Methane pyrolysis is a promising route for low-emission hydrogen (H₂) production, with solid carbon as a potentially valuable byproduct. Despite this potential, the economic feasibility of Catalytic Methane Pyrolysis (CMP) with fluidized bed reactors (FBR) has been insufficiently studied. This study develops a conceptual CMP plant using two novel isothermal reactor models—based on continuous stirred-tank reactor (CSTR) and plug-flow reactor (PFR) assumptions—to represent the operational extremes of FBRs. Our reactor models incorporate reaction and catalyst deactivation kinetics from experiments with nickel-supported catalysts, and the framework enables process simulations that account for the catalyst rate required to sustain reactor activity. These models address the lack of proper reduced-order FBR models and the reliance on oversimplified assumptions in the literature. In the baseline scenario, the conceptual plant yields an LCOH ranging from $3.89 to $4.79 per kilogram, defining the expected cost bounds for an FBR-based CMP plant. At a H₂ selling price of $5.00 per kilogram, the process achieves favorable payback time and net present value. Monte Carlo and sensitivity analyses indicate that CMP remains cost-competitive under economic uncertainties. Increased carbon sales could make CMP more economical than steam methane reforming, while unsold byproducts may incur costly sequestration. Reactor heating assessment shows methane combustion with carbon capture minimizes both cost and emissions. Overall, this work demonstrates the economic potential of CMP for H₂ production and provides a practical modeling framework for process evaluation.

The competitiveness of hydrogen as a sustainable energy carrier depends greatly on its transportation and storage costs. Liquefying hydrogen offers advantages such as enhanced purity, versatility, and higher density, yet current industrial liquefaction processes face efficiency and cost challenges. Although various large-scale and efficient liquefaction concepts exist in the literature, they often overlook the economic and technical viability of such plants. Here, we addresses this issue by establishing a framework for modeling a large-scale hydrogen liquefaction concept and conducting both technical and economic assessments, with a specific focus on 125 tonnes per day (TPD) high-pressure hydrogen Claude-cycle concept. The technical analysis involves preliminary designs of key process components, while the economic assessment utilizes Aspen Process Economic Analyzer. Our findings indicate that at an electricity price of €0.1/kWh, the Claude-cycle liquefier concept yields a specific liquefaction cost (SLC) of €1.55/kg_LH2. A sensitivity analysis was performed, which shows that electricity price has a significant influence on the economics. Further investigation on the compressors design shows that incorporating high-speed centrifugal compressors could reduce the SLC by 5.42% and potentially more. Scaling up to 250 and 500 TPD reveals further cost improvements, while cost projections indicate substantial declines as the technology matures. Ultimately, this paper presents novel cost-scaling and experience curves of hydrogen liquefaction technology, demonstrating the compelling economic viability of integrating large-scale hydrogen liquefaction into sustainable energy infrastructure.