Recent Progress in Heterogeneous Catalysis for Sustainable Chemical Processes

Jahnavi, Patibandla; Kumar, A. Kiran; Prema, S.; Ramana Singamaneni, Venkata; Vidiyala, Nithin; Sunkishala, Pavani; Rani, Soniya; Shankar Gupta, Prem

doi:10.48309/jcr.2026.535464.1482

Recent Progress in Heterogeneous Catalysis for Sustainable Chemical Processes

Document Type : Review Article

Authors

Patibandla Jahnavi ¹

A. Kiran Kumar ²

S. Prema ³

Venkata Ramana Singamaneni ⁴

Nithin Vidiyala ⁵

Pavani Sunkishala ⁶

Soniya Rani ⁷

Prem Shankar Gupta ⁸

¹ Department of Pharmaceutics, KVSR Siddhartha College of Pharmaceutical Sciences, Vijayawada, Andhra Pradesh 520008, India

² Department of Pharmaceutical Analysis and Quality Assurance, Krishna Teja pharmacy college, chadalavada Nagar, Renigunta Road Tirupati. 517506. A.P, India

³ Crescent School of Pharmacy, B.S Abdur Rahman Crescent Institute of Science and Technology, Vandalur, Chennai 600048, India

⁴ Senior Scientist II, Department of Analytical Research and development, Cambrex, Address: 1006 Ellis Dr # 2, Charles City, Iowa- 50616, United States

⁵ Principal Scientist, Cerevel therapeutics, 222 Jacobs St. Suite 200, Boston, Massachusetts 02141, United States

⁶ Senior Validation Specialist, PCI Pharma Services ,23 Commerce Drive, Bedford, NH, 03110, United States

⁷ Department of Pharmacology, GITAM School of Pharmacy, GITAM (Deemed to be University), campus Hyderabad, Telangana-502329, India

⁸ Department of Pharmaceutics, Teerthanker Mahaveer College of Pharmacy, Teerthanker Mahaveer University, Moradabad, Uttar Pradesh 244001, India

https://doi.org/10.48309/jcr.2026.535464.1482

Abstract

Recent advances in heterogeneous catalysis have significantly propelled the development of sustainable chemical processes, addressing key challenges in green chemistry. Metal-based catalysts—including nanostructured and single-atom types—have demonstrated remarkable improvements in activity and selectivity, with turnover frequencies (TOFs) reaching up to 250 h⁻¹ and product selectivities exceeding 90% in biomass conversion and CO₂ utilization. These capabilities enable efficient transformation of renewable feedstocks into value-added chemicals and fuels. Zeolite and mesoporous catalysts maintain high thermal stability (up to 600 °C) and tunable pore sizes (~2-50 nm), which are crucial for enhancing the catalytic performance in fine chemical synthesis and waste valorization. Emerging materials, such as metal–organic frameworks (MOFs) and carbon-based catalysts, provide high surface areas (often exceeding 1500 m²/g) and novel active sites, resulting in improved recyclability and catalytic lifetimes of over 50 cycles. Advances in catalyst design, particularly bimetallic and multimetallic systems, have led to synergistic effects, increasing conversion rates by 30–50% compared to their monometallic counterparts. Surface modification techniques have further improved catalyst durability, reducing deactivation rates by up to 40%. Photocatalysis and electrocatalysis are gaining momentum, achieving solar-to-hydrogen efficiencies of 10-15%, especially in water splitting and hydrogen production, thus facilitating the integration of renewable energy into chemical manufacturing. Despite the ongoing challenges in catalyst scale-up, deactivation, and economic feasibility, recent developments in reactor engineering and catalyst regeneration have reduced production costs by 15–20%. Additionally, the incorporation of AI and machine learning in catalyst discovery has accelerated the identification of novel candidates using optimized metrics, such as energy efficiency and reaction specificity. Overall, the integration of innovative catalytic systems with green feedstocks and renewable energy paves the way for sustainable, efficient, and economically viable chemical processes that support long-term global sustainability goals.

Graphical Abstract

Keywords

Heterogeneous

Catalysis

Surface chemistry

Biocatalysts

Enzyme

Carbon

Subjects

Catalysis

Content

1. Introduction

2. Fundamentals of Heterogeneous Catalysis

2.1. Mechanism and surface chemistry

2.2. Catalyst supports and active sites

2.3. Characterization techniques

3. Types of Heterogeneous Catalysts

3.1. Metal-based catalysts

3.2. Zeolite and mesoporous catalysts

3.3. Metal–organic frameworks (MOFs)

3.4. Carbon-based catalysts

3.5. Biocatalysts and enzyme-immobilized systems

4. Applications in Sustainable Chemical Processes

4.1. Biomass conversion

4.2. CO₂ utilization and conversion

4.3. Water splitting and hydrogen production

4.4. Green synthesis of fine chemicals

4.5. Waste-to-value processes

5. Challenges Future Trends and Perspectives

5.1. AI and machine learning in catalyst discovery

5.2. Integration with renewable energy

5.3. Policy and sustainability considerations

6. Conclusion

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