactor

> 0.05 gH2/cm3/h

Target energy density, comparable to PEM fuel cells

The business problem

What needed solving

Producing hydrogen today mostly means steam methane reforming, which dumps massive amounts of CO2 into the atmosphere. Companies face tightening carbon regulations and rising emission costs, but alternatives like electrolysis are expensive and energy-hungry. The industry needs a way to get clean hydrogen from cheap, abundant methane without the carbon penalty.

The solution

What was built

The project developed a low-temperature methane decomposition catalyst with a target activity above 0.45 gH2/gCat/h and an innovative regeneration method, plus a membrane reactor prototype that was tested for at least 3,000 hours under real conditions. The reactor produces fuel-cell grade hydrogen directly from methane with zero COx emissions.

Audience

Who needs this

Industrial hydrogen producers looking to eliminate CO2 from their processNatural gas utilities wanting to pivot toward hydrogen without scrapping infrastructureFuel cell manufacturers needing reliable sources of high-purity hydrogenChemical companies using hydrogen as feedstock who face carbon tax exposureBiogas plant operators seeking higher-value products from their methane output

Business applications

Who can put this to work

Industrial gas supply

mid-size

Target: Hydrogen production companies and gas suppliers

If you are a hydrogen producer dealing with rising carbon taxes and tightening emissions regulations — this project developed a membrane reactor that splits methane into fuel-cell grade hydrogen with zero COx emissions. The catalyst targets over 0.45 gH2/gCat/h activity and 10,000 hours of stability, meaning lower replacement costs and continuous output. The prototype was tested for at least 3,000 hours under real conditions.

Natural gas utilities

enterprise

Target: Gas distribution and utility companies

If you are a gas utility looking to future-proof your infrastructure as the world moves toward hydrogen — this technology converts methane to hydrogen using existing gas pipelines and storage. Operating at around 600°C, it works with fossil, renewable, or synthetic methane sources. The solid carbon byproduct can be sold to materials industries instead of being emitted as CO2.

Fuel cell systems

any

Target: Fuel cell manufacturers and mobility integrators

If you are a fuel cell company struggling with hydrogen purity requirements — this project built a reactor that produces fuel-cell grade hydrogen directly, with an energy density above 0.05 gH2/cm3/h comparable to PEM fuel cells. The system is designed for both stationary and mobile applications, eliminating the need for separate hydrogen purification steps.

Frequently asked

Quick answers

What would this technology cost compared to current hydrogen production?

The project data does not include specific cost figures or cost comparisons. However, the technology targets catalyst stability of 10,000 hours and easy regeneration, which directly reduces operational costs versus catalysts that need frequent replacement. The use of existing methane infrastructure also avoids major capital expenditure for new distribution networks.

Can this scale to industrial hydrogen production volumes?

The project demonstrated a prototype reactor running for at least 3,000 hours under real conditions. The membrane reactor uses a modular stack design (individual cells for hydrogen production and pumping), which is inherently scalable. The 100% selective reaction (CH4 → C + 2H2) means no side products to manage at scale.

What is the IP situation — can we license this technology?

The project ran under EU Horizon 2020 (RIA funding scheme), meaning IP is owned by the consortium partners. Universidade do Porto coordinates a 7-partner consortium across 5 countries including 3 industrial partners. Licensing discussions would need to go through the consortium, likely starting with the coordinator.

Does this meet current hydrogen purity regulations for fuel cells?

Yes — the project explicitly targets fuel-cell grade hydrogen. The membrane reactor design separates and pumps out high-purity hydrogen as part of the process. The 100% selective methane decomposition reaction produces only solid carbon and hydrogen, with no COx contamination.

How long until this could be deployed commercially?

The project closed in November 2024 after testing the prototype for at least 3,000 hours under real conditions. The catalyst targets 10,000 hours of stability. Based on available project data, the technology is past the lab stage but would likely need engineering scale-up and certification before full commercial deployment.

Can this work with our existing natural gas infrastructure?

Yes, this is a key advantage. The project objective explicitly states the approach can be implemented swiftly, taking advantage of present infrastructure. It works with fossil methane, renewable methane from biogas, or synthetic methane — all of which use existing pipelines and storage.

Consortium

Who built it

The 112CO2 consortium brings together 7 partners from 5 countries (Switzerland, Germany, Spain, Luxembourg, Portugal), with a strong 43% industry ratio — 3 industrial partners alongside 2 universities and 2 research organizations. This mix matters: the industrial partners provide real-world testing environments and commercial perspective, while the academic side handles catalyst science and reactor engineering. Having 1 SME in the group suggests potential for agile commercialization. The coordinator, Universidade do Porto in Portugal, is a well-established research university with strong chemical engineering credentials. The geographic spread across Western Europe gives the technology access to multiple regulatory markets and potential early adopters.

UNIVERSIDADE DO PORTOCoordinator · PT
ECOLE POLYTECHNIQUE FEDERALE DE LAUSANNEparticipant · CH
AGENCIA ESTATAL CONSEJO SUPERIOR DE INVESTIGACIONES CIENTIFICASparticipant · ES
PAUL WURTH SAparticipant · LU
DEUTSCHES ZENTRUM FUR LUFT - UND RAUMFAHRT EVparticipant · DE
Quantis Sarlparticipant · CH

How to reach the team

Universidade do Porto, Portugal — reach out to the chemical engineering or energy department leads involved in hydrogen research

Order a report on this consortium See UNIVERSIDADE DO PORTO profile →

Next steps

Talk to the team behind this work.

Want an introduction to the 112CO2 team? SciTransfer can connect you with the right consortium partner for your specific application — whether you need the catalyst technology, the reactor design, or integration support.

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