Plasma-based methane pyrolysis (MP) is one of the most technologically advanced pathways for low-emission hydrogen production due to its high conversion efficiency, rapid reaction kinetics, and potential for decarbonized hydrogen generation with valuable solid carbon co-products. In this review, we provide a comprehensive assessment of research outcomes and industrial developments in plasma-assisted methane pyrolysis (PAMP) for hydrogen production. Although research activity has intensified in recent years, most investigations are conducted at laboratory-scale experimentation, with significant emphasis placed on reactor optimization, plasma stability enhancement, energy efficiency improvement, and carbon by-product management. Among the various reactor configurations explored, thermal arc plasma reactors demonstrate the highest industrial readiness due to their superior methane conversion rates, continuous operational capability, and scalability for large-volume hydrogen production. However, critical challenges, including high electricity demand, electrode degradation, reactor material limitations, and inconsistent carbon quality, continue to hinder large-scale commercialization. Future progress will depend on integrating renewable electricity sources, advancing reactor durability, improving process economics, and developing value chains for carbon by-products. With continued technological innovation and supportive policy frameworks, PAMP is becoming a key transitional technology for scalable, low-carbon hydrogen production in the emerging hydrogen economy.
Sarkinbaka et al. (Thu,) studied this question.