Non-thermal Plasma Reactor for Continuous Fertilizer Production

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Solution Overview

Problem

The Haber-Bosch process for nitrogen-based fertilizer production faces challenges such as imbalances between throughput and energy efficiency, inability to achieve continuous and practical manufacture, and significant carbon dioxide emissions and energy demands.

Innovation Solution

A non-thermal plasma reaction assembly using a coaxial dielectric barrier discharge reactor, which includes two plasma discharge zones and a ground electrode, is employed for continuous aqueous nitrogen-based fertilizer production. This assembly utilizes atmospheric air or nitrogen gas and water as inputs, generating electric fields to facilitate the production of nitrate, nitrite, and ammonium fertilizers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the Haber-Bosch process is used for nitrogen-based fertilizer production, then ammonia can be produced at scale, but energy consumption and carbon dioxide emissions increase significantly

Engineering Contradiction:

Improveammonia production throughputVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The patent replaces the high-temperature high-pressure mechanical Haber-Bosch process with a non-thermal plasma system operating at atmospheric pressure and ambient temperature. The plasma reactor uses electrical discharge to generate reactive nitrogen species that dissolve in water to form fertilizers, eliminating the need for extreme mechanical conditions while maintaining production capability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention fundamentally changes the operating parameters from the Haber-Bosch process (400-500°C, 150-200 atm) to plasma conditions (atmospheric pressure, ambient temperature). This parameter transformation enables energy-efficient nitrogen fixation by using electrical energy to create plasma states that facilitate nitrogen activation without requiring thermal or pressure inputs

Inventive Principle:

Principle #35Parameter changes

2Duration of action of stationary object

If the Haber-Bosch process is used for nitrogen-based fertilizer production, then ammonia can be produced continuously, but the process shows supply chain vulnerabilities and sustainability issues

Engineering Contradiction:

Improvecontinuous production capabilityVSAvoidcarbon dioxide emissions

Core Design Contradiction:

Duration of action of stationary objectVSObject-generated harmful factors

Solution Approach 1:

The plasma system uses atmospheric air as the nitrogen source, eliminating dependence on external natural gas supplies and complex supply chains. The reactor directly extracts nitrogen from ambient air and converts it to fertilizers on-site, making the system self-sufficient and independent of vulnerable global ammonia supply chains

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The invention converts atmospheric nitrogen, which is inert and unusable in its natural state, into reactive nitrogen species through plasma activation. This transformation turns a harmful or useless component (N2 gas) into valuable fertilizers (nitrates, ammonium) while avoiding the carbon-intensive processes traditionally required

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Productivity

If traditional nitrogen-based fertilizer production methods are used, then fertilizer can be manufactured, but throughput and energy efficiency are imbalanced

Engineering Contradiction:

Improvefertilizer production throughputVSAvoidenergy efficiency

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The plasma reactor is divided into distinct functional zones: a discharge zone for nitrogen activation, a reaction zone for fertilizer formation, and a collection zone for fertilizer recovery. This segmentation allows each zone to be optimized independently, maintaining high throughput while minimizing energy consumption in each stage

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The plasma reactor operates continuously with steady-state plasma discharge, ensuring constant nitrogen activation and fertilizer production. The continuous flow of water through the reactor maintains uninterrupted conversion of atmospheric nitrogen to soluble fertilizers, eliminating idle time while maintaining energy efficiency

Inventive Principle:

Principle #20Continuity of useful action

Data Source

PatentUS20250188000A1Non-thermal plasma reaction assembly for continuous aqueous nitrogen-based fertilizer production and method thereof

Publication Date: 2025.06.12 UNIVERSITY OF TENNESSEE RESEARCH FOUNDATION

AI summary

A non-thermal plasma reaction assembly continuously produces an aqueous nitrogen-based fertilizer. Atmospheric air or nitrogen gas and water are fed to the non-thermal plasma reaction assembly. One or more coaxial dielectric barrier discharge reactors are provided as part of the non-thermal plasma reaction assembly. The coaxial dielectric barrier discharge reactor(s), per an implementation, has a first plasma discharge zone with a first high-voltage electrode and a second plasma discharge zone with a second high-voltage electrode. The first and second plasma discharge zones and high-voltage electrodes are arranged in succession relative to each other. Compared to past approaches, a higher throughput and higher yield can be furnished with employment of the non-thermal plasma reaction assembly, as well as lower electricity consumption, among many other advancements.