From CO₂ to methane: Politecnico di Milano study featured on the cover of ACS Catalysis

Milan, 5 June 2025 - Every day, tonnes of CO₂ are released into the atmosphere, but what if we could transform it using clean energy? This is the question explored in a recent Politecnico di Milano study, which was featured on the cover of the scientific journal ACS Catalysis. The research focuses on a process that transforms carbon dioxide and hydrogen into methane using carefully engineered nickel nanoparticles. Entitled “Deciphering Size and Shape Effects on the Structure Sensitivity of the CO₂ Methanation Reaction on Nickel”, the study by Gabriele Spanò, Matteo Ferri, Raffaele Cheula, Matteo Monai, Bert M. Weckhuysen and Matteo Maestri investigates how the size and shape of nickel nanoparticles influence the rate at which carbon dioxide is converted into methane.

Researchers at the Laboratory of Catalysis and Catalytic Processes (LCCP) at Politecnico di Milano’s Department of Energy are tackling a key climate challenge: reusing CO₂ to produce sustainable fuels. The LCCP is an internationally recognised leader in heterogeneous catalysis, driving forward practical solutions for cleaner energy.

Combining atomistic simulations with experimental data, the team demonstrated that the size and shape of nickel nanoparticles play a decisive role in accelerating the methanation reaction. This insight resolves a longstanding scientific debate and opens new avenues for optimising other industrial processes such as ammonia synthesis and the Fischer–Tropsch process.

The study’s lead author and PhD candidate at the Politecnico di Milano’s Department of Energy Gabriele Spanò said: "Understanding the role of nanoparticle shape and size allows us to design more efficient catalysts. It’s a vital step in treating CO₂ as a resource rather than waste to be mitigated.”

Politecnico di Milano’s Department of Energy full professor and LCCP coordinator Matteo Maestri said: “This work shows that combining experimental evidence with advanced modelling can tackle complex, real-world challenges. The methodologies applied are the result of years of development in atomistic analysis for catalytic systems.”

The study offers valuable guidelines for developing catalytic materials geared towards CO₂ conversion, contributing meaningfully to the energy transition.