Promotional roles of second metals in catalyzing methane decomposition over the Ni-based catalysts for hydrogen production: A critical review

Abstract

The thermocatalytic decomposition (TCD) of methane is considered as a milestone towards the production of valuable COx-free hydrogen and carbon nanomaterials without the use of steam or O2. Previous reviews have been aimed at methane decomposition over the different catalysts, such as nickel-based catalysts, non-nickel-based catalysts, metal oxide-supported catalysts, and carbon-supported catalysts. The Ni-based catalysts are suitably applied for methane TCD process due to their high activity and low cost. However, the loss of activity and/or stability with reaction time is one of the most notable challenges in the use of Ni-based catalysts, and a number of studies on the roles of various factors in overcoming such a problem can be found in the literature. Recently, the use of the second metal as a promoter to control catalyst deactivation has attracted much attention. The present review focuses on classification of the different promoters based on the periodic table of elements, such as alkali metals, alkaline earth, transition metals, noble metals, and rare earth metals, and makes a detailed discussion on promotional roles in influencing their physicochemical properties and catalytic performance of the Ni-based catalysts. The generalized structure-performance relationship of the metals-doped catalysts may give an appreciated reference to the design of catalysts with highly pure hydrogen production and carbon nanomaterials. In addition, this review also covers the works on effects of the promoters on nature and morphology of the formed carbon nanomaterials. The use of transition metals (Fe, Co or Cu), noble metal (Pd or Pt), and rare earth metal (La) with a suitable loading as a promoter influenced performance and lifespan of the catalyst and the interaction of Ni particles with the support. Among these promoters, Cu, Pd, La, and Cu–Pd as a dopant have demonstrated superior performance, which was attributed to the capability of these elements in prohibiting carbon accumulation on the active Ni components.