The chemical industry is undergoing a fundamental shift driven by the rapid growth of variable renewable energy sources. Conventional catalytic chemical processes, designed around steady-state operation, are increasingly challenged by the intermittent nature of solar and wind power [1]. This contribution presents Casale’s perspective on how unconventional operations in catalysis — and ultimately unconventional catalytic reactors — represent the most effective response to this challenge.

We first examine the techno-economics of flexible ammonia and methanol synthesis, demonstrating that adapting the synthesis loop to follow renewable energy availability — rather than buffering variability through expensive upstream storage — reduces both capital expenditure and the levelized cost of the product. In the context of rising geopolitical risk and energy price volatility, energy-independent production at a stable, predictable cost offers a compelling investment case.

We then address process electrification as the enabling technology for catalytic dynamic operation [2]. Electrification — e.g. through Joule heating, induction, microwave, and plasma — allows materials to heat and cool at rates unachievable with conventional thermal systems, enabling the catalyst to operate in a periodically forced regime. Under the right forcing conditions, the time-averaged catalytic rate can exceed the maximum achievable under any fixed static condition: a phenomenon known as dynamic catalysis. Ongoing R&D projects at Casale are exploring electrified monolith reactors, microwave-assisted catalysis, non-thermal plasma for CO₂ valorisation, and microwave-plasma torch processes for syngas generation.

[1]  Palys, M. J.; Moot, T.; Parvathikar, S.; Zhang, K.; Kavale, C. A.; Gupta, J. K.; Daoutidis, P. Techno-Economic Optimization of Flexible Distributed Green Ammonia Production. Int. J. Hydrogen Energy 2026, 206, 153230. https://doi.org/10.1016/j.ijhydene.2025.153230
[2]  Monai, M.; Albrecht, W.; Alkemper, A.; Artrith, N.; Baldi, A.; Beck, A.; Berry, R. T.; Bianco, E.; Brzesowsky, F. A.; Dong, Q.; et al. Grand Challenges and Opportunities in Stimulated Dynamic and Resonant Catalysis. ChemRxiv 2025. https://doi.org/10.26434/chemrxiv-2025-6czq6.
[3]   Stankiewicz, A. I.; Nigar, H. Beyond Electrolysis: Old Challenges and New Concepts of Electricity-Driven Chemical Reactors. React. Chem. Eng. 2020, 5, 1005–1016. https://doi.org/10.1039/D0RE00116C.