Production of hydrogen from fossil fuel: A review

Production of hydrogen, one of the most promising alternative clean fuels, through catalytic conversion from fossil fuel is the most technically and economically feasible technology. Catalytic conversion of natural gas into hydrogen and carbon is thermodynamically favorable under atmospheric conditions. However, using noble metals as a catalyst is costly for hydrogen production, thus mandating non-noble metal-based catalysts such as Ni, Co, and Cu-based alloys. This paper reviews the various hydrogen production methods from fossil fuels through pyrolysis, partial oxidation, autothermal, and steam reforming, emphasizing the catalytic production of hydrogen via steam reforming of methane. The multicomponent catalysts composed of several nonnoble materials have been summarized. Of the Ni, Co, and Cu-based catalysts investigated in the literature, Ni/Al₂O₃ catalyst is the most economical and performs best because it suppresses the coke formation on the catalyst. To avoid carbon emission, this method of hydrogen production from methane should be integrated with carbon capture, utilization, and storage (CCUS). Carbon capture can be accomplished by absorption, adsorption, and membrane separation processes. The remaining challenges, prospects, and future research and development directions are described.