103: Modular Distributed Ammonia Synthesis

Currently, nearly 50% of all food production is enhanced with fertilizer made by the Haber-Bosch (HB) process. Invented in 1914, this process utilizes purification techniques to refine hydrogen from fossil fuels, then combines it at high pressures and temperatures with nitrogen gas at massive scales. At the time, many scientists believed that alternative methods would inevitably replace the resource-intensive fossil fuel basis. More than 100 years and hundreds of major scientific advancements later, that is finally becoming reality. 

Consisting of around 82% nitrogen, anhydrous ammonia is a popular form of fertilizer among farmers across the country due to its nitrogen content and its widespread infrastructure. However, its popularity has waned over the last 30 years due to its high transportation costs and risks. We aimed to produce locally-sourced, environmentally-friendly ammonia at a market-dominating price.

We designed a system of modular, small-scale ammonia plants spread across the “corn belt.” Our process provides a desirable form of fertilizer with less risk, that significantly shrinks the carbon footprint of traditional production methods. As investment in green energy continues to grow, our product will only become cheaper, which is the singular concern of most farmers.

Our primary alteration to the traditional HB process is our choice of hydrogen generation. Since a major portion of HB production costs come from purifying natural gas, turning it into hydrogen, and then purifying that hydrogen, we used Proton-Exchange Membrane (PEM) electrolysis, which directly turns water (H₂O) into high-purity hydrogen (H₂) at scales perfect for our modular design. In combination with Cryogenic Nitrogen Distillation, modern advanced catalytic materials, and low-temperature flash separation, we can produce 50 metric tons per day of highly pure (<99.5%) anhydrous ammonia. Strategically employing “off-the-shelf” process equipment allows our design to be quickly deployed directly to where it’s needed most, providing a clear path toward a future where our food supply is independent, secure and environmentally conscious.