Plasma catalysis for sustainable industry: lab-scale studies and pathways to upscaling

Non-thermal plasma (NTP) catalysis has emerged as a transformative technology for achieving sustainable chemical production, particularly within energy-intensive industries. With advantages like rapid response times, low thermal input, and the ability to operate at atmospheric pressures, NTP systems are well-suited for integration with renewable energy sources. However, translating lab-scale insights into scalable industrial applications presents substantial challenges, particularly in understanding plasma-catalyst interactions and designing reactors that perform efficiently at larger scales. This review explores recent advancements in plasma catalysis, highlighting lab-scale studies that provide foundational knowledge of plasma-surface chemistry, catalyst behavior, and reactor design. Additionally, we examine novel approaches in plasma photo- and plasma electro-catalysis, which offer added control over reaction pathways. The review further addresses scaling challenges and potential solutions, from reactor design modifications to process optimization under industrially relevant conditions. By linking fundamental research to industrial applications, this narrative aims to identify the pathways through which NTP catalysis can contribute to a zero-emission, circular carbon economy.