V-Zug will soon be operating with environmentally-friendly hydrogen

The Association for the Decarbonization of Industry (VZDI) has developed and inaugurated an experimental plant for producing hydrogen via pyrolysis. In one to two years, it is expected to supply V-Zug's enamelling plant with energy.
 

From the outside, the brand-new methane pyrolysis plant, in a disused building belonging to the long-established V-Zug company, doesn't look particularly spectacular: a man-high metal container with a funnel-shaped opening, together with the microwave reactor, forms the core of the system.

But this reactor will soon be performing a remarkable feat. According to the initiators of the Association for the Decarbonization of Industry (VZDI, Verein zur Dekarbonisierung der Industrie, see below), this is "Europe's first industrially used methane pyrolysis plant." It was officially inaugurated last Friday.

Hydrogen is a CO₂-neutral energy source, and is therefore a genuine alternative to "dirty" energy providers. But not all production processes are sustainable. For this reason, the VZDI has opted for the development of a methane pyrolysis plant. "This is one of the most environmentally friendly ways to produce hydrogen," emphasizes Andreas Bittig, an employee of Tech Cluster Zug AG and overall project manager for the VZDI. "In this process, methane, which is extracted from biogas or natural gas, is irradiated with microwaves in a reactor and split into gaseous hydrogen and solid carbon."

Because storing the gas, which is classified as a hazardous material, is possible but involves stringent safety requirements, the plant will only operate when V-Zug is carrying out the high-energy enamelling process. "It then directly supplies the necessary fuel, and is subsequently switched off again," says Andreas Bittig. Originally, the plan was to also refuel V-Zug's transport vehicles with hydrogen. "But this requires an almost 100% purity level, and producing this with methane pyrolysis is currently not cost-effective."

The generously sized plant will initially be used for further research. "The amount produced is not yet quite sufficient for the enamelling process. One of our goals is therefore to increase capacity." Furthermore, the plant must ultimately be built more compactly and be reproducible for other member companies. "We're confident that we will be able to supply V-Zug with hydrogen from 2027 onwards."

The methane pyrolysis plant is located in a lockable container on the grounds of the Zug Tech Cluster.
Andreas Bittig, an employee of Tech Cluster Zug AG and overall project manager of the VZDI (V-Zug Innovation Centre), welcomes the guests and explains how the methane pyrolysis plant works.             Photos: David Biedert
The pyrolysis plant (outlined in red) is located in the immediate vicinity of V-Zug's enamelling plant (outlined in green).
Photo: supplied
The powdered carbon emerges through the funnel-shaped opening and is later conveyed directly to the granulation plant (not shown).           Photo: David Biedert

Carbon is in high demand
The byproduct of gas splitting is solid carbon. “Three of the VZDI member companies – Avag, Sika, and Holcim – are already interested in purchasing the sought-after material,” reports Andreas Bittig. It is already used today in the production of asphalt, adhesives, and vehicle tyres. “Carbon is also found in batteries and pencils.” Research is also continuing in this area. “Trials are underway to add carbon to concrete to make it more sustainable and durable, as well as to modify its colour or texture, for example.” Concrete accounts for almost 50% of industrially produced materials worldwide. “This would therefore represent a gigantic market and a huge step towards climate neutrality.” Carbon is currently produced in India and China using methods that generate enormous quantities of emissions.

Handling the fine dust, volatile black powder is not easy, however. "Inhaling it is hazardous to your health," notes Andreas Bittig. The carbon is therefore conveyed directly to a granulation plant via a closed system, where it is mixed with water to produce solid granules. "The pyrolysis plant produces one cubic metre of sustainable carbon in powder form per hour, weighing only about 30 kilogram."

A learning factory for further research
The project was budgeted at eight to ten million Swiss francs, and every member of the association and the Canton of Zug contributed their share. "We've only spent three million so far. But it also includes in-kind contributions of at least equal value." And the work isn't finished yet. "So the final cost should be as estimated." The Association for the Decarbonization of Industry intends to continue its research.

“One of our visions is to open a ‘Learning Factory,’ also on the grounds of the Zug Tech Cluster,” continues Andreas Bittig. Experts from Empa, ETH Zurich, and various companies will be brought together there to conduct joint research, experiment, learn, and implement further ideas. “Here, we want to network expertise and create value in close proximity to Zug’s industry.” The city and canton of Zug could also benefit by developing exciting and promising skills for manufacturing companies. “We want to demonstrate that profitable, environmentally friendly, and innovative production is possible in Switzerland as well.”

Information
CO₂-neutral energy carrier
In the Methane Pyrolysis procedure, methane (natural gas or biogas) is heated to extract the hydrogen and carbon from the molecule and use them separately. The process is CO₂-neutral, and therefore makes a significant contribution to the decarbonisation of industry – and, when using biogas, even to the decarbonisation of the atmosphere. The methane pyrolysis plant on the grounds of the Tech Cluster Zug was developed by the non-profit Association for the Decarbonization of Industry (VZDI), which was founded in 2022 on behalf of the initiative of the same name. The VZDI aims to find a way to produce hydrogen economically and in an environmentally friendly manner and to use it for high-energy industrial processes. The members of the association include the Swiss Federal Laboratories for Materials Science and Technology (Empa: Eidgenössische Materialprüfungs- und Forschungsanstalt) and 16 renowned companies, such as Accelleron, Siemens, Sika, Sulzer, WWZ, Tech Cluster Zug, V-Zug, and Metall Zug. The Canton of Zug is a funding partner of the association. The plant is located at V-Zug AG as part of an industrial demonstrator, and is intended to pave the way for bringing the process to market maturity by 2030.