Recent Progress in Intensifying Synthesis of Acrylic Microspheres for Catalysis

Over the past decades, there has been an escalating rise in the need for chemicals and catalytic materials to keep up with global demands. Addressing those issues by conventional methods often becomes inefficient, with myriad operational risks. Process intensification methods through procedural and equipment‐based modifications have been considered greener, have higher heat and mass transfer rates, and operate with lower costs. In this review, research using ultrasonic reactors and microreactors, along with developments through an integrated external energy source, for synthesizing acrylic microspheres is covered extensively. Acrylic microspheres have garnered much interest for their biocompatibility, affinity toward functionalization, and wide range of applications. Core–shell, composite, functional‐group modified, and porous acrylic microspheres are used for enzyme immobilization and as catalyst carriers. The use of acrylic support has provided huge improvements in catalytic activity, reusability, recyclability, and overall stability. Finally, various other process intensification methods and alternate support materials are covered to help enhance future developments in the field of catalysis. This review covers process intensification techniques, including ultrasonic reactors and microreactors, to synthesize acrylic microspheres for various applications in catalysis. The advantages of using acrylic microspheres include biocompatibility, improving catalytic activity, reusability, and comparing stability. The review also touches upon alternative support materials and process intensification methods to enhance future developments in the field of catalysis.