Process for producing hydrogen, carbon, and ethylene from methane-containing feedstock

A method for producing carbon (C), ethylene (C2H4), and hydrogen (H2) from methane, comprising the steps of:

• step a) forming a first product comprising unreacted methane, carbon, and hydrogen through methane pyrolysis by transferring a methane-containing feedstock to a first methane conversion step;
• step b) separating a first gaseous mixture containing hydrogen and methane and solid carbonaceous materials from the first product, wherein a hydrogen (H2)/methane (CH4) molar ratio in the first gaseous mixture is adjusted within a range of 1 to 6;
• step c) forming a second gaseous mixture containing hydrogen and acetylene through a methane coupling reaction by transferring the first gaseous mixture to a second methane conversion step,
• wherein the second methane conversion step is performed through a direct non-oxidative methane coupling reaction by thermal conversion,
• wherein in the second methane conversion step, a methane conversion is at least 35% and selectivity for acetylene is at least 60%, and
• wherein a hydrogen (H2)/acetylene (C2H2) molar ratio in the second gaseous mixture is adjusted within a range of 20 to 150;
• step d) forming a third gaseous mixture containing hydrogen and ethylene by subjecting acetylene in the second gaseous mixture to selective hydrogenation in the presence of a hydrogenation catalyst;
• and
• step e) separating and recovering hydrogen and ethylene, respectively, from the third gaseous mixture.