Two complementary processes for converting carbon emissions into valuable clean energy products — at industrial scale.
Direct conversion of natural gas methane into two valuable products: clean hydrogen fuel and solid carbon black — powered entirely by electricity with zero direct CO₂ emissions.
Natural gas methane is fed through the bottom of the ceramic reactor at controlled flow rates (1,000 sccm at scale).
Methane bubbles rise through the Sn-Cu-Ga-Bi molten alloy catalyst pool heated to 960°C by electrical resistance.
Hydrogen gas exits from the top. Solid carbon black floats on the alloy surface and is continuously removed as a valuable product.
| Metric | Value |
|---|---|
| Scale-Up Achievement | 100× (10→1,000 sccm) |
| Conversion at Scale | 85% at 960°C |
| Pilot Target Conversion | 91–93% |
| H₂ Production Rate | 164.4 kg/day |
| Carbon Production Rate | 492.9 kg/day |
| Pilot Capacity | 1,000 m³/day |
| CAPEX Estimate | $1.38M |
| Payback Period | ~2 years |
| ROI | 43.4% |
Decompose carbon dioxide into solid carbon and oxygen using Ga-In molten alloy catalysts — enabling permanent carbon removal at lower temperatures.
CO₂ is injected with a small methane co-feed into the deep-column ceramic reactor containing the Ga-In alloy catalyst.
The Ga-In alloy dramatically lowers required temperature — achieving >46% conversion at just 500°C vs conventional >1,000°C.
Solid carbon accumulates at the alloy surface for recovery. Oxygen exits as a usable byproduct. 480+ hours of stable operation demonstrated.
| Metric | Value |
|---|---|
| Conversion at 500°C | >46% (Ga-In alloy) |
| Conversion at 800°C | ~84% |
| Conversion at Scale | >90% at 1,000 sccm |
| Stable Operation | 480 hours demonstrated |
| Pilot Capacity | 1 tonne CO₂/day |
| CAPEX Estimate | $962,000 |
| Construction Timeline | 6 months |
| Temperature Advantage | ~500°C reduction vs. baseline |
MATi's molten alloy platform delivers superior performance across every critical dimension compared to incumbent hydrogen production methods.
| Metric | ✦ MATi (Molten Alloy) | Steam Methane Reforming (SMR) | Water Electrolysis |
|---|---|---|---|
| CO₂ Emissions | Zero direct CO₂ | 9–12 kg CO₂/kg H₂ | 0 (if green power) |
| H₂ Conversion Rate | 85% (CH₄ pathway) | ~80–85% | ~70–80% |
| Operating Temperature | 960°C (electric) | 700–1,000°C (gas-fired) | Room temp (PEM) |
| Valuable Co-product | Carbon black (~$800/tonne) | None (CO₂ waste) | O₂ (low value) |
| Carbon Capture Required? | No — carbon is solid product | Yes — expensive CCS needed | N/A |
| ROI (Pilot Scale) | 43.4% · 2.3yr payback | ~15–25% | Negative without subsidies |
| Technology Readiness | TRL 6 — Pilot Ready | TRL 9 — Mature | TRL 8–9 — Commercial |
| Scale-Up Validated | 100× demonstrated ✓ | Fully commercial | Fully commercial |
* SMR data from IEA Hydrogen Report 2023. MATi data from M1–M5 milestone reports.
MATi overcame four critical engineering challenges through systematic innovation and rigorous validation.
Corrosion, thermal degradation, and alloy containment at operating temperatures above 960°C.
Advanced ceramic reactor design with optimized alloy composition ensuring long-term stability and performance.
Maintaining conversion efficiency and thermal uniformity when increasing throughput 100-fold.
Deep-column ceramic geometry providing extended gas residence time and optimal heat/mass transfer at scale.
Conventional methane pyrolysis requires extreme temperatures (>1,100°C), increasing energy costs and materials stress.
Sn-Cu-Ga-Bi multi-component alloy catalyst enables 85% conversion at 960°C — a ~150°C temperature reduction.
Continuous removal of solid carbon from the alloy surface without disrupting reactor operation.
Engineered separation systems allowing continuous product recovery while maintaining stable reactor operation.
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