Breaking heat and equilibrium barriers in catalytic reactions via a membrane integrated flow reactor

Catalytic systems are limited by a long-standing thermochemical decoupling between reaction kinetics, heat transfer, and product separation, which constrains attainable conversion and overall reactor performance. Although several strategies have been explored, coupling between heat and chemical flux remains unaddressed. Here, we report an integrated flow reactor, for the first time, resolves this challenge by co-locating conductive and selective domains within a single architecture. The integrated flow reactor combines a 3D-printed catalytic static mixer with a tubular palladium membrane, coupling heat conduction with in situ hydrogen removal. Under a representative liquid organic hydrogen carrier dehydrogenation condition, the coordinated heat–mass transport lowers radial temperature gradients by 83% and increases conversion by 34% compared with a benchmark packed bed, ultimately reaching 111% of the equilibrium limit. A validated two-dimensional model reproduces experimental conversion and temperature within 20% and 5%, respectively. This work establishes a general framework for non-equilibrium catalysis, demonstrating that coordinated energy and mass transport can surpass thermodynamic limits and enable thermally balanced hydrogen-release reactions. • 3D-printed catalytic static mixer integrated membrane reactor enables coordinated heat–mass transport. • Co -located conductive and selective domains intensify endothermic LOHC dehydrogenation. • Radial temperature gradients reduced by 83% and conversion increased by 34% versus a packed bed. • Integrated reactor surpasses equilibrium, achieving 111% of the LOHC dehydrogenation equilibrium limit. • Validated two-dimensional model accurately reproduces experimental conversion and temperature.