Periodic Reporting for period 2 - VERGE (VERSATILE AND DIRECT E-FUEL AND FERTILISER GENERATION FROM RENEWABLE ELECTRICITY)
Okres sprawozdawczy: 2024-05-01 do 2025-10-31
The VERGE technology developed in this project was the first of its kind with the main objective to develop a proof-of-concept N2 electrolyser to produce liquid ammonia at ambient conditions for fuel and fertiliser, designed for direct coupling to sustainable intermittent energy sources. The consortium consisted of two universities, one technological research institute, one SME and three established companies, bringing together expertise from all the disciplines needed within this inter-disciplinary project.
Industrial synthesis of ammonia (Haber-Bosch) for fertiliser applications is responsible for 1% annual anthropogenic greenhouse gas (GHG) emissions. Furthermore, the future of e-Fuel is strongly directed towards ammonia. In the field of maritime transport, up to 3% of annual anthropogenic GHG emissions can be avoided by moving from fossil fuels to ammonia. Through its contribution towards lower GHG emission, the VERGE technology has contributed towards a faster transition to a net-zero GHG emissions of the EU economy by 2050. An additional benefit of the VERGE technology is that it will fully utilise the production potential of renewable electricity infrastructure. The VERGE process will convert otherwise curtailed electrical energy to ammonia for use as fertiliser and fuel, thereby increasing the value of wind- and solar-installations.
Industrial synthesis of ammonia (Haber-Bosch) for fertiliser applications is responsible for 1% annual anthropogenic greenhouse gas (GHG) emissions. Furthermore, the future of e-Fuel is strongly directed towards ammonia. In the field of maritime transport, up to 3% of annual anthropogenic GHG emissions can be avoided by moving from fossil fuels to ammonia. Through its contribution towards lower GHG emission, the VERGE technology has contributed towards a faster transition to a net-zero GHG emissions of the EU economy by 2050. An additional benefit of the VERGE technology is that it will fully utilise the production potential of renewable electricity infrastructure. The VERGE process will convert otherwise curtailed electrical energy to ammonia for use as fertiliser and fuel, thereby increasing the value of wind- and solar-installations.
Different parts of the N2 electrolyzer cell were developed and improved; catalyst materials, membranes and gas diffusion electrodes (GDEs). Theoretical simulations of electrochemical nitrogen reduction reaction (eNRR) on proposed catalysts were carried out to clarify experimental results and suggest new catalysts. The project was finalized with an inter-laboratory study using 15N isotope labelling to obtain proof of catalysis in GDE setups at Atmonia, RWTH Aachen and VITO, thus reaching TRL4.
Other parts of the whole VERGE system were developed. The relevant time scales for operating the VERGE technology coupled with either the electric grid or renewable electricity sources were analyzed and optimized to obtain the configuration with the lowest production costs. A 200 kVA transformer was developed to distribute electrical energy for the cells in a 40 ft container for the on-grid solution. For the off-grid solution, it is more practical to use DC/DC inverters for each cell stack to increase the adaptability to the electricity availability. Dosage system for simplified gas mixture derived from electrocatalytic cell was set up by mixing nitrogen and ammonia. Separation of ammonia from this gas mixture was achieved by absorbing ammonia in diluted sulfuric acid, forming an ammonium sulphate solution.
An extensive Life Cycle Inventory of the VERGE system was developed. Through the Life Cycle Impact Assessment a contribution analysis was done to assess hotspots, including a sensitivity analysis for comparison with a Haber-Bosch system. Additionally, a Resource Efficiency Analysis was developed and compared with Planetary Boundaries Framework and UN Sustainable Development goals. Finally, the Regulatory Framework analysed 75 different related-to-ammonia regulations on a global scale.
Other parts of the whole VERGE system were developed. The relevant time scales for operating the VERGE technology coupled with either the electric grid or renewable electricity sources were analyzed and optimized to obtain the configuration with the lowest production costs. A 200 kVA transformer was developed to distribute electrical energy for the cells in a 40 ft container for the on-grid solution. For the off-grid solution, it is more practical to use DC/DC inverters for each cell stack to increase the adaptability to the electricity availability. Dosage system for simplified gas mixture derived from electrocatalytic cell was set up by mixing nitrogen and ammonia. Separation of ammonia from this gas mixture was achieved by absorbing ammonia in diluted sulfuric acid, forming an ammonium sulphate solution.
An extensive Life Cycle Inventory of the VERGE system was developed. Through the Life Cycle Impact Assessment a contribution analysis was done to assess hotspots, including a sensitivity analysis for comparison with a Haber-Bosch system. Additionally, a Resource Efficiency Analysis was developed and compared with Planetary Boundaries Framework and UN Sustainable Development goals. Finally, the Regulatory Framework analysed 75 different related-to-ammonia regulations on a global scale.
The project has the potential to significantly impact the world on a scientific, climate, economic, social and political level. Sustainable and versatile small-scale ammonia production that can be distributed to all renewable energy producers for local production and use is a disruptive approach. To realize this many scientific and engineering challenges must be solved. The VERGE project has taken the first step to address these challenges.
With a positive result from an inter-laboratory study using 15N isotope labelling, the scientific results from VERGE are pioneering the global field of eNRR. This was accomplished through careful research and development of the main components of an electrochemical cell; from theoretical catalysis, experimental catalyst synthesis, membrane development, GDE preparation and electrocell construction to operando electrochemical and ammonia quantification methodology and reproducibility in experiments. The reaction rate, current efficiency and operational time will be improved further beyond the project lifetime.
The production costs are determined by investment costs for the electrolyzer and can be reduced significantly with further catalyst and process development. Choices on power conversion technologies were proposed and designed with emphasis on flexibility. The release of ammonia from the ammonium sulphate solution needs to be further developed and optimized. Further development of the convertor is required to ensure efficient intermittent operations and optimization of the ammonia separation to produce liquid anhydrous ammonia.
A fully verified system-level assessment of electrochemical ammonia production under specific conditions went beyond the state of the art. The analysis demonstrated the potential for improved environmental performance compared to conventional Haber–Bosch pathways. The integrated hotspot, sensitivity, and benchmarking approach provided actionable guidance for system design, siting, and operation that is rarely available at this stage of technology development. Overall, the results reduce uncertainty, de-risk scale-up decisions, and support informed pathways toward demonstration and market uptake. For technological transition and market uptake, further funding is needed to ensure optimization of process parameters, regulatory framework and permit pathway definition for small scale ammonia production. Market carbon emission trading system and government incentives for sustainable fertilizer and fuels will further support process market uptake. Early market approach, networking and communication with all stakeholders will allow for faster decision-making and outreach to relevant industry players and stakeholders. It is important that all stakeholders are aware of the VERGE project and the opportunities it will bring to the ammonia economy.
With a positive result from an inter-laboratory study using 15N isotope labelling, the scientific results from VERGE are pioneering the global field of eNRR. This was accomplished through careful research and development of the main components of an electrochemical cell; from theoretical catalysis, experimental catalyst synthesis, membrane development, GDE preparation and electrocell construction to operando electrochemical and ammonia quantification methodology and reproducibility in experiments. The reaction rate, current efficiency and operational time will be improved further beyond the project lifetime.
The production costs are determined by investment costs for the electrolyzer and can be reduced significantly with further catalyst and process development. Choices on power conversion technologies were proposed and designed with emphasis on flexibility. The release of ammonia from the ammonium sulphate solution needs to be further developed and optimized. Further development of the convertor is required to ensure efficient intermittent operations and optimization of the ammonia separation to produce liquid anhydrous ammonia.
A fully verified system-level assessment of electrochemical ammonia production under specific conditions went beyond the state of the art. The analysis demonstrated the potential for improved environmental performance compared to conventional Haber–Bosch pathways. The integrated hotspot, sensitivity, and benchmarking approach provided actionable guidance for system design, siting, and operation that is rarely available at this stage of technology development. Overall, the results reduce uncertainty, de-risk scale-up decisions, and support informed pathways toward demonstration and market uptake. For technological transition and market uptake, further funding is needed to ensure optimization of process parameters, regulatory framework and permit pathway definition for small scale ammonia production. Market carbon emission trading system and government incentives for sustainable fertilizer and fuels will further support process market uptake. Early market approach, networking and communication with all stakeholders will allow for faster decision-making and outreach to relevant industry players and stakeholders. It is important that all stakeholders are aware of the VERGE project and the opportunities it will bring to the ammonia economy.