A main charter point of the Energy Consortium is to focus on exploratory and collaborative research. The TREND Setter program is one such initiative with an aim to identify the long-range research initiatives of the industry and build capability within the consortium to address it. Faculty members are invited to address industry challenges, and eight were chosen for the first cohort in 2023.
With concept of circular economy catching pace in industries, Kothandaraman Ramanujam, Professor, Department of Chemistry’s research on Renewable Ammonia Fuel for Circular Energy Economy – A Carbon Free Approach holds good promise to decarbonize several hard to abate sectors. He explains on his project and further highlights on the outcomes and also on his TREND Setter experience…
The Energy Consortium (TEC): Can you provide a brief overview on your TREND Setter project and its objectives?
Kothandaraman Ramanujam (KR): Ammonia is typically produced using hydrogen generated through methane cracking, which generates carbon dioxide alongside hydrogen. This hydrogen is then combined with nitrogen from the atmosphere at very high temperatures and pressures. Maintaining these extreme conditions requires burning fossil fuels. For every ton of ammonia produced, about 30 tons of carbon dioxide are released.
Our method, in contrast, eliminates carbon dioxide production entirely. The project focuses on synthesizing ammonia through an electrochemical method using nitrogen, which is abundant in the environment. Initially, we took a theoretical approach to identify suitable 2D materials for nitrogen absorption. After selecting certain materials, we aimed to replicate their properties in experiments. While the results were not exact replicas, we were able to test the chosen materials, and we found that one or two of them successfully produced ammonia. This process becomes green, if we can harness renewable energy for this. With the increasing focus on green hydrogen, ammonia, and green ammonia in the context of the energy transition, our work is highly relevant.
TEC: What were the challenges that you faced?
KR: Our goal is to develop a reactor for ammonia production. We have identified the materials needed for this process, but constructing the reactor is more labor-intensive. While we’ve met all our project objectives, we also want to showcase a tangible product, which will take longer than the initial one-year timeframe, we expected.
The ultimate aim of the project is to produce liquid nitrogen ammonia. To achieve this, we need to create a prototype that accurately mimics what occurs in the laboratory. The issue stems from the unavailability of suitable substrate materials to host the electrode materials identified for the NH3 production . We’ve been using simple carbon paper, which produces a lot of hydrogen alongside nitrogen and ammonia, but we need a type of carbon that generates less hydrogen and more ammonia. This specific substrate material is called glassy carbon. Unfortunately, we only have access to small electrodes, about 3 mm to 4 mm in diameter, while we require larger pieces, around 10 cm. We will continue to search for alternative substrate materials or larger glassy carobn substrate materials to build our reactors, but sourcing them may take some time.
TEC: What was the most rewarding aspect of this project?
KR: This project has allowed us to explore new materials, leading to the creation of at least two patents and two publications, which are crucial for securing larger funding and impressing the industry with our ammonia production technology. This lays the groundwork for expanded research efforts.
I collaborated on this with other researchers, including Professor V Subramanian from chemistry and Professors S Ramanathan and Rajneesh Kumar from chemical engineering. We have had opportunities to present our findings to industry partners during events like the industry day organized by energy consortium.
In terms of the impact, once it moves beyond the lab scale to a larger production model, it could revolutionize the ammonia industry, making it greener and more self-sufficient. With carbon and nitrogen available abundantly in the environment, industries could rely solely on electricity, preferably from renewable sources, to produce ammonia, thus transforming their supply chains and reducing dependence on external raw materials.
That said, it’s important to manage expectations; while the potential is significant, we are still at the laboratory stage. Moving forward, we plan to refine our proposal for the Department of Science and Technology, GoI’s call for Hydrogen and Fuel Cell research initiatives to secure further support for our research.
TEC: How can TREND Setter’s impact be furthered?
KR: From the TREND Setter program, we seek support for fundamental research. Typically, the Energy Consortium presents problems faced by industries, but in this case, we are suggesting that industry too could directly fund as well. Since the industry has already identified a problem, we can get funded for the implementable research and on the other hand, through grants like TREND Setter, we can focus on the fundamental research part of the same project.
For example, while we already have the capability to build a reactor, its efficiency could be significantly improved with the discovery of new catalytic materials. Such a collaboration would allow us to implement our findings with the industry while still focusing on the underlying science. The intellectual property generated from this research could be directed to The Energy consortium, while the reactor development would remain in partnership with the industry. This model will benefit all, creating a win-win situation.
TEC: Currently what are you working on?
KR: In addition to our work on ammonia, we are also focused on battery technology. Emerging technologies such as sodium-ion batteries are being explored as alternatives to lithium-ion batteries, and there is significant interest in redox flow batteries as well. In India, we are at the forefront of this innovation; no one else has come close to our level of development in the flow battery front. In the realm of redox flow batteries, we have made notable advancements by creating new redox couples and higher-capacity electrolytes. For sodium-ion batteries, we are also investigating the use of polymer electrolytes instead of traditional liquid ones. This shift is expected to reduce the risk of flammability, minimizing thermodynamic issues and enhancing overall safety.
We’re also exploring carbon dioxide sequestration by converting CO2 into formic acid. We have already developed a small reactor for carbon dioxide reduction, and our goal is to build a larger reactor focused on carbon dioxide sequestration, addressing real industry challenges. The reactor captures the carbon dioxide emitted by industries, before it reaches the atmosphere, and it can be converted into a chemical, thereby improving their carbon credit status and gaining government incentives. Our current setup is at a Technology Readiness Level (TRL) of around 5 or 6, which we aim to advance to TRL 8 or 9.
Furthermore, we produce hydrogen through a unique electrolysis method called decoupled electrolysis. Unlike conventional electrolysis, where hydrogen and oxygen are generated simultaneously and can mix, our approach allows for the production of hydrogen and oxygen at different times. This separation means there’s no risk of mixing, resulting in high-purity hydrogen as well as easier operational management.
