Green Plasma Process for Converting Natural Gas into Valuable Organic Products and Carbon with Preferential Ethane Adsorption

To accelerate the transition to sustainable energy, efficient methods for CO2-free hydrogen production and carbon utilization are needed. This study presents a new, sustainable approach for the simultaneous production of hydrogen, valuable hydrocarbons, and functional carbon materials by converting methane in low-pressure microwave plasma. Compared to traditional methane reforming methods (such as steam reforming), our plasma-based process operates at low temperatures, eliminates direct CO2 emissions, and enables the conversion of methane into three valuable products: (1) environmentally friendly hydrogen for fuel cells and energy storage systems, (2) a range of valuable organic products (C2H2, C2H4, C2H6), and (3) functional carbon films with self-improving catalytic properties. Optical emission spectroscopy (OES) and the Langmuir double probe method were used for plasma diagnostics, revealing an increase in the concentration of active species (CH, Hα, C2) and electron temperature upon argon addition. The structure, morphology, and impurity composition of the deposited films were investigated using X-ray diffraction (XRD), scanning electron microscopy (SEM), and inductively coupled plasma mass spectrometry (ICP-MS), respectively. Gas-phase byproducts were analyzed using gas chromatography–mass spectrometry (GC-MS). Argon addition at an Ar/CH4 ratio of 1 leads to the formation of carbon films with a more ordered structure, as confirmed by XRD data, and improved surface morphology. It was established that argon, by effectively participating in the excitation and dissociation processes of methane molecules through energy transfer from metastable states and increased electron temperature, optimizes plasma–chemical reactions, promoting the deposition of higher-quality carbon coatings.