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Hydrogen and Carbon Black Production from Methane Pyrolysis

Hydrogen has become an important option for the decarbonization of power plants and industrial facilities because the combustion of hydrogen does not produce CO2 emissions. But traditional hydrogen production methods can be two to five times more costly than natural gas. Government incentives mitigate some of the higher costs, but continued innovation is needed to make replacing fossil fuels with hydrogen a viable decarbonization strategy.

To that end, the U.S. Department of Energy (DOE) sought out Lummus Consultants to evaluate a novel hydrogen production technology. Monolith Inc. developed the first commercial-scale technology to employ methane pyrolysis, converting natural gas to produce cleaner carbon black and hydrogen using electric plasma torches powered by renewable energy. The proposed DOE loan guarantee would support Monolith’s facility expansion in Olive Creek, Nebraska, including the installation of 12 pyrolysis reactors, a hydrogen cleanup system, and an ammonia unit.

Monolith’s technology has broad commercial appeal. Carbon black is used for improved strength and abrasion in tire and rubber products, among other applications. Hydrogen is used in many petrochemical applications but chiefly in ammonia and fertilizers, and as a potential alternative fuel to decarbonization power plants and industrial facilities.

As part of our technical review, Lummus Consultants evaluated the technology, execution and operational risks of the expansion project. For example, a key mitigant for technology risk is a demonstration that the existing reactor can produce carbon black within the tire manufacturer’s specification and can operate at levels consistent with the technical assumptions in the financial model. Furthermore, given the project’s size, execution risk was also a concern. The involvement of an experienced EPC contractor and clear definition of responsibilities helped mitigate execution risks.

As Monolith achieves new milestones in the expansion, Lummus Consultants will support the due diligence efforts through financial close, after which we will shift to construction monitoring.

At-a-Glance

Technology: Hydrogen and carbon black production
Our role: Independent engineer
Scope of services: Technical advisory, due diligence and risk assessment
Location: Olive Creek, Nebraska, U.S.
Client: U.S. Department of Energy

Highlights

  • Evaluated methane pyrolysis technology for cleaner hydrogen and carbon black production
  • Assessed technology, execution and contract risks
  • Construction monitoring will follow due diligence efforts

Resources

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Charlie Bowser leads the decarbonization advisory practice and is responsible for strategy, execution and financing support for net zero projects and greenhouse gas reduction planning. Charlie has more than 25 years of experience in nuclear, renewable (wind and solar) and natural gas-fired power generation technologies. His expertise includes finance, engineering, business development, project development and operations. Previously, Charlie was president of NET Power, leading the engineering, development, construction, commissioning and operation of a first-of-a-kind, supercritical CO2 zero emission prototype, as well as various positions with Exelon Generation and the U.S. Navy. Charlie earned a Master of Business Administration in Corporate Finance from Cornell University and a Bachelor of Science in Systems Engineering from the United States Naval Academy.
John Senner is responsible for the power industry technical advisory practice for North America and Asia. He has more than 40 years of industry experience in technical support, financing, acquisition, execution and divestiture on a wide range of projects. John’s expertise includes renewable and non-renewable power generation, waste management, emissions controls, new technology evaluations involving pyrolysis and gasification, and decarbonization involving carbon capture and hydrogen production technologies. Previously, he managed life-cycle inventory assessment projects in waste-to-energy and solid waste for the aluminium, paper and plastics industry. John has worked for Lummus Consultants and its predecessor companies for 25 years after earning a Bachelor of Science in Chemical Engineering from Cornell University.
Mark White is responsible for the power industry technical advisory practice for Europe and the Middle East. He has more than 30 years of experience in design, engineering, construction, commissioning, testing, project management, operation and maintenance, business development, and consulting. Mark has managed technical assignments, studies, advisory roles and due diligence reviews and specializes in the technical, contractual and commercial issues associated with the development of independent power and water projects, primarily in Europe, Asia, the Middle East and Africa. Mark earned a Master of Engineering in Fuel and Energy Engineering from the University of Leeds with energy engineering coursework at the National Institute of Applied Science, Lyons, France.
Shahid Bhatti is responsible for the process industry technical advisory practice for the Middle East. He has more than 35 years of experience in refining, petrochemicals, oil and gas development, liquefied natural gas, and oil storage terminals. Shahid provides technical expertise, critical studies and support on technology evaluation, process design, construction, startup and operations. He has worked for Lummus Consultants and its predecessor companies for almost 30 years. He earned a Bachelor of Science in Chemical Engineering from the Polytechnic of the South Bank, London, and Master of Business Administration from Cranfield University, Bedfordshire.
Keith Darby leads the process industry technical advisory practice in the United States. He has 45 years of experience in design, construction and operation of oil and gas facilities, focusing on technical, environmental and social due diligence to support the international finance community. Keith is responsible for global projects encompassing the production, transportation and treatment of oil and gas into products and biofuel, as well as technical due diligence for project financing. Previously, he was a technical director for WS Atkins and led its Scottish operation. Keith has been with Lummus Consultants and its predecessor companies for 25 years and earned a Bachelor of Science with First-Class Honors from Portsmouth University in the United Kingdom, where he is a Chartered Engineer.
Dr. Amalia Pantazidis serves as president and managing director of Lummus Consultants. She has more than 30 years of international industry experience in business development, business planning and consulting, strategy, M&A, technology licensing, feasibility and marketing studies, R&D, refining and petrochemicals operations and project management. Amalia leads the decarbonization advisory practice and is responsible for strategy, execution and financing support for net zero projects and greenhouse gas reduction planning. Prior to Lummus Consultants, she worked for consulting firms Jacobs Consultancy and KBR Technology & Consulting, as well as for the oil and gas and chemicals industry majors TotalEnergies, ExxonMobil and BASF. Amalia holds a Ph.D. in Heterogeneous Catalysis with magna cum laude honors from the Université Claude Bernard Lyon 1 in France and a Master of Chemical Engineering from the National Technical University of Athens in Greece. She is a Project Management Professional (PMP) and holds a Certificate in Strategy and Innovation from the MIT Sloan Management School.
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The execution phase typically carries the highest level of risk for cost overruns in a project lifecycle. Lenders and owners benefit from an independent engineer to monitor the construction and initial operations, assessing quality control, costs, schedule, permitting and startup/testing of the project are properly executed; reviewing costs and schedules against corresponding budgets and contracts; offering guidance on emerging technical issues, and certifying construction completion and performance.

Lummus Consultants has performed construction and operations monitoring services for power plants, LNG facilities, process facilities and pipeline facilities all over the world. Our decades of experience in this area give us broad and deep knowledge across the spectrum of project construction methods, and from mega-projects to small single process units, enabling us to quickly identify critical risks and assess mitigation plans to ensure the best outcome for projects during construction, commissioning and commercial operation.

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Given the high stakes and shareholder visibility of today’s large energy and infrastructure projects, an independent, outside review of project plans can give owners greater confidence in a project’s overall success, as well as help achieve critical speed to market by identifying and mitigating problems before they occur.

Lummus Consultants has a proven track record of success performing cold-eye peer reviews for clients with large and complicated projects throughout the energy sector. The purpose and scope of every independent project review are developed closely with each client and typically include an assessment of project costs, schedule, execution plans, project team, quality factors, environmental, social and safety risks, and management systems. Findings include an analysis of key risks, a list of key mitigation actions and recommended timing of mitigating actions to improve successful outcomes.

Due diligence services help companies and investors understand the technical, commercial and environmental factors involved in a potential investment, venture or project, providing an independent, fully objective and thorough assessment that helps strengthen decision making and mitigate project risks before they occur. Lummus Consultants’ due diligence advisory services are the hallmark of our firm, having provided technical advisory and consultancy in the power, oil and gas, refining and chemicals, and infrastructure space for decades. In fact, our teams have provided technical due diligence review services on more than 800 transactions representing more than $500 billion in funding on assets across the globe.

As an independent technical consultant or lender’s engineer, we use our decades of hands-on experience in the essential aspects of process, power and water plant design, construction and operation to assess areas of risk. We work with the global financial sector and investment groups, providing technical guidance to support project finance and acquisitions around the world. Our seasoned experts provide an effective combination of technical and commercial experience when assessing and confirming a project’s design, technology, expected performance, capital costs, operating and maintenance costs, schedule, operation, contractual obligations and pro forma financial projections are reasonable and aligned — to minimize our client’s risk.

As an independent environmental consultant, we assess the project’s environmental, safety and social impacts, risks and liabilities, as well as the project’s ability to comply with permits, licenses and applicable environmental guidelines such as the Equator Principles. Our experts stay up to date on the continually changing environmental legislation and trends so clients can have confidence in our insight and advice in this crucial area.

Lummus Consultants understands the risks associated with newly commercialized and evolving technologies, particularly in the growing energy transition areas where new ideas are hitting the market quickly. Through the breadth of our teams’ skills and our extensive due diligence experience, we can identify areas of risk associated with scaleup, design modification, product line evolution and first-of-a-kind technology innovations. Our unique combination of technical expertise and business evaluation skills enables us to effectively suggest appropriate technical and commercial mitigation strategies.
As energy industries and markets mobilize to optimize efficiency and maximize sustainability at every point in the value chain, a strong commitment to careful strategy and planning is more important than ever. From enterprise planning, project development and operational improvements to compliance and sustainability planning and everything in between, the experts at Lummus Consultants bring strong skills and trusted, independent advice to your project team or your investment plans.
As energy industries and markets mobilize to optimize efficiency and maximize sustainability at every point in the value chain, a strong commitment to careful strategy and planning is more important than ever. From enterprise planning, project development and operational improvements to compliance and sustainability planning and everything in between, the experts at Lummus Consultants bring strong skills and trusted, independent advice to your project team or your investment plans.

Due diligence services help companies and investors understand the technical, commercial and environmental factors involved in a potential investment, venture or project, providing an independent, fully objective and thorough assessment that helps strengthen decision making and mitigate project risks before they occur. Lummus Consultants’ due diligence advisory services are the hallmark of our firm, having provided technical advisory and consultancy in the power, oil and gas, refining and chemicals, and infrastructure space for decades. In fact, our teams have provided technical due diligence review services on more than 800 transactions representing more than $500 billion in funding on assets across the globe.

As an independent technical consultant or lender’s engineer, we use our decades of hands-on experience in the essential aspects of process, power and water plant design, construction and operation to assess areas of risk. We work with the global financial sector and investment groups, providing technical guidance to support project finance and acquisitions around the world. Our seasoned experts provide an effective combination of technical and commercial experience when assessing and confirming a project’s design, technology, expected performance, capital costs, operating and maintenance costs, schedule, operation, contractual obligations and pro forma financial projections are reasonable and aligned — to minimize our client’s risk.

​As an independent environmental consultant, we assess the project’s environmental, safety and social impacts, risks and liabilities, as well as the project’s ability to comply with permits, licenses and applicable environmental guidelines such as the Equator Principles. Our experts stay up to date on the continually changing environmental legislation and trends so clients can have confidence in our insight and advice in this crucial area.