Reactor Design Research Articles

Recent achievements in nickel based electrochemical biorefinery of 5-hydroxymethylfurfural

The electrochemical conversion of biomass offers a sustainable approach for energy recycling and environmental protection. Specifically, the electro-oxidation of 5-hydroxymethylfurfural (HMF) to 2,5-furandicarboxylic acid is notable for its potential to produce value-added products, including biodegradable plastics and other environmentally friendly materials. A critical factor in this process is the performance of the catalysts. Nickel-based catalysts have shown high efficiency and durability, primarily due to the formation of Ni-OOH active sites. This paper reviews recent advancements in the nickel-based electrocatalytic oxidation of HMF, including the use of Ni, Ni alloys, Ni oxides, Ni hydroxides, and other Ni complex, and discusses the underlying catalytic mechanisms. Additionally, it introduces the coupling reactions, various reactor designs and outlines future research directions, focusing on exploring reaction mechanisms, developing electrocatalysts, and practical applications of this technology.

Machine learning powered predictive modelling of complex residual stress for nuclear fusion reactor design

Fusion In-vessel components, assembled and maintained using laser welding, one of the most promising techniques, exhibit complex distributions of residual stress, microstructures, and material properties. These residual stresses can compromise structural integrity and lifespan of critical components. Although using advanced experimental measurements can evaluate the residual stress for individual case, extending the measurements to massive number of components are costly and time-consuming. Traditional machine learning (ML) models struggle to account for the heterogeneity and anisotropy of these stress distributions. Here, we develop a novel ML framework based on the Eurofer97 steel, the structural material for in-vessel components. The ML framework is trained on high-resolution residual stress data derived from recently-developed evaluation techniques. Combining with microstructures, the model enables prediction of heterogenous and anisotropic residual stress distribution. It successfully predicts the compressive residual stress in fusion zone (∼−200 MPa) balanced by tensile residual stress in heat affected zone (∼300 MPa), aligning closely with experimental results with the R-squared value of 0.989 and the mean square error of 10−4. Unlike experiments that take hours, the ML model provides predictions within seconds. It offers valuable insights into residual stress prediction for various joints, enhancing the reliability and lifetime prediction of in-vessel components.

From biomass to power: High-performance reactor design for coking-resistant operation

Biomass gasification coupled with solid oxide fuel cell (SOFC) technology utilizes the gas generated from biomass gasification directly as fuel for SOFC, thereby realizing power generation from solid waste. This technology combines the carbon–neutral feature of biomass with the high efficiency and low emissions of SOFC, making it a promising route for clean energy generation. However, biomass gasification syngas possesses a complex composition, including a high concentration of inert gases, which imposes higher requirements on SOFC. This study developed a multi-channel, hierarchical structural design based on the commercial NiO-yttria-stabilized zirconia (YSZ) material system, realizing high-performance power generation using biomass gasification syngas. The results showed that the combination of a unique structural design and an enhanced interface electrochemical reaction effectively mitigates the influence from inert composition dilution. When operating in gasification syngas with nearly 60 % inert components, the power density can reach 2.07 W·cm−2 (750 °C). In addition, due to the spatial separation of the inert support region and the electrochemically active region, the effect of controlling the position of carbon deposits was achieved, demonstrating 100 h stable operation with dry biomass gasification syngas. Hence, the combination of micro-tubular SOFC with distinctive structural regulation and biomass gasification exhibits promising prospects for further development.

A novel tubular single-chamber microbial electrolysis cell for efficient methane production from industrial potato starch wastewater

The integration of microbial electrolysis cells (MEC) with anaerobic digestion (AD) shows great promise for enhancing methane production from high-COD wastewater. However, an efficient MEC-AD reactor design remains elusive. Here, a novel tubular single-chamber MEC-AD reactor was constructed to treat potato starch wastewater (COD over 20000mg/L). The concentric and compact design of the stainless-steel cathode and anode reduced internal resistance, resulting in enhanced methane production. Applying -0.2V vs. Ag/AgCl to the anode increased methane production by 1.73 times compared to the open circuit and halved hydraulic retention time. Moreover, the reactor achieved an average methane content of 82.57%, which was 23.89% higher than the open circuit. The reactor showed a total COD removal of 92.2%, which was 24% higher than the open circuit. Additionally, base consumption to maintain pH was reduced to one-sixth of that in conventional AD, preventing volatile fatty acid accumulation. Microbial analysis showed Geobacter (63.4%) and Methanobacterium (96.8%) were highly enriched in the anode and cathode biofilms, respectively. The proportion of fermentative bacteria also increased in the MEC-AD system. These results demonstrate the effectiveness of the tubular single-chamber MEC-AD reactor in enhancing methane production from potato starch wastewater, with strong potential for scale-up applications.

Development and Verification of a Multi-Physics Transport Code of Molten Salt Reactor Fission Products

The transport of fission products in molten salt reactors has attracted much attention. However, few codes can completely describe the transport characteristic, though the migration of fission products in the molten salt reactor is essential to estimate the source term, decay heat, and radiation shielding. This study built a program named ThorFPMC (Thorium Fission Products Migration Code) that can handle the multi-physics transport characteristic based on the flow burnup code ThorMODEc (Thorium MOlten Salt Reactor Specific DEpletion Code). A problem-related depletion chain compression method was applied to decrease the order of the solve matrix. The matrix exponential and splitting methods were applied to solve the steady state and transient calculation, respectively. Error analysis showed that for a specific problem, the simplified depletion chain matrix index method could solve the fission products migration equation with an arbitrary time-step with high speed (s) and high precision (10−4); the splitting method could reach a precision of 10−2 level for the full fuel depletion chain, multi-nodes, and transient problems. Compared to the Strang splitting method, the perturbation splitting method has higher precision and less time consumption. In summary, the developed programmer could describe the migration effect of fission products in molten salt reactors, which provides a significant tool for the design of molten salt reactors.

Ceramic matrix composites for corrosion-resistant next-generation nuclear reactor systems: A conceptual review of enhancements in durability against molten salt attack

Ceramic matrix composites (CMCs) are emerging as a key material class for enhancing corrosion resistance in next-generation nuclear reactor systems, particularly in high-temperature molten salt environments. These environments, critical for advanced nuclear reactors such as molten salt reactors (MSRs), present severe challenges, including aggressive chemical attacks that degrade traditional structural materials over time. This conceptual review explores the development and application of CMCs to improve the durability and corrosion resistance of nuclear reactors exposed to molten salt attacks. CMCs, which consist of ceramic fibers embedded in a ceramic matrix, offer significant advantages, such as high thermal stability, mechanical strength, and improved corrosion resistance compared to conventional materials. This review examines how CMCs can be tailored to withstand harsh operational conditions, with a focus on the selection of ceramic phases, fiber-matrix interactions, and innovative fabrication techniques that enhance their protective capabilities. Key challenges addressed include the optimization of composite design to resist molten salt corrosion, the effects of temperature on the material properties, and the long-term stability of CMCs under extreme conditions. Advances in surface treatments, coatings, and the development of hybrid CMC systems are also discussed, highlighting their potential to further enhance durability. The review outlines the use of advanced characterization techniques, such as high-temperature corrosion testing and in situ microscopy, to evaluate CMC performance in molten salt environments. Additionally, it identifies knowledge gaps in current research, emphasizing the need for long-term studies on CMC behavior under realistic reactor conditions. This review concludes by proposing future research directions and technological advancements required to integrate CMCs into next-generation nuclear reactor designs, aiming to improve system reliability and operational safety.

Advanced corrosion-resistant materials for enhanced nuclear fuel performance: A conceptual review of innovations in fuel cladding against molten salt degradation

The increasing demand for efficient and sustainable nuclear power has led to the development of advanced corrosion-resistant materials that can significantly enhance nuclear fuel performance. This conceptual review focuses on the innovations in fuel cladding materials designed to resist degradation in molten salt environments, which are crucial for advanced nuclear reactors like molten salt reactors (MSRs). Fuel cladding serves as a critical barrier between the nuclear fuel and the reactor environment, and its ability to withstand extreme temperatures and corrosive conditions is essential for safe and efficient reactor operation. Recent advancements in materials science have introduced novel alloys and coatings that demonstrate superior corrosion resistance in molten salts, which are used as both coolants and fuel solvents in MSRs. These innovations include high-temperature nickel-based alloys, refractory metals, and ceramic coatings, which are engineered to reduce the effects of molten salt corrosion, such as oxidation, pitting, and embrittlement. By enhancing the durability of fuel cladding, these materials contribute to improved fuel performance, longer reactor lifespans, and increased safety. This review explores key developments in corrosion-resistant materials, emphasizing the mechanisms by which these materials mitigate molten salt degradation. Additionally, it highlights the challenges associated with material selection, fabrication, and long-term performance in the highly corrosive environments of advanced nuclear reactors. Ongoing research into these materials offers promising avenues for the future of nuclear energy, particularly in addressing the limitations of current fuel cladding technologies. In conclusion, the use of advanced corrosion-resistant materials represents a significant step toward enhancing the performance and safety of nuclear fuel, ensuring the viability of MSRs and other advanced reactor designs. Continued innovation in this field is essential for the future of nuclear power.

Enhanced photocatalytic hydrogen production via water splitting using cobalt-based organic nanofibers under visible light irradiation.

This study focuses on the development of cobalt-based organic nanofibers as efficient photocatalysts for hydrogen production via water splitting under visible light irradiation. The depletion of fossil fuels necessitates the exploration of alternative energy sources, with hydrogen emerging as a promising candidate due to its clean and renewable nature. While conventional photocatalysts have shown potential, their limited activity under visible light and fast electron-hole recombination hinder their efficiency. In this work, cobalt acetate/poly(vinyl alcohol) (CoAc/PVA) nanofibers were electrospun and treated in a novel reactor design under water gas atmosphere at 160 °C to produce continuous, smooth, and stable nanobelts. The nanofibers displayed a band gap energy of 2.29 eV, indicating strong absorption in the visible light range. Detailed characterization using FTIR, XPS, SEM, and TGA confirmed the formation of organic-inorganic hybrid nanofibers with uniform cobalt distribution. Hydrogen production experiments showed that the proposed nanofibers significantly outperformed Co3O4 nanofibers, with an optimal hydrogen generation rate of 3.266 mmol gcat -1 s-1 at 70 vol% methanol. Furthermore, the treated nanofibers demonstrated good stability over multiple cycles, maintaining a constant hydrogen production rate after the third run. The study highlights the advantages of cobalt-based organic nanofibers in overcoming the limitations of traditional photocatalysts, providing a novel route for sustainable hydrogen production.

Comprehensive Screening of Plasma-Facing Materials for Nuclear Fusion

Plasma-facing materials (PFMs) represent one of the most significant challenges for the design of future nuclear fusion reactors. Inside the reactor, the divertor will experience the harshest material environment: intense bombardment of neutrons and plasma particles coupled with extremely large and intermittent heat fluxes. The material designated to cover this role in ITER is tungsten. While no other materials have shown the potential to match the properties of tungsten, many drawbacks associated with its application remain, including cracking and erosion induced by a low recrystallization temperature combined with a high ductile-brittle transition temperature and neutron-initiated embrittlement; surface morphology changes (helium bubbles and fuzz layer) due to plasma-tungsten interaction with subsequent risk of spontaneous material melting and delamination; and low oxidation resistance in the case of air contamination. Exploring alternatives to tungsten requires the design of a multivariable optimization problem. This work aims to produce a structured and comprehensive material screening of PFM candidates based on known inorganic materials. The method applied in this study to identify the most promising PFM candidates combines peer-reviewed data present in the PAULING FILE database and first-principles density-function theory calculations focusing on two key PFM defects—namely, the sputtering of surface atoms and the incorporation of interstitial hydrogen, respectively characterized by the surface binding energy and the interstitial formation energy. The crystal structures and their related properties, extracted from the PAULING FILE, are ranked according to the heat-balance equation of a PFM subjected to the heat loads in the divertor region of an ITER-like tokamak. The materials satisfying the requirements are critically compared with the state-of-the-art in plasma-facing materials research and in studies of refractory materials exposed to high temperatures, plasma, and neutron bombardment. This comparison assesses their thermo-mechanical properties under such conditions, identifying a subset of promising materials for first-principles electronic structure calculations. Most previously known and extensively studied PFMs, such as tungsten, molybdenum, and carbon-based materials, are captured by this screening process, confirming its reliability. Additionally, less familiar refractory materials suggest performance that calls for further investigations. Published by the American Physical Society 2024

Co‐Pyrolytic Recycling of Bakelite and Polymethyl Methacrylate: Kinetic, Synergistic, and Thermodynamic Analysis

AbstractBakelite, a thermosetting plastic, has limited feasibility for thermal recycling processes such as pyrolysis, unlike thermoplastics, due to its inherent tendency to get charred upon heating and difficulty in being converted into valuable fuel and chemical compounds. In this study, the co‐pyrolysis of bakelite and poly methyl methacrylate is explored to improve the thermal degradation and thus recycling feasibility of bakelite by pyrolysis. The kinetics and thermodynamics of the co‐pyrolysis of blended samples are analyzed using different kinetics models. The thermal degradation experiments of the sample are conducted from ambient to 1000 °C at five various heating rates of 5, 10, 20, 30, and 50 °C/min in an inert N2 gas environment. The results showed that adding poly methyl methacrylate to bakelite changes the pyrolytic degradation temperature and weight loss trend. The kinetic analysis reveals that the thermal degradation at 220–345 °C follows an F2.5 order‐based model with an average activation energy of 181 kJ/mol, while the degradation at 345–475 °C follows an F2 order‐based model with an average activation energy of 318 kJ/mol. The enthalpy changes and free energy change associated with thermal degradation exhibit a positive trend while that of entropy change shows a negative trend. With blending the free energy change and entropy change decreased while enthalpy change increased. During batch pyrolysis at 450 °C, the PMMA‐Bakelite blend generates oil (49.17 %), wax (12.36 %), residue (15.36 %), and gas (23.11 %). According to FTIR and GC‐MS analyses, the pyrolytic oil produced by the co‐pyrolysis of the blended sample at 450 °C comprises 32.23 % saturated hydrocarbons (C9–40), 20.97 % unsaturated hydrocarbons (C6–24), and 46.80 % oxygenated material (C5–19). These findings can assist in the optimization of pyrolysis reactor design for the recycling of thermosetting plastics.

Methanogenesis—General Principles and Application in Wastewater Remediation

The first discovery of methanogens led to the formation of a new domain of life known as Archaea. The Archaea domain exhibits properties vastly different from previously known Bacteria and Eucarya domains. However, for a certain multi-step process, a syntrophic relationship between organisms from all domains is needed. This process is called methanogenesis and is defined as the biological production of methane. Different methanogenic pathways prevail depending on substrate availability and the employed order of methanogenic Archaea. Most methanogens reduce carbon dioxide to methane with hydrogen through a hydrogenotrophic pathway. For hydrogen activation, a group of enzymes called hydrogenases is required. Regardless of the methanogenic pathway, electrons are carried between microorganisms by hydrogen. Naturally occurring processes, such as methanogenesis, can be engineered for industrial use. With the growth and emergence of new industries, the amount of produced industrial waste is an ever-growing environmental problem. For successful wastewater remediation, a syntrophic correlation between various microorganisms is needed. The composition of microorganisms depends on wastewater type, organic loading rates, anaerobic reactor design, pH, and temperature. The last step of anaerobic wastewater treatment is production of biomethane by methanogenesis, which is thought to be a cost-effective means of energy production for this renewable biogas.

Application of microencapsulated phase change materials for controlling exothermic reactions

Abstract Thermal runaway is a frequent source of process safety issues, and the uncontrolled release of chemical energy puts reactors at risk. The design of the exothermic reactor faces challenges due to the selective sensitivity of the product to high temperatures and the need to increase the lifetime of the catalyst, optimize the product distribution, and improve the thermodynamic properties. Phase change material (PCM) encapsulation is recommended to reduce leakage, phase separation, and volume change problems. This work introduces encapsulated PCMs to improve reactor temperature control and minimize thermal runaway in exothermic processes. The warning temperature value setting effectively inhibits fugitive exothermic reactions and enhances heat transfer. When a sufficient quantity of encapsulated PCMs is input, the response speed will automatically accelerate. Spontaneous acceleration of the reaction rate due to thermal runaway of the reaction may be completely avoided by adding a sufficient amount of encapsulated PCM. Microencapsulation is used to control volume changes and inhibit thermal reactions. Preventive strategies include cooling, depressurization, safety release, emergency resources, and reaction containment. Encapsulated PCMs improve mechanical and thermal properties, surface-to-volume ratio, heat transfer surface, thermal capacity, and efficiency.

Thermal Fluid Modeling Approaches in SAM for High Temperature Gas-Cooled Reactor Applications

This paper provides an overview of the unique modeling and simulation challenges and needs in the system and safety analysis of two common types of High Temperature Gas-cooled Reactor (HTGR) designs. The challenges are associated with the complex core geometry configurations and the change of the dominant heat removal mechanisms between normal operating conditions and decay heat removal transients. This requires that simulation tools utilize models with reasonable length scales and capture both the localized heat transfer and the core-scale heat transfer at the same time. To meet such analysis needs, different methodologies were developed. This includes adopting existing methods and further developing/improving them, as well as proposing innovative methods that leverage advanced computational frameworks such as the Multiphysics Object Oriented Simulation Environment (MOOSE).

Non-thermal plasma decontamination of microbes: a state of the art.

Microbial decontamination is a critical concern in various sectors, from healthcare to food processing. Traditional decontamination methods, while effective to a degree, present limitations in terms of environmental impact, efficiency, and potential harm to the target material. This review investigates the emerging realm of non-thermal plasma (NTP) as a promising alternative for microbial decontamination, emphasizing its mechanisms, reactor designs and applications. The mechanism decomposed into physical, chemical and biological effects of plasma, are elaborated upon to provide a foundational understanding of the intrinsic principles of plasma decontamination. Except for the generation type of NTP, reactors and other parameters by which NTP achieves microbial decontamination, emphasizing the design considerations and parameters that influence its efficacy. Moreover, the latest applications of NTP in decontaminating air, water, and surfaces, supported by the latest research findings in each domain are explored. Additionally, the perspectives on the future research tendencies of NTP decontamination and disinfection are highlighted with potential avenues for exploration and innovation. Through this comprehensive review, the aim is to underscore the potential of NTP, particularly DBD plasma, as a versatile, efficient, and environmentally friendly method for microbial decontamination.

Novel Venturi injector reactor design and application in ammonia nitrogen wastewater treatment

The Venturi injector reactor has a robust and durable design and is highly efficient and reliable. The flow field control in the Venturi reactor is an effective way to enhance gas−liquid mass transfer. In this study, a novel Venturi injector reactor with an expandable self-priming air inlet and a second water inlet in the diffusion section was designed by combining particle image velocimetry (PIV) experiments with a computational fluid dynamics simulation. This novel design increased the gas holdup, generated smaller and more uniform bubbles, and enhanced mass transfer. Furthermore, we applied the novel Venturi device to the biological degradation of ammonia nitrogen wastewater. The total gas holdup in the novel Venturi was higher than in the conventional Venturi injector reactor by 0.0056 on average. The minimum bubble diameter was approximately 0.71 mm. Moreover, the ammonia nitrogen removal efficiency of the novel Venturi equipment with the second inlet was 2 and 1.1 times higher than that of conventional aeration and conventional Venturi device, respectively. This study provides a theoretical basis and practical significance for improving the performance and efficient degradation of the ammonia nitrogen concentration in Venturi injector reactors.

LES and RANS Modeling of an 84-Pin Hexagonal Rod Bundle with Spacer Grid and Experimental Validation

As part of an ongoing integrated research project (IRP), detailed investigations of the flow characteristics of an 84-pin hexagonal rod bundle representing a potential modular gas-cooled fast reactor design have been performed. The rod bundle features a pitch-to-diameter ratio of 1.5 and a large central guide tube, along with simple spacer grids and an outer enclosure. The primary focus of the current work is modeling and simulation of this geometry using multiple computational techniques. These include high-fidelity large eddy simulation (LES) and advanced Reynolds-averaged Navier-Stokes (RANS) approaches. The flow predictions are validated at a Reynolds number of 12 000 using matched index of refraction particle image velocimetry experimental data that were also generated by Texas A&M University as part of the IRP. The comparison data include velocity magnitude and turbulent kinetic energy (TKE) at different lateral locations and at multiple distances downstream of the spacer grid. Many characteristics of the experimental flow are replicated in the LES and RANS runs, and a general agreement between simulation and experiment is shown. Except for the immediate vicinity of the grid, LES is able to capture the velocity magnitude within a 10% error and the TKE to within the experimental uncertainty. The LES shows notably better agreement with the experimental data than RANS, particularly regarding the TKE decay behavior downstream of the grid. Both methods show significant departures from the experiment in their predictions close to the central guide tube. The experimental and high-fidelity data will be used to inform closures for novel multiscale methodologies. The long-term goal of the work is to use the high-fidelity data to yield improved multiscale thermal analysis techniques for solving fuel performance problems of direct relevance to industry.

Particle resolved DNS and URANS simulations of turbulent heat transfer in packed structures

An accurate prediction of turbulent heat transfer in packed-bed reactors is fundamental for the design and performance of such reactors. Various classes of Reynolds-Averaged Navier-Stokes models are available in the literature for predicting turbulent heat transfer via closing the Reynolds stress and Turbulent Heat Flux terms. In this work, we investigate the accuracy of representative unsteady RANS turbulence models in modeling heat transfer characteristics in packed-bed reactors. For this accuracy assessment, the performance of the examined unsteady RANS models is compared with particle-resolved Direct Numerical Simulations including heat transfer. The simulations are conducted in a three dimensional periodic domain consisting of randomly arranged cylindrical particles for Reynolds number Rep=1000. The extracted mean quantities (e.g. velocity and temperature), turbulent heat flux components and turbulent kinetic energy are used as a reference for the RANS models' accuracy assessment. The SST k−ω and Spalart-Allmaras models performed well in predicting mean fields. However, all models tended to mispredicted the turbulent quantities including the turbulent viscosity and heat flux vector. The thermal field calculations rely on the turbulent viscosity based Simple Gradient Diffusion Hypothesis for modeling turbulent heat flux, which introduce challenges in capturing the coupling between thermal and turbulent fields.

Numerical study of a copper oxide-based thermochemical heat storage system

A multi-physics model is developed to investigate the performance of high-temperature thermochemical heat storage using the redox looping cycle of CuO/Cu2O. The model involved flow in free and porous domains, heat transfer in the CuO pellet-packed porous domain (i.e., convection between fluid and pellets, conduction and radiation among pellets), and the endothermic/exothermic reaction. The reaction rate was estimated using a non-parametric kinetic approach which depends on temperature and extent of the reaction. The model was validated within <10 % error margin by the experimental measurements of the temperature inside the reactor and the molar fraction of O2 at the reactor outlet. The validated model is used to determine the temperature variation and reaction evolution in the pellet-packed domain. In the end, parameter studies were implemented, including inlet mass flow rate, reduction temperature, and oxidation temperature. It was found that a large inlet mass flow brings about a high output temperature, and the reaction runs faster with the larger inlet mass flow. Similarly, increasing the furnace temperature during the reduction process (reduction temperature) also increases the output temperature and accelerates the reaction. In contrast, increasing the furnace temperature during the oxidation process (oxidation temperature) only slightly affected the reaction in the present case. This model could provide useful insights into reactor design, scale-up, and operating conditions to improve the energy storage system performance.

A First-Principles Study of the Structural and Thermo-Mechanical Properties of Tungsten-Based Plasma-Facing Materials

Tungsten (W) and tungsten alloys are being considered as leading candidates for structural and functional materials in future fusion energy devices. The most attractive properties of tungsten for the design of magnetic and inertial fusion energy reactors are its high melting point, high thermal conductivity, low sputtering yield, and low long-term disposal radioactive footprint. Despite these relevant features, there is a lack of understanding of how the structural and mechanical properties of W-based alloys are affected by the temperature in fusion power plants. In this work, we present a study on the thermo-mechanical properties of five W-based plasma-facing materials. First-principles density functional theory (DFT) calculations are combined with the quasi-harmonic approximation (QHA) theory to investigate the electronic, structural, mechanical, and thermal properties of these W-based alloys as a function of temperature. The coefficient of thermal expansion, temperature-dependent elastic constants, and several elastic parameters, including bulk and Young’s modulus, are calculated. Our work advances the understanding of the structural and thermo-mechanical behavior of W-based materials, thus providing insights into the design and selection of candidate plasma-facing materials in fusion energy devices.

Continuous Biological Ex Situ Methanation of CO2 and H2 in a Novel Inverse Membrane Reactor (IMR)

A promising approach for carbon dioxide (CO2) valorization and storing excess electricity is the biological methanation of hydrogen and carbon dioxide to methane. The primary challenge here is to supply sufficient quantities of dissolved hydrogen. The newly developed Inverse Membrane Reactor (IMR) allows for the spatial separation of the required reactant gases, hydrogen (H2) and carbon dioxide (CO2), and the degassing area for methane (CH4) output through commercially available ultrafiltration membranes, enabling a reactor design as a closed circuit for continuous methane production. In addition, the Inverse Membrane Reactor (IMR) facilitates the utilization of hydraulic pressure to enhance hydrogen (H2) input. One of the process’s advantages is the potential to utilize both carbon dioxide (CO2) from conventional biogas and CO2-rich industrial waste gas streams. An outstanding result from investigating the IMR revealed that, employing the membrane gassing concept, methane concentrations of over 90 vol.% could be consistently achieved through flexible gas input over a one-year test series. Following startup, only three supplemental nutrient additions were required in addition to hydrogen (H2) and carbon dioxide (CO2), which served as energy and carbon sources, respectively. The maximum achieved methane formation rate specific to membrane area was 87.7 LN of methane per m2 of membrane area per day at a product gas composition of 94 vol.% methane, 2 vol.% H2, and 4 vol.% CO2.