Texas A&M University researchers have developed a new method for producing graphene oxide from methane, potentially creating a lower-cost and more scalable alternative to conventional manufacturing processes.

The research, published in Nature Communications, describes a process that uses a nonthermal plasma-water interface to convert methane, the primary component of natural gas, into high-purity graphene oxide while simultaneously generating hydrogen.

The project was led by Dr. David Staack, associate professor in the Texas A&M University J. Mike Walker ’66 Department of Mechanical Engineering and deputy vice chancellor for research. According to the research team, the discovery emerged during a project initially focused on hydrogen production.

Unlike conventional graphene oxide manufacturing, which typically begins with mined graphite and relies on chemically intensive processing, the new approach builds graphene oxide directly from methane molecules.

Graphene oxide is a carbon nanomaterial used in lithium-ion batteries, electronics, coatings, composites and other advanced manufacturing applications. Researchers noted that current supply chains for graphite and graphite-derived materials remain limited in the United States, increasing interest in alternative production methods.

The team reported that the graphene oxide produced through the plasma process exhibited properties comparable to commercially available graphene oxide. The study also demonstrated a scalable approach capable of producing high-purity, single-layer graphene oxide under atmospheric conditions.

Dr. Micah Green, professor and associate department head of chemical engineering and co-principal investigator on the project, said the work represents the first reported scalable production of graphene oxide from natural gas precursors. He noted that the process aligns with broader industry efforts to convert petrochemical feedstocks into high-value carbon nanomaterials rather than carbon emissions.

Researchers said the technology could support future domestic production of carbon nanomaterials while creating opportunities in energy storage, electronics and advanced manufacturing.

The work was supported by College Station, Texas-based energy company LTEOIL. According to the researchers, the process generates hydrogen while converting carbon into graphene oxide, providing a pathway to produce both advanced materials and energy from the same feedstock.