Carbon Capture and Mechanical Design of Membrane Reactors: A Systematic Review and Design-Performance Framework for Sustainable Energy Systems

• Abdulrahman B. GAMBO

  Author

The imperative to mitigate climate change has accelerated the development of effective carbon capture systems. Of these, membrane reactors (MRs) have become a promising alternative because they can combine chemical reaction and selective separation of gases in a single unit and thus, they are more efficient and with lower energy penalties. This paper gives an in-depth overview of polymeric, ceramic, and mixed-matrix membranes (MMMs), especially focusing on the mechanical design issues, pressure tolerance, sealing integrity, thermal stress control, and modular scalability, that determine the feasibility of reactors at large scale. A systematic literature review and comparative analysis were performed, resulting in the development of a novel design–performance matrix linking membrane material properties with reactor mechanical requirements. Results demonstrate that ceramic membranes provide superior thermal stability and CO₂ selectivity but are constrained by brittleness, while MMMs balance permeability and durability but face interfacial and scale-up challenges. The study concludes that optimal deployment of membrane reactors requires co-optimization of material innovation and mechanical engineering design, supported by emerging approaches such as additive manufacturing, defect-tolerant sealing, and digital twin models for predictive maintenance. These results point at the importance of interdisciplinary innovation to attain scalable and sustainable carbon capture technologies.

• FJET_21_66_66

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