A comprehensive analysis of catalyst design methods, key factors, and performance trends for sustainable syngas production via dry and Bi-reforming of methane

Rising greenhouse gas emissions, particularly CO₂ and CH₄, demand effective mitigation strategies. Dry reforming (DRM) and bi-reforming of methane (BRM) offer promising routes to convert these gases into syngas, a key intermediate for fuels and chemicals. However, catalyst deactivation via sintering and coke formation limits large-scale application. This review critically evaluates recent advances in catalyst design, emphasizing active-site engineering, metal–support interactions, redox properties, and coke resistance. Nickel-based catalysts (Ni, Ni–Co, Ni–Y, Ni–La) remain industrially viable due to high activity and low cost, though they are prone to deactivation. Supports like CeO₂–ZrO₂, MgO, Al₂O₃, and SBA-15 enhance dispersion and oxygen mobility, while promoters (Fe, Sm, Sc) improve durability. A key insight is that catalyst performance depends on synergistic optimization of structural and chemical parameters rather than isolated factors. BRM generally shows superior stability due to steam-assisted coke suppression, but scalability and long-term stability remain challenges.