Process Intensification in Ammonia Synthesis Using Novel Coassembled Supported Microporous Catalysts Promoted by Nonthermal Plasma

Dielectric barrier discharge plasma catalysis as an alternative approach for the synthesis of ammonia: a review

Numerous researchers have attempted to provide mild reactions and environmentally-friendly methods for NH3 synthesis. Research on non-thermal plasma-assisted ammonia synthesis, notably the atmospheric-pressure nonthermal plasma synthesis of ammonia over catalysts, has recently gained attention in the academic literature. Since non-thermal plasma technology circumvents the existing crises and harsh conditions of the Haber-Bosch process, it can be considered as a promising alternative for clean synthesis of ammonia. Non-thermal dielectric barrier discharge (DBD) plasma has been extensively employed in the synthesis of ammonia due to its particular advantages such as the simple construction of DBD reactors, atmospheric operation at ambient temperature, and low cost. The combination of this plasma and catalytic materials can remarkably affect ammonia formation, energy efficiency, and the generation of by-products. The present article reviews plasma-catalysis ammonia synthesis in a dielectric barrier discharge reactor and the parameters affecting this synthesis system. The proposed mechanisms of ammonia production by this plasma catalysis system are discussed as well.

Plasma-microbubble treatment and sustainable agriculture application of diclofenac-contaminated wastewater

The demand for efficient wastewater treatment is becoming increasingly urgent due to the rising threat of pharmaceutical residues in water. As a sustainable advanced oxidation process, cold plasma technology is a promising approach for water treatment. However, the adoption of the technology encounters several challenges, including the low treatment efficiency and the potentially unknown environmental impact. Here, microbubble generation was integrated with cold plasma system to enhance treatment of wastewater contaminated with diclofenac (DCF). The degradation efficiency depended on the discharge voltage, gas flow, initial concentration, and pH value. The best degradation efficiency was 90.9% after 45 min plasma-bubble treatment under the optimum process parameters. The hybrid plasma-bubble system exhibited strongly synergistic performance heralded by up to seven-times higher DCF removal rates than the two systems operated separately. The plasma-bubble treatment remains effective even after addition of SO₄^2-, Cl^-, CO₃^2-, HCO₃^-, and humic acid (HA) as interfering background substances. The contributions of •O₂^-, O₃, •OH, and H₂O₂ reactive species to the DCF degradation process were specified. The synergistic mechanisms for DCF degradation were deduced through the analysis of the degradation intermediates. Further, the plasma-bubble treated water was proven safe and effective to stimulate seed germination and plant growth for sustainable agriculture applications. Overall, these findings provide new insights and a feasible approach with a highly synergistic removal effect for the plasma-enhanced microbubble wastewater treatment, without generating secondary contaminants.

Incorporation of a Metal Catalyst for the Ammonia Synthesis in a Ferroelectric Packed-Bed Plasma Reactor: Does It Really Matter?

Plasma-catalysis has been proposed as a potential alternative for the synthesis of ammonia. Studies in this area focus on the reaction mechanisms and the apparent synergy existing between processes occurring in the plasma phase and on the surface of the catalytic material. In the present study, we approach this problem using a parallel-plate packed-bed reactor with the gap between the electrodes filled with pellets of lead zirconate titanate (PZT), with this ferroelectric material modified with a coating layer of alumina (i.e., Al₂O₃/PZT) and the same alumina layer incorporating ruthenium nanoparticles (i.e., Ru-Al₂O₃/PZT). At ambient temperature, the electrical behavior of the ferroelectric packed-bed reactor differed for these three types of barriers, with the plasma current reaching a maximum when using Ru-Al₂O₃/PZT pellets. A systematic analysis of the reaction yield and energy efficiency for the ammonia synthesis reaction, at ambient temperature and at 190 °C and various electrical operating conditions, has demonstrated that the yield and the energy efficiency for the ammonia synthesis do not significantly improve when including ruthenium particles, even at temperatures at which an incipient catalytic activity could be inferred. Besides disregarding a net plasma-catalysis effect, reaction results highlight the positive role of the ferroelectric PZT as moderator of the discharge, that of Ru particles as plasma hot points, and that of the Al₂O₃ coating as a plasma cooling dielectric layer.

Developing a microwave-driven reactor for ammonia synthesis: insights into the unique challenges of microwave catalysis

Reactor requirements grow with scale as new phenomena can become more and more relevant, creating trends that we've observed in the development of microwave-driven ammonia synthesis – a technique with a unique combination of high output and energy efficiency.

Supported copper on a diamide-diacid-bridged PMO: an efficient hybrid catalyst for the cascade oxidation of benzyl alcohols/Knoevenagel condensation

In this study, a novel periodic mesoporous organosilica (PMO) containing diamide-diacid bridges was conveniently prepared using ethylenediaminetetraacetic dianhydride to support Cu(ii) species and affording supramolecular Cu@EDTAD-PMO nanoparticles efficiently. Fourier transform infrared (FT-IR) and energy dispersive X-ray (EDX) spectroscopy, thermogravimetric analysis (TGA), X-ray diffraction (XRD), field emission scanning electron microscopy (FESEM), Brunauer-Emmett-Teller (BET) analysis, and high-resolution transmission electron microscopy (HRTEM) results confirmed the successful synthesis of Cu@EDTAD-PMO. The stabilized Cu(ii) nanoparticles inside the mesochannels of the new PMO provided appropriate sites for selective oxidation of different benzyl alcohol derivatives to their corresponding benzaldehydes and subsequent Knoevenagel condensation with malononitrile. Therefore, Cu@EDTAD-PMO can be considered as a multifunctional heterogeneous catalyst, which is prepared easily through a green procedure and demonstrates appropriate stability with almost no leaching of the Cu(ii) nanoparticles into the reaction medium, and easy recovery through simple filtration. The recycled Cu@EDTAD-PMO was reused up to five times without significant loss of its catalytic activity. The stability, recoverability, and reusability of the designed heterogeneous catalyst were also studied under various reaction conditions.

Emerging Materials and Methods toward Ammonia-Based Energy Storage and Conversion

Efficient storage and conversion of renewable energies is of critical importance to the sustainable growth of human society. With its distinguishing features of high hydrogen content, high energy density, facile storage/transportation, and zero-carbon emission, ammonia has been recently considered as a promising energy carrier for long-term and large-scale energy storage. Under this scenario, the synthesis, storage, and utilization of ammonia are key components for the implementation of ammonia-mediated energy system. Being different from fossil fuels, renewable energies normally have intermittent and variable nature, and thus pose demands on the improvement of existing technologies and simultaneously the development of alternative methods and materials for ammonia synthesis and storage. The energy release from ammonia in an efficient manner, on the other hand, is vital to achieve a sustainable energy supply and complete the nitrogen circle. Herein, recent advances in the thermal-, electro-, plasma-, and photocatalytic ammonia synthesis, ammonia storage or separation, ammonia thermal/electrochemical decomposition and conversion are summarized with the emphasis on the latest developments of new methods and materials (catalysts, electrodes, and sorbents) for these processes. The challenges and potential solutions are discussed.

Al2O3-Supported Transition Metals for Plasma-Catalytic NH3 Synthesis in a DBD Plasma: Metal Activity and Insights into Mechanisms

N2 fixation into NH3 is one of the main processes in the chemical industry. Plasma catalysis is among the environmentally friendly alternatives to the industrial energy-intensive Haber-Bosch process. However, many questions remain open, such as the applicability of the conventional catalytic knowledge to plasma. In this work, we studied the performance of Al2O3-supported Fe, Ru, Co and Cu catalysts in plasma-catalytic NH3 synthesis in a DBD reactor. We investigated the effects of different active metals, and different ratios of the feed gas components, on the concentration and production rate of NH3, and the energy consumption of the plasma system. The results show that the trend of the metal activity (common for thermal catalysis) does not appear in the case of plasma catalysis: here, all metals exhibited similar performance. These findings are in good agreement with our recently published microkinetic model. This highlights the virtual independence of NH3 production on the metal catalyst material, thus validating the model and indicating the potential contribution of radical adsorption and Eley-Rideal reactions to the plasma-catalytic mechanism of NH3 synthesis.

Review of low-temperature plasma nitrogen fixation technology

Nitrogen fixation is essential for all forms of life, as nitrogen is required to biosynthesize fundamental building blocks of creatures, plants, and other life forms. As the main method of artificial nitrogen fixation, Haber–Bosch process (ammonia synthesis) has been supporting the agriculture and chemical industries since the 1910s. However, the disadvantages inherent to the Haber–Bosch process, such as high energy consumption and high emissions, cannot be ignored. Therefore, developing a green nitrogen fixation process has always been a research hotspot. Among the various technologies, plasma-assisted nitrogen fixation technology is very promising due to its small scale, mild reaction conditions, and flexible parameters. In the present work, the basic principles of plasma nitrogen fixation technology and its associated research progress are reviewed. The production efficiency of various plasmas is summarized and compared. Eventually, the prospect of nitrogen fixation using low-temperature plasma in the future was proposed.

A Comprehensive Review on the Recent Development of Ammonia as a Renewable Energy Carrier

Global energy sources are being transformed from hydrocarbon-based energy sources to renewable and carbon-free energy sources such as wind, solar and hydrogen. The biggest challenge with hydrogen as a renewable energy carrier is the storage and delivery system’s complexity. Therefore, other media such as ammonia for indirect storage are now being considered. Research has shown that at reasonable pressures, ammonia is easily contained as a liquid. In this form, energy density is approximately half of that of gasoline and ten times more than batteries. Ammonia can provide effective storage of renewable energy through its existing storage and distribution network. In this article, we aimed to analyse the previous studies and the current research on the preparation of ammonia as a next-generation renewable energy carrier. The study focuses on technical advances emerging in ammonia synthesis technologies, such as photocatalysis, electrocatalysis and plasmacatalysis. Ammonia is now also strongly regarded as fuel in the transport, industrial and power sectors and is relatively more versatile in reducing CO2 emissions. Therefore, the utilisation of ammonia as a renewable energy carrier plays a significant role in reducing GHG emissions. Finally, the simplicity of ammonia processing, transport and use makes it an appealing choice for the link between the development of renewable energy and demand.

Plasma-Induced Catalytic Conversion of Nitrogen and Hydrogen to Ammonia over Zeolitic Imidazolate Frameworks ZIF-8 and ZIF-67

Microporous crystals have emerged as highly appealing catalytic materials for the plasma catalytic synthesis of ammonia. Herein, we demonstrate that zeolitic imidazolate frameworks (ZIFs) can be employed as efficient catalysts for the cold plasma ammonia synthesis using an atmospheric dielectric barrier discharge reactor. We studied two prototypical ZIFs denoted as ZIF-8 and ZIF-67, with a uniform window pore aperture of 3.4 Å. The resultant ZIFs displayed ammonia synthesis rates as high as 42.16 μmol NH₃/min gcat. ZIF-8 displayed remarkable stability upon recycling. The dipole-dipole interactions between the polar ammonia molecules and the polar walls of the studied ZIFs led to relatively low ammonia uptakes, low storage capacity, and high observed ammonia synthesis rates. Both ZIFs outperform other microporous crystals including zeolites and conventional oxides in terms of ammonia production. Furthermore, we demonstrate that the addition of argon to the reactor chamber can be an effective strategy to improve the plasma environment. Specifically, the presence of argon helped to improve the plasma uniformity, making the reaction system more energy efficient by operating at a low specific energy input range allowing abundant formation of nitrogen vibrational species.

Feasibility Study of Plasma-Catalytic Ammonia Synthesis for Energy Storage Applications

Plasma catalysis has recently gained traction as an alternative to ammonia synthesis. The current research is mostly fundamental and little attention has been given to the technical and economic feasibility of plasma-catalytic ammonia synthesis. In this study, the feasibility of plasma-catalytic ammonia is assessed for small-scale ammonia synthesis. A brief summary of the state of the art of plasma catalysis is provided as well as a targets and potential avenues for improvement in the conversion to ammonia, ammonia separation and a higher energy efficiency. A best-case scenario is provided for plasma-catalytic ammonia synthesis and this is compared to the Haber-Bosch ammonia process operated with a synthesis loop. An ammonia outlet concentration of at least 1.0 mol. % is required to limit the recycle size and to allow for efficient product separation. From the analysis, it follows that plasma-catalytic ammonia synthesis cannot compete with the conventional process even in the best-case scenario. Plasma catalysis potentially has a fast response to intermittent renewable electricity, although low pressure absorbent-enhanced Haber-Bosch processes are also expected to have fast responses to load variations. Low-temperature thermochemical ammonia synthesis is expected to be a more feasible alternative to intermittent decentralized ammonia synthesis than plasma-catalytic ammonia synthesis due to its superior energy efficiency.

A Review about the Recent Advances in Selected NonThermal Plasma Assisted Solid-Gas Phase Chemical Processes

Plasma science has attracted the interest of researchers in various disciplines since the 1990s. This continuously evolving field has spawned investigations into several applications, including industrial sterilization, pollution control, polymer science, food safety and biomedicine. nonthermal plasma (NTP) can promote the occurrence of chemical reactions in a lower operating temperature range, condition in which, in a conventional process, a catalyst is generally not active. The aim, when using NTP, is to selectively transfer electrical energy to the electrons, generating free radicals through collisions and promoting the desired chemical changes without spending energy in heating the system. Therefore, NTP can be used in various fields, such as NOx removal from exhaust gases, soot removal from diesel engine exhaust, volatile organic compound (VOC) decomposition, industrial applications, such as ammonia production or methanation reaction (Sabatier reaction). The combination of NTP technology with catalysts is a promising option to improve selectivity and efficiency in some chemical processes. In this review, recent advances in selected nonthermal plasma assisted solid-gas processes are introduced, and the attention was mainly focused on the use of the dielectric barrier discharge (DBD) reactors.

Unconventional Catalytic Approaches to Ammonia Synthesis

Ammonia is a critically important industrial chemical and is largely responsible for sustaining the growing global population. To provide ammonia to underdeveloped regions and/or regions far from industrial production hubs, modular systems have been targeted and often involve unconventional production methodologies. These novel approaches for ammonia production can tap renewable resources at smaller scales located at the point of use, while decreasing the CO2 footprint. Plasma-assisted catalysis and electrochemical ammonia synthesis have promise owing to their atmospheric pressure and low-temperature operation conditions and the ability to construct units at scales desired for modularization. Fundamental and applied studies are underway to assess these processes, although many unknowns remain. In this review, we discuss recent developments and opportunities for unconventional ammonia synthesis with a focus on plasma-stimulated systems.

Plasma Generating—Chemical Looping Catalyst Synthesis by Microwave Plasma Shock for Nitrogen Fixation from Air and Hydrogen Production from Water for Agriculture and Energy Technologies in Global Warming Prevention

Simultaneous generation of plasma by microwave irradiation of perovskite or the spinel type of silica supported porous catalyst oxides and their reduction by nitrogen in the presence of oxygen is demonstrated. As a result of plasma generation in air, NOx generation is accompanied by the development of highly heterogeneous regions in terms of chemical and morphological variations within the catalyst. Regions of almost completely reduced catalyst are dispersed within the catalyst oxide, across micron-scale domains. The quantification of the catalyst heterogeneity and evaluation of catalyst structure are studied using Scanning Electron Microscopy, Energy Dispersive X-ray Spectroscopy and XRD. Plasma generating supported spinel catalysts are synthesized using the technique developed by the author (Catalysts; 2016; 6; 80) and BaTiO3 is used to exemplify perovskites. Silica supported catalyst systems are represented as M/Si = X (single catalysts) or as M(1)/M(2)/Si = X/Y/Z (binary catalysts) where M; M(1) M(2) = Cr; Mn; Fe; Co; Cu and X, Y, Z are the molar ratio of the catalysts and SiO2 support. Composite porous catalysts are synthesized using a mixture of Co and BaTiO3. In all the catalysts, structural heterogeneity manifests itself through defects, phase separation and increased porosity resulting in the creation of the high activity sites. The chemical heterogeneity results in reduced and oxidized domains and in very large changes in catalyst/support ratio. High electrical potential activity within BaTiO3 particles is observed through the formation of electrical treeing. Plasma generation starts as soon as the supported catalyst is synthesized. Two conditions for plasma generation are observed: Metal/Silica molar ratio should be > 1/2 and the resulting oxide should be spinel type; represented as MaOb (a = 3; b = 4 for single catalyst). Composite catalysts are represented as {M/Si = X}/BaTiO3 and obtained from the catalyst/silica precursor fluid with BaTiO3 particles which undergo fragmentation during microwave irradiation. Further irradiation causes plasma generation, NOx formation and lattice oxygen depletion. Partially reduced spinels are represented as MaOb–c. These reactions occur through a chemical looping process in micron-scale domains on the porous catalyst surface. Therefore; it is possible to scale-up this process to obtain NOx from MaOb for nitric acid production and H2 generation from MaOb–c by catalyst re-oxidized by water. Re-oxidation by CO2 delivers CO as fuel. These findings explain the mechanism of conversion of combustion gases (CO2 + N2) to CO and NOx via a chemical looping process. Mechanism of catalyst generation is proposed and the resulting structural inhomogeneity is characterized. Plasma generating catalysts also represent a new form of Radar Absorbing Material (RAM) for stealth and protection from radiation in which electromagnetic energy is dissipated by plasma generation and catalytic reactions. These catalytic RAMs can be expected to be more efficient in frequency independent microwave absorption.

Plasma-Enhanced Catalytic Synthesis of Ammonia over a Ni/Al2O3 Catalyst at Near-Room Temperature: Insights into the Importance of the Catalyst Surface on the Reaction Mechanism

A better fundamental understanding of the plasma-catalyst interaction and the reaction mechanism is vital for optimizing the design of catalysts for ammonia synthesis by plasma-catalysis. In this work, we report on a hybrid plasma-enhanced catalytic process for the synthesis of ammonia directly from N₂ and H₂ over transition metal catalysts (M/Al₂O₃, M = Fe, Ni, Cu) at near room temperature (∼35 °C) and atmospheric pressure. Reactions were conducted in a specially designed coaxial dielectric barrier discharge (DBD) plasma reactor using water as a ground electrode, which could cool and maintain the reaction at near-room temperature. The transparency of the water electrode enabled operando optical diagnostics (intensified charge-coupled device (ICCD) imaging and optical emission spectroscopy) of the full plasma discharge area to be conducted without altering the operation of the reactor, as is often needed when using coaxial reactors with opaque ground electrodes. Compared to plasma synthesis of NH₃ without a catalyst, plasma-catalysis significantly enhanced the NH₃ synthesis rate and energy efficiency. The effect of different transition metal catalysts on the physical properties of the discharge is negligible, which suggests that the catalytic effects provided by the chemistry of the catalyst surface are dominant over the physical effects of the catalysts in the plasma-catalytic synthesis of ammonia. The highest NH₃ synthesis rate of 471 μmol g^–1 h^–1 was achieved using Ni/Al₂O₃ as a catalyst with plasma, which is 100% higher than that obtained using plasma only. The presence of a transition metal (e.g., Ni) on the surface of Al₂O₃ provided a more uniform plasma discharge than Al₂O₃ or plasma only, and enhanced the mean electron energy. The mechanism of plasma-catalytic ammonia synthesis has been investigated through operando plasma diagnostics combined with comprehensive characterization of the catalysts using N₂ physisorption measurements, X-ray photoelectron spectroscopy (XPS), X-ray diffraction (XRD), high-resolution transmission electron microscopy (HRTEM), NH₃-temperature-programmed desorption (TPD), and N₂-TPD. Four forms of adsorbed NH_x (x = 0, 1, 2, and 3) species were detected on the surfaces of the spent catalysts using XPS. It was found that metal sites and weak acid sites could enhance the production of NH₃ via formation of NH₂ intermediates on the surface.

Plasma-assisted catalytic formation of ammonia in N2-H2 plasma on a tungsten surface

Plasma catalysis has drawn attention in the past few decades as a possible alternative to the Haber-Bosch process for ammonia production. In particular, radio frequency plasma assisted catalysis has the advantage of its adaptability to the industrial scale. However, in the past years, very few experimental studies have focused on the synthesis of ammonia from nitrogen/hydrogen radio frequency plasma. As a consequence, to date, there has been little agreement about the complex mechanisms underlying the radio frequency plasma-catalyst interactions. Gaining such an understanding is therefore essential for exploiting the potential of radio frequency plasma catalysis for ammonia production. In this study, we present results of ammonia formation from a nitrogen/hydrogen radio frequency plasma both without and with a tungsten catalyst for different initial nitrogen ratios. High yields of ammonia up to 32% at 25/75% of nitrogen/hydrogen were obtained using a combination of radio frequency low pressure plasma and a W surface as a catalyst. Furthermore, based on chemical analysis of the catalytic surface composition, a formation pathway of ammonia via the Eley-Rideal mechanism between adsorbed nitrogen and hydrogen from the gas phase is presented.

Recent Progress of Plasma-Assisted Nitrogen Fixation Research: A Review

Nitrogen is an essential element to plants, animals, human beings and all the other living things on earth. Nitrogen fixation, which converts inert atmospheric nitrogen into ammonia or other valuable substances, is a very important part of the nitrogen cycle. The Haber-Bosch process plays the dominant role in the chemical nitrogen fixation as it produces a large amount of ammonia to meet the demand from the agriculture and chemical industries. However, due to the high energy consumption and related environmental concerns, increasing attention is being given to alternative (greener) nitrogen fixation processes. Among different approaches, plasma-assisted nitrogen fixation is one of the most promising methods since it has many advantages over others. These include operating at mild operation conditions, a green environmental profile and suitability for decentralized production. This review covers the research progress in the field of plasma-assisted nitrogen fixation achieved in the past five years. Both the production of NOx and the synthesis of ammonia are included, and discussion on plasma reactors, operation parameters and plasma-catalysts are given. In addition, outlooks and suggestions for future research are also given.

Ammonia Plasma-Catalytic Synthesis Using Low Melting Point Alloys

The Haber-Bosch process has been the commercial benchmark process for ammonia synthesis for more than a century. Plasma-catalytic synthesis for ammonia production is theorized to have a great potential for being a greener alternative to the Haber-Bosch process. However, the underlying reactions for ammonia synthesis still require some detailed study especially for radiofrequency plasmas. Herein, the use of inductively coupled radiofrequency plasma for the synthesis of ammonia when employing Ga, In and their alloys as catalysts is presented. The plasma is characterized using emission spectroscopy and the surface of catalysts using Scanning Electron Microscope. A maximum energy yield of 0.31 g-NH3/kWh and energy cost of 196 MJ/mol is achieved with Ga-In (0.6:0.4 and 0.2:0.8) alloy at 50 W plasma power. Granular nodes are observed on the surface of catalysts indicating the formation of the intermediate GaN.