MODULAR INTENSIFICATION OF PETROCHEMICAL REACTORS FOR HIGH-THROUGHPUT CONVERSION: A THERMAL-INTEGRATED FRAMEWORK FOR CATALYTIC EFFICIENCY AND SCALABLE SYSTEM DESIGN

The modernization of petrochemical reactors through modular intensification offers transformative potential for enhancing throughput and thermal efficiency in catalytic systems. This paper proposes a thermally integrated, modular framework designed to maximize conversion efficiency, minimize energy losses, and enable scalable deployment. Drawing from heterogeneous catalysis and process systems engineering, we develop a model for distributed, high-throughput reaction modules that balance thermal gradients and fluid dynamics. Simulation results and prior benchmarks are used to demonstrate a 20–35% increase in yield across various hydrocarbon cracking pathways.