Review of autothermal reactors: Catalysis, reactor design, and processes

Autothermal reactors can sustain the reactor operation without heat addition or removal. Catalyst is used in autothermal reactors to improve selectivity and minimize energy demand. The autothermal reactors can provide an energy-saving route for conducting chemical processes. The autothermal operation may reduce energy demands by 25%. The autothermal operation of the reactor is achieved by conducting heat transfer from an exothermic reaction mixture to an endothermic reaction mixture or by using a cold inlet to the reactor without an intermediate cooling/heating fluid. Catalytic autothermal reactors are used in several industrial applications. Academic and industrial researchers are working on developing innovative catalytic autothermal reactors for additional applications. The catalytic autothermal reactors are widely used in the Ammonia, automotive post-catalytic treatment, and syngas industries. Several pilot and lab-scale units were developed for hydrogen production, hydrocarbon reforming, and bioenergy applications. Several advanced catalytic autothermal systems were designed using recirculating, membrane, electrochemical, and micro-channel reactors. Catalytic autothermal reactors can be coupled with fuel cells to produce clean electricity using reforming products. This article examines autothermal reactor designs, catalysts, advanced methodologies, and economic considerations that position autothermal reactors as a compelling and innovative solution for reducing energy demand and achieving sustainable industrial practices.