Cement and steel are essential ingredients of buildings, cars, dams, bridges and skyscrapers. But these industries are among the dirtiest on the planet. Production of cement creates 2.3 billion tonnes of carbon dioxide per year, and making iron and steel releases some 2.6 billion tonnes -or 6.5% and 7.0% of global CO 2 emissions, respectively 1 .
Synthetic nitrogen fertilizers such as urea are a necessity for food production, making them invaluable toward achieving global food security. Conventional manufacture of urea is conducted in centralized production plants at an enormous scale, with the subsequent prilled urea product distributed to the point-of-use. Despite consuming carbon dioxide in the synthesis, the overall process is carbon positive due to the use of fossil feedstocks, resulting in significant net emissions. Blue Urea could be produced using attenuated reaction conditions and hydrogen derived from renewable-powered electrolysis to produce a reduced-carbon alternative. This paper demonstrates the intensified production of urea and ammonium nitrate fertilizers from sustainable feedstocks, namely water, nitrogen, and carbon dioxide. Critically, the process can be scaled-down such that equipment can be housed in a standardized ISO container deployed at the point-of-use, delocalizing production and eliminating costs, and emissions associated with transportation. The urea and ammonium nitrate were synthesized in a semi-continuous process under considerably milder conditions to produce aqueous fertilizers suitable for direct soil application, eliminating the financial and energetic costs associated with drying and prilling. The composition of the fertilizers from this process were found to be free from contaminants, making them ideal for application. In growth studies, the synthesized urea and ammonium nitrate were applied under controlled conditions and found to perform comparably to a commercial fertilizer (Nitram). Crucially, both the synthesized fertilizers enhanced biomass growth, nitrogen uptake and leaf chlorophylls (even in depleted soils), strongly suggesting they would be effective toward improving crop yields and agricultural output. The Blue Urea concept is proposed for installation in ISO containers and deployment on farms, offering a turnkey solution for point-of-need production of nitrogen fertilizers.
New insights have been gained into chemical transformations occurring in the initial stages of aerosol-assisted sol–gel (AASG) synthesis of catalysts. This has been achieved through the combined application of optical trapping and Raman spectroscopy. AASG is an emerging technology in catalyst manufacturing that presents numerous advantages over conventional approaches, including the ability to access unique catalyst morphologies. However, the processes occurring during synthesis are largely inferred from bulk-phase analyses due to challenges in conducting in situ or operando measurements on moving aerosols within a flow tube. Herein, these obstacles are overcome through Raman spectroscopic interrogation of a single aerosol droplet constrained within an optical trap, which acts as a direct analogue for a particle moving along a flow tube. These studies represent the first operando investigations of AASG synthesis. The synthesis of Ni/Al2O3 catalysts has been studied, with spectroscopic interrogation conducted on each component of the precursor synthesis solution, where possible, up to and including a mixture containing all components necessary for catalyst synthesis. Raman spectroscopy confirms the formation of stable self-assembled macrostructures within the aerosol and provides direct insights into the reaction mechanisms. Crucially, evidence was obtained allowing alternative reaction pathways to be postulated within the confined environment of an aerosol droplet in comparison to bulk-phase syntheses. In aerosols where nickel was not present, but contained all other components, isothermal room-temperature studies showed the formation of stable but unreactive droplets of ∼1 μm, which were proposed to contain micelle-type structures. Upon heating, initial gelation transformations were seen to be achieved at temperatures higher than ∼56 °C. Notably, little loss of spectral intensity corresponding to the C–H stretch (ethanol) was observed from the heated aerosol, implying that evaporation is not a prerequisite for the reaction. When nickel is present in the synthesis solution reactive transformations occur at room temperature, proposed to result in a continuous Al–O–Ni–NO3 structure; a more rapid transformation takes place at elevated temperatures. These results provide the first direct evidence of the processes occurring within aerosols during AASG and shed new light on the mechanistic understanding of this technology. This therefore facilitates the design of new synthetic approaches and hence the production of catalysts and other materials with enhanced properties.
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