A process with multidisciplinary technology was designed and analysized.This process comprised three systems, i.e.catalytic chemical vapor deposition (CCVD), pressure swing adsorption (PSA),and a proton exchange membrane (PEM) fuel cell.The CCVD process realized the cracking of methane into carbon and pure hydrogen without CO or CO2 emission.By using the stainless steel catalyst, the methane was decomposed into hydrogen and highly graphitic carbon nano onions which could be collected for the advanced application such as in lithium ion battery, supercapacitor, and lubricant.The catalysts were deeply studied and the active catalytic element of metal carbide was unveiled.The optimum cracking temperature was at 800oC upon which a nearly equilibrium limited methane conversion (around 90%) was achieved.The PSA process was followed with the CCVD system and was designed for the separation of hydrogen from the un-cracked methane feed gas.The purified hydrogen was fed into a ten-stacked PEM fuel cell for electricity generation.The chain energy efficiency was analyzed for this complex system.