A detailed techno-economic analysis (TEA), which we performed together with colleagues from University of Twente, predicts that plasma-based NOx synthesis, using our best results, is almost competitive with the Haber–Bosch process combined with the Ostwald process. Indeed, the energy cost (EC) target value to become competitive is defined as 1.0–1.5 MJ/mol, and we already reached an EC of 2 MJ/mol at 3.8% NOx concentration in microwave plasma, and an EC of 1.8 MJ/mol in a gliding arc plasma at a pressure of 3 barg, at nearly 5% NOx concentration. We believe we can further improve these numbers, towards the target, via smart reactor design, tuning the chemistry and vibrational kinetics, avoiding back-reactions, or combination with catalysts.
Our research attracted a lot of interest from companies. We had a bilateral project with N2 Applied (Norwegian SME, Dec ’22 – Dec ’23) on experiments and modeling for plasma-based NOx production, where we investigated the performance of an upscaled plasma reactor. They are currently seeking investments to start a follow-up bilateral project.
Furthermore, in collaboration with KULeuven (J. Martens, L. Hollevoet), we had a new project directly funded by the Flemish Ministry of Farming, to demonstrate the proof-of-concept of air washer technology with a large plasma reactor, to combine the plasma-produced NOx with NH3 emissions from farms, which will allow farmers making their own NH4NO3 fertilizer, and simultaneously solve the problem of NH3 emission (as described in our ERC PoC project). We also collaborate in this project with CB Group (Belgian company building air washers) and VitalFluid (Dutch company making larger plasma reactors, who also showed interest to further collaborate, and we are seeking for possibilities). The new air washer with plasma reactor is now operational at TRANSfarm (demo-farm in Leuven), and the demo attracted already a lot of interest. We can test here the plasma reactor in real world context, i.e. air with varying humidity and exploring the reactor robustness for both continuous long-term and intermittent operation, as written in our PoC proposal. We are working towards the creation of a spinoff company next year, together with KULeuven. We also have 2 patent applications together, that will form the basis of the spinoff.
Finally, we will start a bilateral project with another company (still confidential), on plasma-based NOx production for fertilizer applications. The large pilot reactor for this is currently being built, and will be operational by end of 2024, in the pilot hall of BlueApp (pre-incubator of UAntwerp, for demo-purposes, as also described in our proposal), where we will evaluate the performance at large scale, in a wide range of conditions.