Catalytic molten metals for the direct conversion of methane to hydrogen and separable carbon

Metals that are active catalysts for methane (Ni, Pt, Pd), when dissolved in inactive low–melting temperature metals (In, Ga, Sn, Pb), produce stable molten metal alloy catalysts for pyrolysis of methane into hydrogen and carbon. All solid catalysts previously used for this reaction have been deactivated by carbon deposition. In the molten alloy system, the insoluble carbon floats to the surface where it can be skimmed off. A 27% Ni–73% Bi alloy achieved 95% methane conversion at 1065°C in a 1.1-meter bubble column and produced pure hydrogen without CO2 or other by-products. Calculations show that the active metals in the molten alloys are atomically dispersed and negatively charged. There is a correlation between the amount of charge on the atoms and their catalytic activity.