The growing demand for sustainable and efficient chemical manufacturing has driven the exploration of advanced process intensification strategies, including ultrasound-assisted reactions, non-thermal plasma technologies, and hybrid catalytic systems. Ultrasound and plasma-based methodologies have demonstrated remarkable potential in reducing reaction times, enhancing selectivity, and lowering energy consumption in diverse chemical transformations. This review investigates the theoretical underpinnings, mechanistic pathways, and industrial implications of ultrasound- and plasma-assisted chemical processes, emphasizing their integration into green and continuous manufacturing paradigms. The study synthesizes experimental findings across multiple reaction types, including Suzuki–Miyaura cross-coupling, enzymatic transesterifications, bromination reactions, and ammonia synthesis. Special attention is devoted to process optimization approaches, including uniform design for ultrasound-assisted syntheses and reactor design for plasma-enhanced reforming technologies. The work further examines the synergistic interactions between ultrasound and catalysts, as well as the non-thermal plasma effects on molecular activation and pollutant abatement. Challenges such as scale-up limitations, energy efficiency, and mechanistic uncertainties are critically analyzed, highlighting future directions for the development of industrially viable, environmentally benign chemical processes. This comprehensive exploration underscores the potential of integrating ultrasound and plasma technologies into the fourth industrial revolution, facilitating sustainable production of pharmaceuticals, platform chemicals, and energy carriers while minimizing environmental impact.

Ultrasound-assisted synthesis, non-thermal plasma, process intensification

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