Dry reforming of methane on supported nickel catalysts: Recent advances on process modelling, carbon pathways and life cycle assessment

Dry reforming of methane (DRM) is a process that converts CH₄ and CO₂ into synthesis gas (H₂/CO), offering a dual environmental benefit by utilizing two major greenhouse gases toward the production of valuable chemicals. However, the widespread and sustainable application of DRM over supported Ni catalysts is limited by catalyst deactivation, primarily caused by carbon deposition originating from methane cracking and the reverse Boudouard reaction. A comprehensive examination of carbon formation and removal steps during DRM is presented. The influence of Ni metal particle size and morphology, the support and promoter chemical composition, and the metal-support interactions in governing resistance to carbon accumulation are discussed. Carbon mitigation pathways, and the use of basic and reducible metal oxide supports of nickel are analyzed in depth. Recent advances in operando characterization techniques, isotopic labelling, and DFT calculations have provided insights into the mechanism and dynamics of carbon formation and gasification, as well as the dynamic restructuring of active sites under DRM reaction conditions. In addition, kinetic modelling and microkinetic simulations, and reactor-level numerical analysis have emerged as powerful tools to predict carbon formation trends, evaluate deactivation behavior, and optimize catalyst performance. Furthermore, the industrial applications of DRM and the role of modelling and numerical analysis in scaling up this process are discussed. The principal challenges and prospective avenues in catalytic DRM, particularly regarding modelling and numerical analysis, are delineated, thereby facilitating future research in this area. Finally, this review integrates the framework of Life Cycle Assessment (LCA) within the DRM context, emphasizing the environmental and resource-efficiency implications of process design, catalyst selection, and system boundaries.