Catalytic decomposition of methane produces COx-free hydrogen, which is necessary for PEM fuel-cell applications. In this paper, hydrogen production by catalytic decomposition of methane at 550 degrees C over Ni on HY, USY, SiO2 and SBA-15 supports is examined at atmospheric pressure. The catalytic activities and the life times of the catalysts are evaluated and discussed. The relationships between catalyst performance and characterization of the fresh and used catalysts are discussed with the results obtained from SEM, XRD, TPR, solid acidity and the measured carbon contents generated of the used samples along with their H, production rates. Among all the catalysts tested, Ni supported on HY zeolite showed a higher activity of 955 mol H-2 (mol Ni)(-1) and a longevity of 720 min at 550 degrees C. (c) 2006 Elsevier B.V. All rights reserved.