Valorizing carbon black byproducts from methane pyrolysis

Methane (CH 4 ) pyrolysis offers a low-carbon route for hydrogen (H 2 ) production while co-generating substantial quantities of solid carbon, much of which may appear as carbon black. The quality and fate of this carbon co-product strongly affect the techno-economics and life cycle performance of methane-pyrolysis systems. This review evaluates the fit-for-purpose valorization of methane-pyrolysis-derived carbon black in smart construction materials, batteries, biosensors, and catalytic methane pyrolysis. We highlight how particle size, aggregate structure, surface chemistry, purity, conductivity, and dispersibility govern application performance and often necessitate post-treatment. Key challenges include variability relative to furnace-grade carbon black, dispersion and durability in cementitious matrices, alignment with industrial specifications, and limited market absorptive capacity. By linking process conditions, carbon properties, technology-readiness levels, and end-use markets, this review identifies where carbon black is application ready and where standardization, upgrading, and scale-aware offtake strategies are required.