Plasma-Catalysis for Ammonia Production
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Giles, Matthew↗
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Interpretable Deep Learning for Advancing Field-Enhanced Catalysis
This DOE Early Career project developed a physics-informed, interpretable AI-and-modeling framework to understand and exploit electric-field effects in heterogeneous catalysis, with ammonia cracking and synthesis as a representative pathway. The team built and validated methods to map local electric fields on metal surfaces and nanoparticles, showing that low-coordination features (tips/edges/corners) can concentrate fields by several-fold relative to flat facets. Using DFT-generated datasets, the project created physics-guided machine learning models that rapidly predict local electric fields and field-dependent adsorption energetics with near-DFT accuracy while reducing computational cost by orders of magnitude. These predictions were integrated with microkinetic modeling to quantify how field-dipole interactions reshape reaction energetics and mechanisms, enabling large increases in predicted catalytic rates and substantial reductions in operating temperature under favorable field conditions. To accelerate discovery of earth-abundant catalysts, the project combined interpretable ML screening (with electronic-structure descriptors identified as key drivers) with a generative inverse-design workflow based on diffusion models and physics constraints. The resulting closed-loop approach, linking simulation, mechanistic modeling, and AI, provides reusable tools and datasets for designing catalysts and operating conditions in field-enhanced catalysis, with broad relevance to electrostatic catalysis, plasma catalysis, electrocatalysis, and other energy-related chemical transformations.
30 DIRECT ENERGY CONVERSION↗
Investigation of Ni catalyst activation during plasma-assisted methane oxidation
Atmospheric pressure plasma has shown promise in improving thermally activated catalytic reactions through a process termed plasma-catalysis synergy. In this work, we investigated atmospheric pressure plasma jet (APPJ)-assisted CH 4 oxidation over a Ni/SiO 2 .Al 2 O 3 catalyst. Downstream gas-phase products from CH 4 conversion were quantified by Fourier transform infrared spectroscopy. The catalyst near-surface region was characterized by in-situ diffuse reflectance infrared Fourier transform spectroscopy. The catalyst was observed to be activated at elevated temperature (500 °C) if it was exposed to the APPJ operated at large plasma power. 'Catalyst activation' signifies that the purely thermal conversion of CH 4 using catalysts which had been pre-exposed to plasma became more intense and produced consistently CO product, even if the plasma was extinguished. Without the application of the APPJ to the Ni catalyst surface this was not observed at 500 °C. The study of different exposure conditions of the activated catalyst indicates that the reduction of the catalyst by the APPJ is likely the cause of the catalyst activation. We also observed a systematic shift of the vibrational frequency of adsorbed CO on Ni catalyst when plasma operating conditions and catalyst temperatures were varied and discussed possible explanations for the observed changes. Furthermore, this work provides insights into the plasma-catalyst interaction, especially catalyst modification in the plasma catalysis process, and potentially demonstrates the possibility of utilizing the surface CO as a local probe to understand the plasma-catalyst interaction and shed light on the complexity of plasma catalysis.
methane oxidation↗
Plasma-assisted catalysis for ammonia synthesis in a dielectric barrier discharge reactor: key surface reaction steps and potential causes of low energy yield
Ammonia synthesis experiments were carried out in a coaxial dielectric barrier discharge (DBD) reactor packed with several different supports and metal catalysts. There was a marked increase in the reaction rate, over that obtained in an empty DBD plasma reactor, upon introduction of a packed bed of γ-Al 2 O 3 , Ru/γ-Al 2 O 3 , or SiO 2 particles. The difference in the reaction rates over γ-Al 2 O 3 and Ru/γ-Al 2 O 3 was minimal. Complementary zero-dimensional plasma kinetic model analysis was also performed using inputs from experimental data. This kinetic analysis allowed for gas phase reactions, Eley–Rideal (E–R) reactions, and direct adsorption of radical species on the γ-Al 2 O 3 surface. On the metal surface, dissociative adsorption of N 2 and H 2 , and Langmuir–Hinshelwood reactions were also included. This analysis revealed that, under the conditions of our experiments, ammonia synthesis proceeds principally by the formation of reactive radicals in the gas phase, which then adsorb and participate in E–R reactions on both the metal and support material surfaces. Furthermore, this finding illustrates a challenge for substantially increasing the energy yield for plasma-assisted ammonia synthesis in typical DBD reactors containing packed catalyst beads.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Molecular beam mass spectrometry measurements of vibrationally excited N 2 in the effluent of an atmospheric plasma jet: a comparison with a state-to-state kinetic model
Vibrationally excited N 2 molecules are suggested to be one of the possible key species responsible for the observed synergistic effects in plasma catalysis for NH 3 synthesis. To assess the impact of vibrationally excited species in plasma-catalysis, quantitative measurements near interfaces are required, which remains challenging. In this letter, we report spatially resolved measurements of vibrationally excited N 2 in the effluent of an atmospheric pressure plasma jet by molecular beam mass spectrometry (MBMS). The mass spectrometry signals as a function of electron energy of the ionizer were fitted with the effective electron-impact ionization cross section of N 2 (v) considering the vibrational distribution function as determined by a detailed vibrational level resolved plasma kinetic calculation. Here, the reported method presented in this letter shows the capability of MBMS to measure vibrationally excited species of N 2 near interfaces when the vibrational distribution function is known or assumed and shows excellent agreement with state-to-state kinetic models of N 2 (v).
42 ENGINEERING↗
In Situ Identification of NNH and N 2 H 2 by Using Molecular-Beam Mass Spectrometry in Plasma-Assisted Catalysis for NH 3 Synthesis
In this work, ammonia synthesis at 533 K and atmospheric pressure was investigated in a coaxial dielectric barrier discharge (DBD) plasma reactor without packing and with porous γ-Al 2 O 3 , 5 wt % Ru/γ-Al 2 O 3 , or 5 wt % Co/γ-Al 2 O 3 catalyst particles. Gas-phase species were monitored in situ using an electron impact molecular-beam mass spectrometer (EI-MBMS). Gas-phase species NNH and N 2 H 2 were first identified under common conditions of plasma-assisted ammonia synthesis and were present at levels comparable to that of NH 3 in the plasma discharge. Concentrations of NNH, N 2 H 2 , and NH in a reactor packed with γ-Al 2 O 3 or other particles were lower than those observed in an empty reactor, while the concentration of NH 3 increased. These observations point to the importance of NNH and N 2 H 2 in plasma-assisted surface reactions in ammonia synthesis. Reaction pathways of direct adsorption of gas-phase NNH and N 2 H 2 on solid surfaces and subsequent reactions were proposed. This study demonstrated that in situ identification of gas-phase species via EI-MBMS provides a powerful approach to study the kinetics of plasmaassisted catalysis.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Investigation of the Mechanisms Underpinning Plasma-Catalyst Interaction for the Conversion of Methane to Oxygenates
Plasma catalysis is a promising approach to further enhance the conversion of methane into value-added products such as methanol. In this work, the mechanisms enabling the conversion of methane to CO, CO 2 and methanol enabled by plasma-enhanced catalysis were investigated. A catalyst reactor was incorporated downstream of the plasma jet to enable the separation between plasma generation and the catalyst bed. An enhancement in CH 3 OH and CO 2 production was observed for the shortest distance between the plasma and catalyst compared to the plasma-only case. Plasma-enabled gas heating was shown not to be responsible for the observed synergy while a gas temperature increase as low as 30-40 K significantly impacted desorption rates of CH 3 OH/C 2 H 5 OH on alumina particles. Correlations between molecular beam mass spectrometry (MBMS) measurements at the inlet and outlet of the catalytic reactor suggest that the observed synergistic effect was caused by radical species most likely the CH 3 O 2 radical. As a result, this study shows that surface reactions induced by radicals such as alkylperoxy radicals might play an important role in surface reactions in plasma-catalysis.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Enhancements of electric field and afterglow of non-equilibrium plasma by Pb(ZrxTi1−x)O3 ferroelectric electrode
Abstract Manipulating surface charge, electric field, and plasma afterglow in a non-equilibrium plasma is critical to control plasma-surface interaction for plasma catalysis and manufacturing. Here, we show enhancements of surface charge, electric field during breakdown, and afterglow by ferroelectric barrier discharge. The results show that the ferroelectrics manifest spontaneous electric polarization to increase the surface charge by two orders of magnitude compared to discharge with an alumina barrier. Time-resolved in-situ electric field measurements reveal that the fast polarization of ferroelectrics enhances the electric field during the breakdown in streamer discharge and doubles the electric field compared to the dielectric barrier discharge. Moreover, due to the existence of surface charge, the ferroelectric electrode extends the afterglow time and makes discharge sustained longer when alternating the external electric field polarity. The present results show that ferroelectric barrier discharge offers a promising technique to tune plasma properties for efficient plasma catalysis and electrified manufacturing.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
Understanding the cold plasma synthesis of ammonia with model metal catalysts through plasma diagnostics (Final Report)
The industrial synthesis of ammonia, which amounts to over 200 million tons annually, is the most energy-intensive chemical process. Therefore, there is a critical need and increased interest in exploring less energetic routes to produce ammonia. Not only does ammonia have a direct impact on the food market, but also it has the potential as a fuel and hydrogen carrier. Recently, plasma catalysis has emerged as a promising alternative for synthesizing ammonia at mild (pressure, temperature and power) conditions. The key to this catalytic process is the synergy between the plasma and the catalyst, where the non-equilibrium plasma allows the generation of excited species, which recombine at the catalyst surface to form ammonia. However, our current understanding of this process is in its infancy. In this respect, model metals are ideal candidates for gaining a basic understanding of this reaction. Moreover, a major roadblock to rationally designing novel effective catalysts for plasma-assisted ammonia production is the need for fundamental aspects of this process. Through a comprehensive plan that integrates model metals as catalysts and world-class diagnostics, the proposed work aims to provide fundamental knowledge about the nature of reactive processes occurring during plasma-assisted catalysis and to demonstrate the selective production of ammonia, catalyzed by employing selected metals under non-thermal plasma conditions. Toward this goal, the central thrust of this proposal was to demonstrate that the synergy between plasma and rationally selected model metals will boost ammonia yields during plasma-assisted ammonia synthesis by delaying hydrogen recombination. Specifically, we aimed to (1) understand the formation and role of gas-phase active species such as NH, N 2 , N 2 + and Ha during the plasma-enhanced synthesis of ammonia through OES and FTIRAS using different reaction configurations: a) only plasma (non-packed DBD reactor) and b) packed DBD reactor with metal nanoparticles. This proposal was awarded/recommended with a run time on the PCRF facility FY20.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Propagation of atmospheric pressure plasmas through interconnected pores in dielectric materials
We report the propagation of atmospheric pressure plasmas (APPs) on and through porous dielectric materials is being investigated for plasma-catalysis and functionalizing biomedical materials for tissue scaffolding and bone regeneration. Such plasma functionalization improves wettability and cell attachment, and so uniformity of the treatment of the pore surfaces is important. The method of propagation of APPs through porous media is not well characterized. In this paper, we discuss results from a computational investigation of humid air APPs propagating through short fully interconnected pore-chains in a dielectric substrate. The properties of the dielectric and pores (diameter 150 μm) were chosen to resemble bone scaffolding. We found that photoionization is an important feature in plasma propagation through pore-chains to seed electrons in the following pore in the chain. This seeding of electrons in regions of high electric field allows for the formation of micro-streamers and surface ionization waves. This is particularly important when the openings between pores are small. The orientation of the pore-chain with respect to the applied electric field has a significant impact on plasma generation, mode of propagation, and fluences of short-lived, reactive species to the surfaces of the pores. The uniformity of fluences of charged and short-lived neutral species to the pore surfaces decreases as the angle of the pore chain deviates from being aligned with the applied electric field. Diffusion within pores
71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
Plasma assisted distributed chemical production
The present development is a process to produce commodity chemicals such as methanol and syngas using an integrated plasma catalysis technology. The method comprises providing a fixed or fluidized bed reactor having a microwave plasma flame and a catalyst bed with a catalyst, wherein the catalyst is an alloyed bimetallic nanowire. In the process, the plasma flame fluidizes the catalyst thereby producing a more effective catalyst than the non-fluidized catalyst. It is anticipated that the reactor can have a throughput capacity of up to 30 Lpm/kW and can be effective for the conversion of CO 2 , CH 4 , air, water, and combinations thereof, through reactions such as pure CO 2 splitting, reverse water gas shift (RWGS) for CO production, methanol synthesis, and plasma reforming of methane, thereby making a system that would be attractive for small GTL units.
Sunkara, Mahendra↗
Plasma catalytic ammonia synthesis on Ni nanoparticles: The size effect
Herein we demonstrate the synthesis of ammonia via atmospheric DBD plasma discharge over nickel nanoparticles supported on silica. We evaluated the performance of nickel nanoparticles with average sizes of 5.6nm and 13.5 nm. The smallest nanoparticle size sample resulted in an ammonia synthesis rate at least 2 times higher than that of the larger nanoparticle size sample and nickel bulk at equimolar composition. This allowed us to observe experimentally, for the first time, the size effect in the area of plasma catalysis. Moreover, the presented results allowed us to investigate a hydrogen sink metal such as nickel under atmospheric plasma conditions and determine the gas composition that resulted beneficial for this surface chemistry.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Enhanced production of active species and NH 3 using non-equilibrium ferroelectric barrier discharge
Non-equilibrium plasma-assisted ammonia synthesis is investigated through enhanced active species production with ferroelectric discharge. Time-resolved in-situ diagnostics of femtosecond two-photon absorption laser-induced fluorescence, coherent anti-Stokes Raman scattering, and laser absorption spectroscopy, as well as optical emission spectroscopy, were conducted to probe the key intermediate species, such as H and N radicals as well as N 2 (ν), ions, and NH 3 to achieve better understanding of non-equilibrium energy transfer and ammonia formation. The results reveal that ferroelectric discharge improved ammonia yield by four times. Results also show that ferroelectrics not only enhanced ions (N 2 + ) production, radicals (N, H) number density, but also increased the N 2 vibrational temperature. Further plasma modeling identified the couplings between elevated radical and ion production and enhanced vibrational excitation reactions, e.g., N + H 2 (ν)→NH + H, N 2 (ν)+H → NNH, N 2 + + H 2 → H + N 2 H + , and N 2 H + +e→NH + N, facilitated by ferroelectric discharge. These findings provide critical insight into the mechanism of ferroelectric plasma catalysis and highlight their potential in advancing energy-efficient chemical synthesis.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Plasma catalytic non-oxidative methane conversion to hydrogen and value-added hydrocarbons on zeolite 13X
Non-thermal plasma has unfolded highly efficient, safe to operate novel routes for methane conversion to hydrogen. In this work, methane conversion is performed under atmospheric dielectric barrier discharge (DBD) plasma with and without 13X zeolite-based catalysts i.e., 13X, Ga/13X, Pd/13X, and Pd-Ga/13X. Experimental results indicate that the plasma catalytic process delivered almost twofold higher product yield than the plasma only route. The binary Pd-Ga catalyst possesses highest catalytic performance with about 40 % CH 4 conversion at an input flowrate of 5 cm 3 min -1 and 2W due to the formation of the Pd-Ga alloy, which acts as catalytic active centre for activating C–H bonds. Product yield can be tailored by the catalyst design where the bimetallic Pd-Ga/13X preferably favours the hydrocarbon formation while H 2 is the dominant product obtained over the Pd/13X. The cleavage of C–H bonds of methane molecule over the plasma only route is mainly governed by energetic electrons in the gaseous phase the catalyst activity, and plasma-catalyst synergism play a significant role in the plasma catalysis process. Further, the findings from this work provide significant insights into the methane activation for subsequent optimization of the methane conversion processes operated on floating production, storage, and offloading vessels (FPSOVs). Exploiting untapped offshore natural gas reserves, where conventional pipeline systems are less economical.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Measurement of atomic oxygen densities using TALIF on a dielectric barrier discharge: insights into the volume above a micro cavity plasma array
Dielectric barrier discharges, particularly micro cavity plasma arrays, offer significant potential for plasma-catalytic research due to their ability to ignite plasma in direct contact with a catalytic surface, enabling the observation of plasma-surface interactions. A key factor in their application is the generation of reactive species, such as atomic oxygen, within the cavities. These species can interact with both the surface (e.g. for activation or cleaning) and the gas being treated (e.g. for oxidation). Given the central role of oxygen atoms in plasma catalysis and their use as a model for more complex species, this work investigates the transport of these atoms out of the cavities. Two-photon absorption laser-induced fluorescence spectroscopy with picosecond laser excitation is performed in the volume above the cavities. The results are compared with a basic diffusion model. The reactor operates with a He/O 2 mixture at a flow rate of 1 slm and atmospheric pressure. Densities of up to 10 16 cm -3 are measured near the surface. Time-dependent measurements show that, at a distance of 350 µm from the surface, a density equilibrium is reached within less than 3 ms of reactor operation. Decay times due to ozone formation after the reactor is turned off are on a similar scale. Spatially resolved measurements show that the oxygen density decreases exponentially from the surface but remains detectable up to approximately 1 mm above the surface, indicating significant application potential. Variations in the O 2 admixture show a density maximum at 0.4%, confirming previous helium state enhanced actinometry measurements within the cavities.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE Plasma Science Center - Predictive Control of Plasma Kinetics: Multi-Phase and Bounded Systems (Final Report DE-SC0001939)
Low temperature plasmas (LTPs) are the plasmas of electron-volt (eV) physics and eV technologies. LTPs have characteristic electron temperatures of a few eV and fractional ionizations that are typically small. Since LTPs have electron temperatures commensurate with the threshold energies of excited states in neutral atoms and molecules, power transfer from electrons to these atoms and molecules efficiently produces activated species (e.g., radicals, excited states, photons). Acceleration of ions in the sheaths of LTPs to energies of tens to hundreds of eV enable activation of surface modifying processes – sputtering, etching, deposition. With such properties, LTPs are often and beneficially used in technological devices, ranging from etching and deposition in microelectronics and solar cell fabrication, to hardening of surgical instruments. LTPs harbor fundamental science issues that are intellectually challenging and rewarding. At the same time, there are enormous societal benefits that are enabled by LTPs. The entire present-day and future information technology infrastructure owes its very existence to LTPs. Renewable energy sources, such as solar cell arrays, could not be economically produced in the absence of deposition and etching by LTPs. In acknowledgment of the importance of LTPs, the DOE Office of Fusion Energy Sciences supported the Plasma Science Center for Predictive Control of Plasma Kinetics: Multi-Phase and Bounded Systems from August 2009 to July 2021, consisting of an initial 5-year grant, 3 funded extensions and 2 no-cost extensions. This is the final report of the Center in which the productivity of the Center is discussed in terms of publications, impact and personnel. High-lights of the research performed in the Center are provided.
36 MATERIALS SCIENCE↗
Mechanistic aspects of plasma-enhanced catalytic methane decomposition by time-resolved operando diffuse reflectance infrared Fourier transform spectroscopy
To study mechanistic aspects of plasma-enhanced catalysis, methane is decomposed by a supported Ni catalyst assisted by an Ar/O 2 atmospheric pressure plasma jet (APPJ). Here, the time-resolved surface response of the Ni catalyst is investigated by operando diffuse reflectance infrared Fourier transform spectroscopy (DRIFTS) using various experimental settings. Catalyst temperatures of room temperature (RT) and 500 °C and nozzle-catalyst surface distances of 3, 5 and 8 mm were examined, and the amount of O 2 of the Ar/O 2 gas mixture flowing through the APPJ was either 0 or 0.5%. A synergistic effect of surface bonded C-O was observed during the exposure of the Ni catalyst to the APPJ for low oxygen operating conditions (pure Ar jet). Surface bonded C-O formed only when there was plasma present and the C-O signal was enhanced for higher catalyst temperature. When the supported Ni catalyst was subjected to the plasma-generated particle fluxes using highly oxidizing conditions, the presence of surface bonded C-O was suppressed. The plasma-catalytic CO and CO 2 production in the gas phase measured downstream mirrored the surface behavior of C-O bonds when the plasma source operating condition was changed from a low oxygen portion to a high oxygen portion at high catalyst temperature (500 °C). CH n (n =1, 2, ) species on the catalyst surface were also studied by DRIFTS, and CHn destruction was found to correlate with C-O formation. In particular, the time-resolved CH n response showed a possible conversion process of CH n to C-O when the Ni catalyst was exposed to the plasma source. This finding may indicate a plasma-mediated regeneration of the catalyst by plasma-catalyst surface interactions.
42 ENGINEERING↗