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A 67-person Finnish startup called Hycamite has just completed a facility it hopes will revolutionize production of low-carbon hydrogen.
The plant, in the industrial port city of Kokkola, on Finland’s west coast, will soon receive gas shipments from a nearby liquefied natural gas import terminal and turn the fossil fuel into hydrogen. That in itself is not novel — pretty much all of the world’s commercially produced hydrogen comes from methane, the main ingredient in natural gas. But all those legacy hydrogen producers end up with carbon dioxide as a byproduct, and they vent it into the atmosphere, exacerbating climate change. Hycamite will make hydrogen without releasing CO2, using a little-known process called methane pyrolysis.
“We split the methane with the help of catalysts and heat — there’s no oxygen present in the reactor, so that there’s no CO2 emissions at all,” founder and Chairman Matti Malkamäki told Canary Media in a December interview. “We are now entering industrial-scale production.”
Hycamite’s Customer Sample Facility in Kokkola can produce 5.5 tons of clean hydrogen per day, or 2,000 tons per year, Malkamäki said. Instead of creating carbon dioxide as an inconvenient gaseous byproduct, pyrolysis yields solid carbon. Hycamite uses catalysts developed over 20 years by professor Ulla Lassi at the University of Oulu, which transform the methane into “carbon nanofibers with graphitic areas.” This solid carbon can be processed further to produce graphite that Malkamäki plans to sell to battery manufacturers and other high-tech industries.
Hycamite closed a $45 million Series A investment in January to fund operations at the hydrogen plant. But it’s just one of a growing cluster of climatetech startups betting that the dual revenue stream of hydrogen and useful carbon products gives them an edge in the nascent marketplace for clean hydrogen, a much-hyped, little-produced wonder fuel for solving tricky climate problems.
Low-carbon hydrogen theoretically could clean up emissions-heavy activities like long-distance trucking, shipping, steel making, and refining — if anyone can manage to make it, at volume, at prices that compete with the dirty stuff that’s already available. In the U.S., some hydrogen producers and fossil fuel majors have talked about retrofitting carbon-capture machinery onto existing hydrogen plants, but nobody’s built a full-scale “blue hydrogen” operation so far. Renewables developers have evangelized “green hydrogen,” which is made by running clean electricity through water to isolate hydrogen, but they need electrolyzers and the production of clean electrons to get considerably cheaper. Until then, they’ll depend heavily on government policy support.
Now President Donald Trump is treating Joe Biden’s suite of clean energy policies like a piñata, and it’s hard to tell if incentives for producing green hydrogen will even survive. That’s already scaring off investors from large, capital-intensive green hydrogen projects. But the up-and-coming pyrolysis crew could find a niche: Their projects are smaller and nimbler, and they consume natural gas, one sector that Trump has ordered his government to encourage.
Methane pyrolysis entrepreneurs like Malkamäki are heeding the call of fundamental chemistry.
“Thermodynamically, it’s far more energy-favorable to split methane than to split water,” said Raivat Singhania, a materials scientist who scrutinizes hydrogen startups at Third Derivative, a clean energy deep-tech accelerator. Water’s chemical bonds hold together more fiercely than methane. That means companies trying to make clean hydrogen by splitting water need huge amounts of electricity to overcome the strength of its bonds; sourcing that electricity creates a daunting cost and a logistical hurdle.
Not only does methane-splitting require less energy, it can be done with a simpler plant design than water electrolysis, using fewer moving parts or fragile pieces of equipment, Singhania noted. This analysis informed Third Derivative’s investment in Aurora Hydrogen, which breaks methane using microwaves.
Those thermodynamic advantages come with tradeoffs. Namely, would-be methane pyrolyzers need a ready source of methane, which in practical terms means a pipe delivering fossil gas. That inevitably entails some level of upstream emissions.
Methane pyrolyzers also need to be located where gas is abundant. It’d be hard to scale up in places like Europe, post Russia’s invasion of Ukraine, or Massachusetts when winter rolls around. But supply is ample across much of the U.S., which is producing more fossil gas than any country ever. Hycamite is building its commercial test facility in its home base of Finland, but the company is looking to the U.S. to deploy its technology, Malkamäki said.
Right after taking office in January, Trump responded to world records in U.S. fossil fuel production by declaring an “energy emergency” and ordering his administration to clear the way for even more fossil fuel extraction.
It’s not clear whether the fossil fuel industry can or wishes to increase production dramatically; in market-based systems, excess supply tends to deflate prices. Whether production stays at current record highs or pushes further skyward, the U.S. will have plenty of gas to go around, and methane pyrolysis companies could generate the kind of new demand that the industry desperately needs. Moreover, they would be using American fossil fuel abundance to create materials useful for the transition to clean energy.
For that to happen, though, pyrolysis startups need to break through early technical demonstrations and start producing at scale.
Hycamite is not the only company chasing the pyrolysis dream.
The American startup Monolith is arguably furthest along in the quest to turn laboratory science into industrial-scale production. It uses high-heat pyrolysis to produce hydrogen and a dark powdery substance called carbon black, an additive used in tire and rubber manufacturing.
Monolith received a conditional $1 billion loan from the Department of Energy in late 2021 to build out its facility in Nebraska, which would deliver clean hydrogen to decarbonize fertilizer production. Monolith had to run a gauntlet to prove to DOE’s Loan Programs Office that it deserved such a loan. It has the rare distinction among pyrolysis startups of having actually sold its carbon products: Goodyear makes a tire for electric vehicles using Monolith’s carbon black.
However, Monolith did not finalize the loan before the Trump administration came to office and froze new disbursements for clean energy. The company was running short on cash while struggling to get its high-heat process to work reliably around the clock, per a Wall Street Journal article published in September. Monolith secured additional financing from its investors just before that story published.
Several other startups want to boost their revenues by turning methane into higher-value forms of carbon than carbon black, a relatively inexpensive commodity — if they can achieve the quality and consistency necessary to sell into those specialized and demanding markets.
A group of Cambridge University scientists founded Levidian in 2012 to create reliable, large-scale production of graphene, a carbon-based supermaterial discovered in Manchester, England, in 2004. After another eight years of research and development under the moniker Cambridge Nanosystems, the company was acquired and brought to market by a British entrepreneur.
Levidian eschews the catalysts, heat, and pressure that other startups use to split methane. Instead, the team ended up building a nozzle that sucks in methane gas, then uses electricity to generate microwave energy, which in turn creates a cold plasma torch that shaves carbon atoms from hydrogen atoms.
This yields hydrogen and graphene, which can be used in semiconductors, electronics, and batteries. Levidian can sell graphene for hundreds of dollars per kilogram, far more than carbon black, CEO John Hartley told Canary Media in January. Indeed, the company will host its first graphene auction on March 24. To install its technology, though, Levidian has focused on customers who want to clean up their fossil gas emissions.
“It’s really an onsite carbon-capture unit at its core: It catches carbon, makes hydrogen, and decarbonizes methane gas,” Hartley said. The first customers include Worthy Farm, which hosts the Glastonbury music festival; a wastewater treatment plant in Manchester; and the Habshan gas processing facility in Abu Dhabi.
U.S.-based Etch builds on research by founder Jonah Erlebacher, a materials science professor at Johns Hopkins University. The startup splits methane with what it describes as a recyclable catalyst that contains no rare minerals; it produces graphite and other forms of carbon.
The Etch team is wrapping up commissioning for its first “commercial-scale pilot” in Baltimore, a spokesperson told Canary Media. Last fall, the startup brought in a new CEO with commercial chops: Katie Ellet previously served as president of hydrogen energy and mobility for North America at Air Liquide, one of the few companies actually producing low-carbon hydrogen at scale, and a key player in six of the seven hydrogen hubs funded by the Department of Energy.
All these companies need to hit their stride just as the clean hydrogen market has entered a period of tumult.
The Biden administration hoped to jump-start a clean hydrogen economy with two major policies: A suite of billion-dollar grants to seven “hydrogen hubs” strategically chosen around the country, which are intended to link up production with entities that could use the fuel to clean up transportation and heavy industry, and a production tax credit to effectively lower the market price of hydrogen produced using low-carbon methods.
Now, the Trump administration has frozen payments on clean energy grants and loans. Prospective hydrogen producers had been waiting breathlessly for the final IRS guidance on the 45V tax credit; now that the lawyers have finally produced that guidance, the nascent hydrogen industry has to plead with the new administration to preserve those credits as it overhauls federal spending this year.
Given this swirling uncertainty, pyrolysis startups can take some solace in the fact that their business is not entirely dependent on the vagaries of hydrogen policy. At least they can sell carbon materials, which have clear value and established buyers who use the stuff in a non-theoretical way.
I asked Malkamäki if Hycamite identifies as a carbon company that also makes hydrogen or a hydrogen company that also makes carbon. He pointed out that the company name itself is a mashup of “Hy-” for hydrogen and “ca-” for carbon (and the -mite is a reference to a fanciful super-fuel that Donald Duck invented in a vintage comic strip). The revenues from the carbon products are “elementary for us to be profitable,” he said. “A couple of investors have said to us that hydrogen makes you sexy, carbon makes you money.”
That’s not to suggest breaking into the battery supply chain will be easy. It requires passing rigorous, multi-year testing by the battery makers that might buy Hycamite’s carbon products. But this kind of revenue can bolster a young business as it rides out the storm in Washington.
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