Membrane reactors technologies for e-fuel production & processing: A review

Membrane reactors, which integrate catalytic reactions with product separation or reactant addition, have emerged as transformative technologies to overcome traditional thermodynamic and kinetic limitations. Although extensively reviewed, their applications within the Power-to-X framework—enabling the conversion of renewable hydrogen into sustainable molecules and facilitating their utilization—remain relatively underexplored. A comparative top-down approach is taken, examining key design attributes such as membrane materials, heat management strategies, and catalyst configurations, followed by an evaluation of laboratory performance and an assessment of process-scale performance across a range of molecules. Innovations such as additive manufacturing and electric heating are highlighted for their ability to enhance heat and mass transfer. Reported laboratory-scale performance improvements include ∼250% in methanol synthesis, ∼200% in DME synthesis, ∼175% in methane reforming, and ∼30% in ammonia decomposition. Membrane reactors also mitigate side reactions, as observed in Fischer-Tropsch synthesis. This review provides a comprehensive analysis of membrane reactor potential in the Power-to-X framework, emphasizing cross-application insights.