Unlocking catalytic longevity: a critical review of catalyst deactivation pathways and regeneration technologies

Abstract

Catalyst deactivation remains a fundamental challenge in heterogeneous catalysis, compromising performance, efficiency, and sustainability across numerous industrial processes. This review critically examines the principal deactivation pathways including coking, poisoning, thermal degradation, and mechanical damage and evaluates the breadth of regeneration strategies developed to restore catalytic activity. Traditional methods such as oxidation, gasification, and hydrogenation are assessed alongside emerging approaches like supercritical fluid extraction (SFE), microwave-assisted regeneration (MAR), plasma-assisted regeneration (PAR) and atomic layer deposition (ALD) techniques. The environmental implications and operational trade-offs associated with each regeneration method were evaluated. By integrating recent scientific advancements with bibliometric analysis, this study identifies prevailing research trends and exposes key knowledge gaps in catalyst regeneration. Unlike prior reviews, this work offers a holistic perspective that spans multiple deactivation mechanisms and regeneration routes. Insights into process optimization and environmental impact reduction are presented to guide future innovation in sustainable catalytic system design. By contrasting current progress with unexplored potential, this study provides a basis for promoting innovation and management of sustainable catalysts. It serves as a strategic roadmap for enhancing catalyst longevity and performance in next-generation industrial applications.