Investigation of Fe-Ni Catalyst Drying Influence on Methane Pyrolysis for Turquoise Hydrogen Production

Abstract Methane pyrolysis is a promising method for turquoise hydrogen production with reduced CO₂ emissions. This study investigates how drying of catalyst before pyrolysis influences catalyst surface and its relation to hydrogen production. The Fe–Ni catalyst system was prepared by magnetron sputtering onto γ-Al₂O₃ support. Structure and surface chemistry were analysed using FTIR, Raman spectroscopy, XPS, SEM, and XRD. Pre-treatment was found to remove hydroxyl and organic residues, alter Fe/Ni oxidation states, and influence carbon morphology after pyrolysis. Pyrolysis produced mainly nanostructured carbon (CNT and graphene-like) materials, while vacuum drying improved metal dispersion and reduced surface oxygen. The results were compared to pyrolysis outcomes at higher temperatures, showing that optimized catalyst pre-treatment enhanced hydrogen yield and carbon quality. Results supported not only the development of efficient catalysts for turquoise hydrogen production but also procedure importance.