Simultaneous Industrial Decarbonization and High-Value Materials Production via Microwave Plasma-Based Methane Cracking: Demonstration in an Industrial Setting

Abstract Robust, scalable, and cost-effective decarbonization technologies are key to the energy transition roadmaps of the energy sector and the industrial segments at large. In particular, to reach ADNOC's target of net-zero emissions by 2045, the reduction of methane emissions, a potent greenhouse gas, is critical. To accelerate the deployment of decarbonization technologies, these innovative solutions must be proven in real and scaled environments in a safe, efficient, and reliable way. This paper aims to showcase a pilot study led by Levidian, Abu Dhabi National Oil Company (ADNOC), ADNOC Gas, and Baker Hughes, deploying the LOOP technology. This technology platform converts hydrocarbons into a high-value revenue stream through hydrogen-rich output gas and graphene. This work presents collaborative effort on field deployment studies and preliminary outcomes, lessons learned, next steps and future potential. The energy sector faces the multifaceted challenge of industrial decarbonization while concurrently ensuring security, affordability, and sustainability. In industrial facilities such as oil refineries and upstream oil and gas sites, there are currently limited solutions that can provide the following: Proving flare gas sites can be decarbonized at scale and cost-effectively.Enabling hydrogen production from methane-rich gas sources.Demonstrating carbon capture in the form of high-value material, e.g., graphene. The LOOP technology – a demonstration of circular economy in action – is a platform that decarbonizes gas, produces a hydrogen-rich gas stream and locks carbon in high-value graphene. Graphene is being incorporated into materials to make them last longer and perform better. It has unique characteristics, such as high mechanical strength and excellent thermal and electrical conductivities, which make it possible to enhance a wide range of materials, improving product performance, increasing lifespan, and reducing carbon footprint. Levidian, ADNOC, and Baker Hughes collaborated to accelerate the technology readiness level of the LOOP through a pilot study, enabling the deployment of the system at the Habshan Gas Processing Plant in the UAE.