2025 AIChE Annual Meeting

(382am) Catalyst and Reactor Innovations for COx-Free Hydrogen Production Via Methane Pyrolysis

Research Interests:

Clean Hydrogen Production, Methane Pyrolysis, CO₂ Conversion, Catalysis, Fluidized Bed Reactors, Carbon Nanotubes, Carbon Valorization, Energy Transition

Core Skills:

Catalyst Synthesis, Reactor Design, Fluidized Bed Operation, Kinetic Analysis, Materials Characterization, Process Scale-Up, Microwave Catalysis

Abstract

My research focuses on addressing key challenges in clean hydrogen production and carbon management by integrating heterogeneous catalysis, advanced reactor systems, and scalable process design. I have worked extensively on methane pyrolysis in fluidized bed reactors to co-produce blue hydrogen and high-value carbon nanomaterials such as CNTs. During my doctoral studies at IIT Delhi, I designed and operated lab-scale fluidized bed systems in collaboration with HPCL and the Centre for High Technology (CHT). These industry-sponsored projects emphasized catalyst scale-up, process robustness, and product utilization—laying a strong foundation for my industry-aligned research approach.

At Stanford University, as part of an ARPA-E funded initiative, I extended this work by developing strategies to achieve continuous methane pyrolysis using a reaction–regeneration cycle in fluidized bed reactors. We implemented in-situ CNT dislodgement techniques and engineered catalyst-support systems that resisted sintering while maintaining high hydrogen yield and control over CNT morphology. This work directly addressed one of the most persistent bottlenecks in methane pyrolysis—catalyst deactivation—and enabled proof-of-concept demonstrations of a nearly continuous process. Our broader goal was to move beyond lab-scale feasibility and build momentum toward commercial and decentralized hydrogen production technologies.

Currently, at the National Energy Technology Laboratory (NETL), I am contributing to the development of CO₂ conversion technologies through both technical readiness level (TRL) white paper assessments and experimental validation. My future work includes designing and testing catalysts for CO₂ hydrogenation to methanol, formic acid, and carbonates, along with detailed kinetic analysis and process modeling. In parallel, I am exploring alternative methane pyrolysis pathways that integrate carbon removal and syngas generation. These efforts are part of a broader vision to accelerate the deployment of negative-emission technologies and contribute to DOE’s clean energy objectives.

My prior work at West Virginia University, funded by the U.S. DOE, involved developing microwave-assisted catalytic systems for the upcycling of plastic waste into olefins and solid carbon. By synthesizing microwave-responsive catalysts and optimizing selective depolymerization conditions, I demonstrated efficient carbon valorization from mixed polyolefins, extending my expertise in unconventional catalytic platforms. Together, these experiences—ranging from fluidized beds to microwave reactors help me to address fundamental and translational challenges across thermal and non-thermal catalytic systems.

The unifying theme in my research is industrial relevance. From carbon-free hydrogen to carbon reuse, my work aims to deliver scalable solutions backed by robust experimentation and techno-economic insight. I routinely apply advanced characterization techniques (BET, XRD, TEM, Raman, DRIFTS, TGA, GC-TCD) to interpret catalyst behavior and guide process optimization. Future directions include the development of bifunctional catalysts for tandem methane/CO₂ conversion, carbon nanoform valorization in environmental and energy applications. Through continued collaboration with industry and national laboratories, I aim to drive innovations that are both scientifically rigorous and commercially viable.

Selected Peer-Reviewed Publications

  1. Parmar, K. R.; Pant, K. K.; Roy, S. Blue Hydrogen and Carbon Nanotube Production via Direct Catalytic Decomposition of Methane in Fluidized Bed Reactor: Capture and Extraction of Carbon in the Form of CNTs. Energy Convers. Manag. 2021, 232, 113893.
  2. Parmar, K. R.; Dora, D. T. K.; Pant, K. K.; Roy, S. An Ultra-Light Flexible Aerogel Based on Methane Derived CNTs as a Reinforcing Agent in Silica-CMC Matrix for Efficient Oil Adsorption. J. Hazard. Mater. 2019, 375, 206–215
  3. Parmar, K. R.; Wang, Y.; Caiola, A.; Hu, J. Sustainable Production of Hydrogen and Carbon Nanotubes/Nanofibers from Plastic Waste through Microwave Degradation. Int. J. Hydrogen Energy 2024, 51, 488.