Advancing CO2 methanation with 3D-engineered catalysts: Innovations, challenges, and future prospects

The increasing global energy demand and the urgent need to reduce greenhouse gas emissions have intensified interest in CO₂ methanation, a pivotal process in carbon capture and utilization (CCU) technologies for sustainable energy systems. Three-dimensional (3D) catalyst materials have emerged as groundbreaking solutions, offering enhanced structural properties, increased surface area, and superior stability, thereby significantly improving the efficiency and effectiveness of the methanation process. Conventional catalyst designs face limitations, including short operational lifespans, suboptimal selectivity, and inefficient heat and mass transfer, which hinder their scalability and broader industrial adoption. Despite advancements, the potential of innovative fabrication methods, such as 3D printing and templating, to optimize catalyst performance in CO₂ methanation remains insufficiently explored and systematically reviewed. This review systematically examines the development and application of 3D catalyst materials in CO₂ methanation, emphasizing their fabrication techniques, performance enhancements, and contributions to industrial processes. The study highlights how 3D catalysts outperform traditional designs regarding of stability, selectivity, and energy efficiency, presenting a comprehensive analysis of novel material innovations and their scalability for industrial applications. It bridges knowledge gaps by linking emerging fabrication technologies to practical CO₂ utilization solutions. 3D catalyst materials represent a paradigm shift in CO₂ methanation, addressing critical challenges in catalyst performance while supporting the global transition toward carbon neutrality and sustainable energy systems. This review provides important new information for developing 3D catalysts, highlighting their revolutionary potential to bring cutting-edge materials science into line with large-scale energy solutions. It emphasizes the value of 3D catalysts in addressing the twin demands of energy sustainability and climate action by outlining a course for future research.