Catalytic Hydrogenation of CO2 to Alternative Fuels: A Review of Methanation and Related Pathways

The imperative to mitigate climate change has accelerated the development of Carbon Capture, Utilization, and Storage (CCUS) technologies, particularly CO2 hydrogenation into high-value chemicals and alternative fuels. This work evaluates the fundamental thermodynamic limitations and the primary directions of CO2 conversion, with a primary focus on methanation, alongside related pathways such as methanol synthesis and the reverse water-gas shift (RWGS) reaction. To overcome the high kinetic barriers of CO2 activation, various catalytic systems are analyzed. While noble metal catalysts exhibit high catalytic performance, nickel-based catalysts serve as a viable and cost-effective alternative. To overcome nickel’s susceptibility to thermal sintering and coking, advanced bimetallic and multimetallic formulations are being developed to enhance structural stability and selectivity. These advancements are crucial for producing Synthetic Natural Gas (SNG) and sustainable aviation fuels (SAF). Ultimately, the objective of this comprehensive review is to systematically summarize recent advancements in catalyst design, critically analyze the advantages and fundamental bottlenecks of distinct catalytic systems, and outline prospective paths for the efficient industrial-scale production of sustainable alternative fuels.