UNSW researchers aim to turn industrial waste into low-emissions urea fertilizer

Australia relies heavily on imported urea to meet the needs of its agricultural sector, importing roughly 3.8 million tonnes in 2024. At the same time, the country faces growing pressure to reduce industrial emissions across multiple sectors. Researchers at the University of New South Wales are seeking to address both challenges by developing technology that converts waste carbon dioxide and nitrogen pollutants into urea fertilizer, potentially creating a domestic source of this essential agricultural input while reducing environmental impact.

From lab bench to industrial scale

Unlike typical fundamental research that concludes at the laboratory stage, the UNSW team is actively pursuing industrial-scale translation. The researchers are employing urea electrolysers, devices considered benchmarks for scalable urea production, to test the feasibility of converting emissions into fertilizer at a larger scale. To understand how the materials behave under real-world conditions, the team used advanced electron-beam characterization at the Australian Synchrotron. This technique allows them to observe chemical reactions in real time, generating critical data for future industrial implementation.

Dr. Daiyan, the project lead, emphasizes that careful catalyst engineering and real-time monitoring are essential for ensuring selectivity and efficiency, especially when scaling from controlled laboratory conditions to industrial environments.

Addressing Australia’s urea dependency

Despite being a major agricultural exporter, Australia does not produce sufficient urea domestically, leaving the sector vulnerable to global market fluctuations. “This dependence is a pity, as well as a strategic vulnerability,” Dr. Daiyan said. By producing clean urea locally from renewable electricity and waste carbon, the country could reduce import reliance and improve supply chain resilience. The approach also aligns with increasing regulatory scrutiny of emissions, which now extends beyond carbon dioxide to include other nitrogen-based pollutants.

The research highlights how circular chemistry principles can integrate waste streams from cement plants and agricultural residues into fertilizer production, turning environmental challenges into commercially valuable products.

The carbon capture and conversion approach

Unlike direct air capture technologies, the UNSW method focuses on using unavoidable emissions from industrial and biogenic sources. Early laboratory tests show promising results in selectivity, suggesting that CO₂ from existing industrial operations can be effectively transformed into urea. The project is still in development, but it represents a practical pathway for converting carbon and nitrogen pollutants into materials required in agriculture, chemicals, and fuel production.

Dr. Daiyan presented these findings at the United Nations Climate Change Conference, advocating for investments in circular economy solutions. “There’s enough carbon dioxide around. We just need to start thinking and investing in a circular economy,” he said.

Timeline and industrial outlook

Scaling a laboratory process to an industrial application typically takes over a decade, but the UNSW team aims to accelerate this timeline. Dr. Daiyan estimates that within two to three years, the project could secure an industry partner to begin pilot-scale trials. Success would demonstrate that emissions-intensive industries can generate value from their waste streams while simultaneously addressing environmental targets.

Ultimately, this research illustrates the potential of circular chemistry to reshape industrial production. By converting waste carbon and nitrogen into fertilizer, Australia could strengthen domestic supply chains, reduce emissions, and contribute to a more sustainable chemical sector. As Dr. Daiyan notes, “Thoughtful catalyst engineering paired with real-time characterization can turn environmental problems into opportunities.”

Sources: The National Tribune