Full runner electrolyzer stack for industrial-current-density NOx−-mediated ammonia synthesis from air and water

Wei Liu, Yang Lv, Honghui Ou (), Jiqiu Zhang, Yuxi Ren, Mengyang Xia, Yang Li, He Li, Xiaoling Ren, Huagui Hu and Guidong Yang ()
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Wei Liu: Xi’an Jiaotong University
Yang Lv: Xi’an Jiaotong University
Honghui Ou: Xi’an Jiaotong University
Jiqiu Zhang: Xi’an Jiaotong University
Yuxi Ren: Xi’an Jiaotong University
Mengyang Xia: Xi’an Jiaotong University
Yang Li: Xi’an Jiaotong University
He Li: Xi’an Jiaotong University
Xiaoling Ren: Xi’an Jiaotong University
Huagui Hu: China Energy Yulin Chemical Company
Guidong Yang: Xi’an Jiaotong University

Nature Communications, 2025, vol. 16, issue 1, 1-12

Abstract: Abstract Plasma-electrochemical tandem conversion with NOx− as intermediates promises a route for renewable ammonia (NH3) synthesis from air and water. However, a critical challenge lies in developing electrolyzers capable of operating efficiently at large current densities. Here, we present a scalable membrane electrode assembly electrolyzer with a full runner design (MEA-FR) that achieves efficient NH3 production at industrial current densities. Compared to conventional serpentine runner configuration, MEA-FR leveraging forced convection within porous electrodes achieves three-order-of-magnitude enhancement in NOx− mass transfer flux. This design, meanwhile, generates strong shear forces across the porous electrode, promoting rapid detachment of O2 bubbles at the anode and reducing overpotential losses. Notably, MEA-FR exhibits a high Faradaic efficiency of 91.8 ± 1.4% for NH3 synthesis at 500 mA cm−2, significantly outperforming the serpentine runner counterparts (64.9 ± 1.1%). Furthermore, a scaled-up 4 × 25 cm2 MEA-FR stack with four modular cells is assembled with rotationally symmetric bipolar plates, delivering high NOx− conversion efficiency (>95%), high Faradaic efficiency (>91%), and long-term stability (>200 h) under industrial-relevant current densities.

Date: 2025
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DOI: 10.1038/s41467-025-61069-6

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