Microwave Catalytic Ammonia Synthesis Catalyst

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Solution Overview

Problem

The Haber-Bosch process for ammonia production is energy-intensive and large-scale, making it inefficient in terms of energy consumption and capital costs, and alternative methods like electrochemical and biomimetic routes face challenges such as high energy requirements, slow kinetics, and costly co-factors.

Innovation Solution

Development of heterogeneous catalysts using metals from Groups 7, 8, 9, 10, or 11, with a metal oxide support, and ruthenium-based catalysts, combined with microwave irradiation for ammonia synthesis at ambient pressures, allowing for efficient ammonia production with reduced energy and capital costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the Haber-Bosch process is used for ammonia production, then large-scale production capability is achieved, but energy consumption and capital costs increase significantly

Engineering Contradiction:

Improveammonia production scaleVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The patent changes the fundamental operating parameters of ammonia synthesis by using microwave irradiation instead of conventional thermal heating, enabling the reaction to proceed at ambient pressure and lower temperatures while maintaining high productivity through efficient energy coupling to the catalyst

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the conventional thermal-mechanical heating system with an electromagnetic field-based microwave system, substituting the mechanical/thermal energy input mechanism with a more efficient electromagnetic energy coupling method that directly activates the catalyst and reactants

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Use of energy by moving object

If the Haber-Bosch process is scaled down to match renewable energy capacity, then energy efficiency improves, but production cost increases by a factor of 2 to 3

Engineering Contradiction:

Improveenergy efficiencyVSAvoidproduction cost

Core Design Contradiction:

Use of energy by moving objectVSEase of manufacture

Solution Approach 1:

The patent changes the scale and operating parameters simultaneously, enabling small-scale production to achieve cost-effectiveness through microwave-catalyzed processes that eliminate the need for large-scale infrastructure while maintaining efficiency through direct energy coupling to the reaction

Inventive Principle:

Principle #35Parameter changes

3Stress or pressure

If electrochemical approaches are used for ammonia synthesis, then ambient pressure operation is achieved, but current efficiency and ammonia yield remain low

Engineering Contradiction:

Improveoperating pressureVSAvoidammonia yield

Core Design Contradiction:

Stress or pressureVSProductivity

Solution Approach 1:

The patent substitutes electrochemical energy input with microwave electromagnetic field input, replacing the electrochemical conversion mechanism with a more efficient microwave-catalyzed pathway that achieves both ambient pressure operation and high ammonia yield through direct energy coupling to the catalyst

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Temperature

If biomimetic routes are used for ammonia synthesis, then ambient conditions are achieved, but reaction kinetics become slow and co-factor costs increase

Engineering Contradiction:

Improvereaction temperatureVSAvoidreaction kinetics

Core Design Contradiction:

TemperatureVSSpeed

Solution Approach 1:

The patent replaces biomimetic enzymatic pathways with microwave-catalyzed inorganic catalyst systems, substituting the slow biological conversion process with a faster microwave-driven catalytic process that achieves ambient temperature operation without requiring complex co-factors while maintaining rapid kinetics

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach enables ammonia synthesis with improved energy efficiency, reduced capital and operating costs, and the ability to pair with renewable energy sources, offering a scalable and cost-effective solution for ammonia production.

Implementation Method 1

heating the heterogeneous catalyst using microwave energy

Methodology Applied

Scientific EffectMicrowave irradiation: Microwave Radiation

Implementation Method 2

heating the heterogeneous catalyst using microwave energy

Methodology Applied

Scientific EffectDielectric heating: Dielectric Heating

Implementation Method 3

reacting the reactant gas mixture in contact with the heterogeous catalyst, thereby providing a product gas mixture

Methodology Applied

Scientific EffectCatalysis: Catalysis

Data Source

PatentUS10974969B2Methods and compositions for microwave catalytic ammonia synthesis

Publication Date: 2021.04.13 THE UNITED STATES AS REPRESENTED BY THE DEPARTMENT OF ENERGY

AI summary

In one aspect, the disclosure relates to relates to heterogeneous catalysts useful for the synthesis of ammonia under microwave irradiation, processes for preparing the disclosed heterogeneous catalysts, and processes for synthesizing ammonia using the heterogeneous catalysts with microwave irradiation. In various aspects, the disclosed heterogeneous catalysts comprise: a metal selected from Group 7, Group 8, Group 9, Group 10, Group 11, or combinations thereof; a metal oxide support; and optionally a promoter material. This abstract is intended as a scanning tool for purposes of searching in the particular art and is not intended to be limiting of the present disclosure.