Decarbonizing Ammonia Production: A Comparative Study of Electrolysis and Plasmalysis

Strategic Insights -

Decarbonizing ammonia production is a critical step towards meeting global climate targets in agriculture. Researchers at the University of Windsor, Canada, have conducted a comprehensive study to evaluate the feasibility of two hydrogen pathways: plasmalysis and electrolysis. The study, supported by the Ontario Ministry of Agriculture, Food and Agribusiness (OMAFA), Canada, used detailed techno-economic modeling to analyze the performance of both pathways at the Courtright Complex.

Key Takeaways:

  • The natural gas-based plasma system achieves the lowest hydrogen cost ($1.35/kg) but incurs high annual fuel expenses ($297.7 M/y) and shows strong sensitivity to natural gas prices.
  • Electrolysis, powered by a renewable energy mix, produces hydrogen at $2.07/kg with lower fuel costs ($29.7 M/y) and significant grid interaction, enhancing operational flexibility.
  • Over a 15-year horizon, both pathways deliver substantial CO2 reductions, with plasmalysis reducing 27,000 kt and electrolysis reducing 26,045 kt of CO2.
  • Extending plant lifetimes from 10 to 30 y reduces the levelized cost of hydrogen from $2.25 to $1.91/kg in the plasmalysis case and from $1.52 to $1.18/kg in the electrolysis case.
  • Although electrolysis requires higher capital investment ($5.53 B compared with $1.79 B), it demonstrates resilience to fuel price volatility and provides additional grid revenue.
  • The research concluded that plasmalysis offers near-term cost advantages but remains dependent on fossil gas, underscoring its role as a transitional rather than fully green option for ammonia decarbonization.

Statistics:

  • $1.35/kg: Lowest hydrogen cost achieved by the natural gas-based plasma system
  • $2.35/kg: Highest hydrogen cost achieved by the electrolysis pathway
  • 27,000 kt: CO2 reductions achieved by the plasmalysis pathway over 15 years
  • 26,045 kt: CO2 reductions achieved by the electrolysis pathway over 15 years
  • 15 y: Horizon period for economic analysis
  • 10 y: Base plant lifetime
  • 30 y: Extended plant lifetime
  • $297.7 M/y: Annual fuel expenses incurred by the natural gas-based plasma system
  • $29.7 M/y: Annual fuel costs achieved by the electrolysis pathway
  • 2.67 TWh/y: Grid imports achieved by the electrolysis pathway
  • 1.89 TWh/y: Grid exports achieved by the electrolysis pathway
  • 5.53 B: Capital investment required for the electrolysis pathway
  • 1.79 B: Capital investment required for the plasmalysis pathway

Sources:

  • Hydrogen Pathways for Green Fertilizer Production: a Comparative Techno-economic Study of Electrolysis and Plasmalysis. International Journal of Hydrogen Energy, 2025;178.
  • International Journal of Hydrogen Energy can be contacted at: Pergamon-elsevier Science Ltd, The Boulevard, Langford Lane, Kidlington, Oxford OX5 1GB, England. (Elsevier - www.elsevier.com; International Journal of Hydrogen Energy - www.journals.elsevier.com/international-journal-of-hydrogen-energy/)
  • NewsRx. New Energy Data Have Been Reported by Researchers at University of Windsor (Hydrogen Pathways for Green Fertilizer Production: a Comparative Techno-economic Study of Electrolysis and Plasmalysis). Energy Weekly News. October 24, 2025; p 297.