Electrification of Chemical Reactors: Microwave, Plasma, and Induction Routes to Net-Zero Chemistry
Keywords:
reactor electrification, microwave heating, plasma catalysis, induction heating, net-zero chemistry, sustainable chemical processes, energy efficiency, process intensificationAbstract
This review aims to synthesize recent advances in microwave, plasma, and induction reactor electrification to evaluate their potential for enabling net-zero chemical manufacturing. A qualitative literature review was conducted on 16 peer-reviewed studies published between 2013 and 2025, selected for their relevance to reactor electrification, energy efficiency, and sustainability. Data were analyzed using Nvivo 14 software through open and axial coding to identify thematic patterns and conceptual clusters. The analysis followed a theoretical saturation approach, ensuring that emerging themes were exhaustively explored. The study focused on three main reactor types—microwave, plasma, and induction—and considered subthemes including energy transfer mechanisms, catalyst and material design, reactor configuration, process integration, and techno-environmental performance. The review revealed distinct advantages and limitations for each electrification route. Microwave-assisted reactors enable rapid volumetric heating and selective catalyst activation, enhancing reaction kinetics and selectivity, though field uniformity and penetration depth remain challenges. Plasma-assisted reactors exploit non-thermal activation via radicals and excited species, allowing conversion under milder conditions, yet energy efficiency and catalyst stability constrain large-scale application. Induction heating provides precise localized thermal control with fast response times and modular scalability, though coil design, thermal uniformity, and system integration require optimization. Across all three approaches, integration with renewable electricity and consideration of life-cycle emissions are critical for achieving net-zero chemistry. Hybrid strategies and modular, grid-responsive reactor designs emerge as promising avenues for industrial deployment. Electrification of chemical reactors using microwave, plasma, and induction technologies offers a viable pathway toward decarbonized chemical manufacturing. While each route exhibits unique mechanistic and engineering benefits, overcoming scale-up, energy efficiency, and integration challenges is essential. Future research should prioritize hybrid designs, standardized benchmarking, and materials optimization to fully realize the potential of net-zero electrified chemical reactors.
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