LUNA INNOVATIONS INCORPORATED — Department of Agriculture SBIR Phase I: 8.13

Description

Statement of the problem or opportunity:The conventional approach to industrially producing nitrogenous fertilizers helps feed about half of the world's population but is energy inefficient and requires extensive infrastructure. Together, the conventional Haber and Ostwald use about 1 - 2 % of the world's produced energy and produce almost 3 % of anthropogenic carbon dioxide emissions. A relatively simple, efficient, and inexpensive method is needed that can improve the productivity and profitability of farming for all of the world's population while lowering climatic impact. Recent advances in Luna's dual phase membrane technology have developed into an opportunity to directly oxidize nitrogen gas, N2, to nitrates for fertilizers. A catalytic membrane reactor has been designed for producing nitrates with potentially ten times less energy than the conventional processes, is independent of natural gas or other fossil fuel resources, and is amendable to rapid start up and shut down. This means that fertilizer can be locally produced on demand even with intermittent renewable energy sources, such as wind and solar.?Project objectives and description of the efforts:Luna will demonstrate the direct oxidation of nitrogen from air to nitrates with a catalytic membrane reactor. The first objective is to formulate the molten phase chemistry of the dual phase membranes. While all of the relevant chemical processes have been described in the literature, Luna will formulate a molten system that combines all of these processes in the most efficient conditions. The second objective is to fabricate and demonstrate the complete membrane system. The Phase I program will culminate in the design of the scaled up membrane module that will be built in Phase II program. A team will be develop that includes Trimeric Corporation for process engineering and techno-economic analysis, Nooter/Eriksen for integration with power generation infrastructure for pilot scale demonstration in Phase III, and an industrial partner who can process the nitrates into a fully formulated fertilizer product.Anticipated results and potential commercial applications:The catalytic membrane reactor for local, on-demand nitrate production for fertilizers is expected to improve energy efficiency, lower the costs of farming, and foster global food security. Because the Haber process is largely dependent upon fossil fuels as a source of hydrogen, the proposed technology will promote the use of renewable energy by relieving the dependence of fertilizer production on fossil fuels. The reductions in infrastructure requirements can also enable fertilizer production by communities and regions that presently lack this capability.