The
global initiatives on sustainable and green energy resources
as well as large methane reserves have encouraged more research to
convert methane to hydrogen. Catalytic decomposition of methane (CDM)
is one optimistic route to generate clean hydrogen and value-added
carbon without the emission of harmful greenhouse gases, typically
known as blue hydrogen. This Review begins with an attempt to understand
fundamentals of a CDM process in terms of thermodynamics and the prerequisite
characteristics of the catalyst materials. In-depth understanding
of rate-determining steps of the heterogeneous catalytic reaction
taking place over the catalyst surfaces is crucial for the development
of novel catalysts and process conditions for a successful CDM process.
The design of state-of-the-art catalysts through both computational
and experimental optimizations is the need of hour, as it largely
governs the economy of the process. Recent mono- and bimetallic supported
and unsupported materials used in CDM process have been highlighted
and classified based on their performances under specific reaction
conditions, with an understanding of their advantages and limitations.
Metal oxides and zeolites have shown interesting performance as support
materials for Fe- and Ni-based catalysts, especially in the presence
of promoters, by developing strong metal–support interactions
or by enhancing the carbon diffusion rates. Carbonaceous catalysts
exhibit lower conversions without metal active species and largely
result in the formation of amorphous carbon. However, the stability
of carbon catalysts is better than that of metal oxides at higher
temperatures, and the overall performance depends on the operating
conditions, catalyst properties, and reactor configurations. Although
efforts to summarize the state-of-art have been reported in literature,
they lack systematic analysis on the development of stable and commercially
appealing CDM technology. In this work, carbon catalysts are seen
as promising futuristic pathways for sustained H2 production
and high yields of value-added carbon nanomaterials. The influence
of the carbon source, particle size, surface area, and active sites
on the activity of carbon materials as catalysts and support templates
has been demonstrated. Additionally, the catalyst deactivation process
has been discussed, and different regeneration techniques have been
evaluated. Recent studies on theoretical models towards better performance
have been summarized, and future prospects for novel CDM catalyst
development have been recommended.