The thermo-catalytic decomposition of methane is proposed as an alternative for producing hydrogen without CO2 emissions. The present study was divided into three parts. First, a screening study of the rate of methane decomposition (R-CH4) was performed using two types of activated carbons as catalysts with progressive time of methane decomposition at four different temperatures. The catalysts differed in textural properties. A full factorial design consisting of 20 experimental points for each catalyst was applied in the second part. Quadratic R-CH4, models as functions of the relative time of catalyst deactivation and decomposition temperature were developed by regression analysis of variance. The results of the R-CH4 models showed that the relative time had twice as much influence as temperature. Finally, a general R-CH4, model was then developed representing both catalysts regardless of their textural properties. All the empirical models were consistent with experimental results and were adequate for designing the methane decomposition process. Copyright (C) 2014, Hydrogen Energy Publications, LLC. Published by Elsevier Ltd. All rights reserved.