Techno-Economic Evaluation of Turquoise Hydrogen and Carbon Nanotubes Integration in Oil and Gas Infrastructure

Abstract

Summary The carbon nanotubes (CNT) market is anticipated to witness a twofold expansion throughout the 2020s, in parallel with the ascendance of hydrogen (H2) as a pivotal element in the energy mix. This study assesses the economic feasibility of manufacturing CNTs and hydrogen utilizing Floating Catalyst Chemical Vapor Deposition (FC-CVD) methodologies within oil and gas (O&G) infrastructures. This approach is proposed as a strategic initiative to monetize methane, which is frequently subjected to flaring and possesses a Global Warming Potential (GWP) 27–30 times higher than that of carbon dioxide (CO2) over a 100-year period (Understanding Global Warming Potentials 2023). A comprehensive techno-economic model was constructed utilizing a process-driven cost framework that encompasses precursor materials, energy expenditures, and infrastructural investment considerations. These precursors include methane as a carbon source, specialized catalysts facilitating the dissociation of carbon and hydrogen during the reaction, and carriers that enhance the quality of the resultant CNT materials. From an infrastructural perspective, costs incorporate the utilization of distinct reactors tailored for methane pyrolysis. Additionally, the model integrates the costs of pressure swing adsorption systems (PSA) for hydrogen segregation and systems for hot gas processing. For the economic evaluation, a production timeframe of 10 years is postulated. Metrics such as the unit production breakeven price are assessed assuming a discount rate of 10%. An industrial-scale FC-CVD process facility, designed to produce 1,000 metric tons of CNT materials yearly, is projected to manufacture at costs as low as $14/kg. The economic analysis suggests that O&G companies could secure profits given the present market price for CNTs ranging from $100 to $1000, effectively reducing the production costs of hydrogen (another co-product) to a negligible level. This would, in effect, create a "free" revenue stream from hydrogen production while supplying a crucial material integral to advanced technologies, such as highly efficient batteries. Such a low-carbon approach could potentially be an alternative to the Carbon Capture and Storage (CCS) model, which typically incurs high energy and financial costs.