A multidisciplinary team of researchers from the U.S. Department of Energy’s Princeton Plasma Physics Laboratory (PPPL), Oak Ridge National Laboratory, Princeton University, Rutgers University, and Rowan University has developed a new plasma-assisted catalyst that significantly improves ammonia synthesis efficiency. This work presents a promising alternative to conventional ammonia production methods, which typically require large-scale industrial facilities operating at high temperatures and pressures.
Zhang, Z., Kondratowicz, C., Smith, J., Kucheryavy, P., Ouyang, J., Xu, Y., Desmet, E., Kurdziel, S., Tang, E., Adeleke, M., Lele, A. D., Martirez, J. M., Chi, M., Ju, Y., & He, H. (2025). Plasma-Assisted Surface Nitridation of Proton Intercalatable WO 3 for Efficient Electrocatalytic Ammonia Synthesis. ACS Energy Letters, 10(7), 3349–3358. https://doi.org/10.1021/acsenergylett.5c01034
Ammonia plays a critical role in fertilizers and various industrial processes, and it is increasingly recognized as a practical medium for storing and transporting hydrogen. Hydrogen gas, while a clean energy carrier, presents challenges due to its low energy density and the difficulties associated with large-scale storage and transport. Converting hydrogen into ammonia allows it to be handled and moved more safely and efficiently, with the potential for on-demand conversion back to hydrogen at the point of use. The new plasma-assisted approach could enable decentralized ammonia production facilities, reducing both cost and logistical barriers.
Zhiyuan Zhang doctoral candidate at Rutgers University-Newark, stated,
“The process of producing this catalyst was reduced from approximately two days to 15 minutes”.
The innovation centers on a catalyst with a heterogeneous interfacial complexion (HIC) structure, composed of tungsten oxide and tungsten oxynitride. While the chemical components themselves are not new, the method of fabricating the catalyst using low-temperature plasma and controlling its structure in a scalable way is what sets this work apart. Plasma, often referred to as the fourth state of matter, consists of a mixture of neutral molecules and highly energetic electrons. In this system, the electrons carry enough energy to modify the surface of the catalyst, selectively removing or implanting hydrogen and nitrogen atoms. This process creates nitrogen vacancies and highly active hydrogen sites in the catalyst, which work together to convert nitrogen from the air into ammonia more efficiently than traditional thermal catalysis.
Compared with older methods, the plasma-assisted approach offers several advantages. The catalyst production time is dramatically reduced from approximately two days to just 15 minutes, while the overall ammonia yield is increased and the formation of unwanted side products, such as hydrogen gas, is minimized. In addition, the method allows the synthesis to occur at relatively low temperatures and pressures, lowering the energy requirements for ammonia production.
Simulations are playing a key role in understanding the underlying chemical mechanisms. Using advanced computational modeling, researchers can track atomic positions and interactions within the plasma environment, providing insights into how nitrogen and hydrogen atoms migrate and react on the catalyst surface. This detailed understanding is crucial for optimizing the catalyst structure and improving the overall efficiency of the process.
The broader implications of this research extend to energy storage and transportation. By enabling efficient ammonia production in smaller, more distributed facilities, this technology could help integrate hydrogen-based energy solutions into regions where large-scale infrastructure is impractical. The increased energy density and safer handling characteristics of ammonia make it an attractive option for transporting hydrogen over long distances, and plasma-assisted catalysis could play a pivotal role in establishing more sustainable and economically viable hydrogen energy networks.
Moving forward, the research team aims to refine the plasma-assisted catalyst and explore its application in light-activated reactions, which are essential for developing new photocatalysts. These advancements could further improve ammonia synthesis processes, expanding their relevance for both industrial and energy storage applications. Overall, this work demonstrates the potential of combining advanced materials design, plasma technology, and computational insights to tackle complex challenges in chemical manufacturing and energy management.
Adrian graduated with a Masters Degree (1st Class Honours) in Chemical Engineering from Chester University along with Harris. His master’s research aimed to develop a standardadised clean water oxygenation transfer procedure to test bubble diffusers that are currently used in the wastewater industry commercial market. He has also undergone placments in both US and China primarely focused within the R&D department and is an associate member of the Institute of Chemical Engineers (IChemE).
