[et_pb_section fb_built=”1″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}” theme_builder_area=”post_content”][et_pb_row _builder_version=”4.27.4″ _module_preset=”default” custom_padding=”2em||0px||false|false” global_colors_info=”{}” theme_builder_area=”post_content”][et_pb_column type=”4_4″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}” theme_builder_area=”post_content”][et_pb_heading title=”Methane Pyrolysis Corrosion Testing ” _builder_version=”4.27.4″ _module_preset=”default” custom_css_free_form=”selector h1 {|| text-wrap: pretty;||}” locked=”off” global_colors_info=”{}” theme_builder_area=”post_content”][\/et_pb_heading][et_pb_image src=”https:\/\/www.alicat.com\/wp-content\/uploads\/2025\/08\/Laboratory_muffle_furnace.webp” alt=”Laboratory muffle furnace” align=”center” force_fullwidth=”on” module_id=”article-hero-image” _builder_version=”4.27.5″ _module_preset=”default” custom_margin=”1.5rem||||false|false” custom_css_free_form=”selector img {|| object-fit: cover;||}” global_colors_info=”{}” theme_builder_area=”post_content”][\/et_pb_image][et_pb_divider color=”#2A3B47″ divider_weight=”2.5px” _builder_version=”4.27.4″ _module_preset=”default” height=”0px” custom_margin=”3rem||3rem||true|false” global_colors_info=”{}” theme_builder_area=”post_content”][\/et_pb_divider][et_pb_heading title=”Executive Summary” _builder_version=”4.27.4″ _module_preset=”default” title_level=”h3″ global_colors_info=”{}” theme_builder_area=”post_content”][\/et_pb_heading][\/et_pb_column][\/et_pb_row][et_pb_row _builder_version=”4.27.4″ _module_preset=”default” custom_padding=”0px||0px||true|false” locked=”off” global_colors_info=”{}” theme_builder_area=”post_content”][et_pb_column type=”4_4″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}” theme_builder_area=”post_content”][et_pb_text _builder_version=”4.27.4″ _module_preset=”default” custom_margin=”||2rem||false|false” global_colors_info=”{}” theme_builder_area=”post_content”]<\/p>\n
[\/et_pb_text][et_pb_divider color=”#000000″ divider_weight=”2px” _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}” theme_builder_area=”post_content”][\/et_pb_divider][et_pb_text _builder_version=”4.27.4″ _module_preset=”default” custom_margin=”||2rem||false|false” global_colors_info=”{}” theme_builder_area=”post_content”]Corrosion remains one of the most persistent and costly problems in both industrial and commercial sectors. According to the National Association of Corrosion Engineers (NACE), the global annual cost of corrosion is estimated at $2.5 trillion, or 3.5% of global GDP. This figure illustrates not only the scale of the issue, but also the opportunity for developing improved mitigation techniques.<\/p>\n
University researchers are preparing a study for next year on how advanced alloys respond to the extreme thermal and chemical stresses of methane pyrolysis. Unlike most work in this field—aimed at boosting hydrogen yields or optimizing catalysts—this project will focus on material compatibility, offering critical data on the limits of high‐performance alloys and guiding the design of future experiments.[\/et_pb_text][et_pb_heading title=” Experiment outline” _builder_version=”4.27.4″ _module_preset=”default” title_level=”h3″ global_colors_info=”{}” theme_builder_area=”post_content”][\/et_pb_heading][et_pb_text _builder_version=”4.27.4″ _module_preset=”default” custom_margin=”||2rem||false|false” global_colors_info=”{}” theme_builder_area=”post_content”]Small coupons of alloys will be mounted inside a 1200\u00b0C muffle furnace and gradually exposed to methane pyrolysis conditions. Instead of running pyrolysis at production scale, the researchers will generate only small, controlled amounts at a time, just enough hydrogen and carbon to create a reactive atmosphere around the test coupons. Alloys such as 310 stainless steel and Inconel 693 are being selected for their high corrosion resistance, enabling researchers to observe two primary degradation modes: carburization<\/a>, where carbon from decomposed methane diffuses into the alloy and precipitates chromium carbides, and high\u2010temperature hydrogen damage, where hydrogen accelerates grain boundary weakening.<\/p>\n Although pyrolysis can be achieved at lower temperatures, pushing the system to 1200\u00b0C will accelerate both reactions and shorten test durations, allowing researchers to collect meaningful data within a practical window.<\/p>\n The experiment will use several gas mixes, including pure argon, pure hydrogen, a 5% H2<\/sub>\/argon blend, and CH4<\/sub>\/H2<\/sub> mixtures containing 5% and 10% methane. Each stream will be controlled by one of four separate Alicat\u00ae<\/sup> MC-series mass flow controllers<\/a> (MFCs), positioned upstream of the muffle furnace and flowing 10\u00a0\u2013\u00a020 sccm of gas. The MFCs\u2019 accuracy rating\u2014\u00b1\u00a00.5% of reading or \u00b1\u00a00.1% of full scale, whichever is greater\u2014will provide consistent dosing to ensure the temperature remains stable.<\/p>\n Using the GasSelect\u2122<\/a> and Composer\u2122<\/a> functions, MFCs will support gas\u2010swapping presets, allowing researchers to switch between pure gases and custom gas mixtures without recalibration or loss of accuracy. This flexibility means the same hardware can seamlessly adjust between Ar, H2<\/sub>, or CH4<\/sub>\/H2<\/sub> blends as the experiment progresses, enabling multiple test conditions with fewer instruments and minimal downtime.<\/p>\n Without a central DAQ, researchers will log furnace setpoint data and the MFC display readings at fixed intervals. The MFC\u2019s alarm function can be used to monitor and warn researchers of trips in flow rate, supply pressure, or temperature, ensuring the process remains steady<\/p>\n The success of this experiment depends on precise, stable gas delivery over a long period of time. MFCs maintain tight flow control across multiple gases, keeping furnace conditions consistent as test atmospheres change and pressure slightly increases. Without this precision, uncontrolled shifts in hydrogen or methane concentration could obscure corrosion effects. By enabling rapid gas\u2010mix adjustments and providing real\u2010time alarms, Alicat MC\u2011series MFCs will help allow the tests to run with fewer interruptions.[\/et_pb_text][et_pb_heading title=”The future of methane pyrolysis ” _builder_version=”4.27.4″ _module_preset=”default” title_level=”h3″ global_colors_info=”{}” theme_builder_area=”post_content”][\/et_pb_heading][et_pb_image src=”https:\/\/www.alicat.com\/wp-content\/uploads\/2025\/04\/mc-series-mass-flow-controller-50sccm-253×300.webp” alt=”Alicat MC 50 SCCM mass flow controller” show_bottom_space=”off” align_tablet=”” align_phone=”center” align_last_edited=”on|phone” _builder_version=”4.27.4″ _module_preset=”default” max_width=”50%” custom_margin_tablet=”” custom_margin_phone=”1rem||||false|false” custom_margin_last_edited=”on|phone” custom_padding=”||2rem|2rem|false|false” custom_padding_tablet=”||2rem|2rem|false|false” custom_padding_phone=”||2rem|0rem|false|false” custom_padding_last_edited=”on|phone” custom_css_main_element=”float: right;” global_colors_info=”{}” custom_css_main_element_last_edited=”on|phone” custom_css_main_element_phone=”float: none;” custom_css_main_element_tablet=”float: right;” theme_builder_area=”post_content”][\/et_pb_image][et_pb_text _builder_version=”4.27.4″ _module_preset=”default” custom_margin=”||2rem||false|false” global_colors_info=”{}” theme_builder_area=”post_content”]Every big leap in industry starts with small steps in the lab. Careful, small‐scale experiments often shape the way entire industries move forward, giving engineers the insight they need to make better choices in the real world. What makes this work exciting is its potential to uncover how materials truly behave under the toughest conditions—knowledge that directly informs the next generation of industrial design.<\/p>\n Petrochemical producers and materials developers face the challenge of selecting alloys that can withstand highly reactive conditions. For the hydrogen industry especially, electrolyzers, pipelines, and reactors must operate safely within these extremes.<\/p>\n Methane pyrolysis is already being explored<\/a> in reactors as a future path to cleaner hydrogen production. Further testing such as this will feed directly into those advances by showing which alloys can endure the process. By studying methane pyrolysis corrosion and the chemical mechanisms that drive material degradation, researchers can refine alloy selection and lifecycle predictions, leading to more reliable materials, longer equipment life, and more efficient production.[\/et_pb_text][et_pb_heading title=”Why do these researchers choose Alicat MFCs?” _builder_version=”4.27.4″ _module_preset=”default” title_level=”h3″ locked=”off” global_colors_info=”{}” theme_builder_area=”post_content”][\/et_pb_heading][et_pb_text _builder_version=”4.27.4″ _module_preset=”default” custom_margin=”||2rem||false|false” locked=”off” global_colors_info=”{}” theme_builder_area=”post_content”]<\/p>\n [\/et_pb_text][et_pb_text _builder_version=”4.27.6″ _module_preset=”default” text_font=”|700|||||||” custom_margin=”||2rem||false|false” hover_enabled=”0″ locked=”off” global_colors_info=”{}” theme_builder_area=”post_content” sticky_enabled=”0″]See how else Alicat supports laboratory research \n