Evelyn Reynolds

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    Machine learning, harnessed to extreme computing, aids fusion energy development

    MIT research scientists Pablo Rodriguez-Fernandez and Nathan Howard have just completed one of the most demanding calculations in fusion science — predicting the temperature and density profiles of a magnetically confined plasma via first-principles simulation of plasma turbulence. Solving this problem by brute force is beyond the capabilities of even the most advanced supercomputers. Instead, the researchers used an optimization methodology developed for machine learning to dramatically reduce the CPU time required while maintaining the accuracy of the solution.

    Fusion energyFusion offers the promise of unlimited, carbon-free energy through the same physical process that powers the sun and the stars. It requires heating the fuel to temperatures above 100 million degrees, well above the point where the electrons are stripped from their atoms, creating a form of matter called plasma. On Earth, researchers use strong magnetic fields to isolate and insulate the hot plasma from ordinary matter. The stronger the magnetic field, the better the quality of the insulation that it provides.

    Rodriguez-Fernandez and Howard have focused on predicting the performance expected in the SPARC device, a compact, high-magnetic-field fusion experiment, currently under construction by the MIT spin-out company Commonwealth Fusion Systems (CFS) and researchers from MIT’s Plasma Science and Fusion Center. While the calculation required an extraordinary amount of computer time, over 8 million CPU-hours, what was remarkable was not how much time was used, but how little, given the daunting computational challenge.

    The computational challenge of fusion energyTurbulence, which is the mechanism for most of the heat loss in a confined plasma, is one of the science’s grand challenges and the greatest problem remaining in classical physics. The equations that govern fusion plasmas are well known, but analytic solutions are not possible in the regimes of interest, where nonlinearities are important and solutions encompass an enormous range of spatial and temporal scales. Scientists resort to solving the equations by numerical simulation on computers. It is no accident that fusion researchers have been pioneers in computational physics for the last 50 years.

    One of the fundamental problems for researchers is reliably predicting plasma temperature and density given only the magnetic field configuration and the externally applied input power. In confinement devices like SPARC, the external power and the heat input from the fusion process are lost through turbulence in the plasma. The turbulence itself is driven by the difference in the extremely high temperature of the plasma core and the relatively cool temperatures of the plasma edge (merely a few million degrees). Predicting the performance of a self-heated fusion plasma therefore requires a calculation of the power balance between the fusion power input and the losses due to turbulence.

    These calculations generally start by assuming plasma temperature and density profiles at a particular location, then computing the heat transported locally by turbulence. However, a useful prediction requires a self-consistent calculation of the profiles across the entire plasma, which includes both the heat input and turbulent losses. Directly solving this problem is beyond the capabilities of any existing computer, so researchers have developed an approach that stitches the profiles together from a series of demanding but tractable local calculations. This method works, but since the heat and particle fluxes depend on multiple parameters, the calculations can be very slow to converge.

    However, techniques emerging from the field of machine learning are well suited to optimize just such a calculation. Starting with a set of computationally intensive local calculations run with the full-physics, first-principles CGYRO code (provided by a team from General Atomics led by Jeff Candy) Rodriguez-Fernandez and Howard fit a surrogate mathematical model, which was used to explore and optimize a search within the parameter space. The results of the optimization were compared to the exact calculations at each optimum point, and the system was iterated to a desired level of accuracy. The researchers estimate that the technique reduced the number of runs of the CGYRO code by a factor of four.

    New approach increases confidence in predictionsThis work, described in a recent publication in the journal Nuclear Fusion, is the highest fidelity calculation ever made of the core of a fusion plasma. It refines and confirms predictions made with less demanding models. Professor Jonathan Citrin, of the Eindhoven University of Technology and leader of the fusion modeling group for DIFFER, the Dutch Institute for Fundamental Energy Research, commented: “The work significantly accelerates our capabilities in more routinely performing ultra-high-fidelity tokamak scenario prediction. This algorithm can help provide the ultimate validation test of machine design or scenario optimization carried out with faster, more reduced modeling, greatly increasing our confidence in the outcomes.” 

    In addition to increasing confidence in the fusion performance of the SPARC experiment, this technique provides a roadmap to check and calibrate reduced physics models, which run with a small fraction of the computational power. Such models, cross-checked against the results generated from turbulence simulations, will provide a reliable prediction before each SPARC discharge, helping to guide experimental campaigns and improving the scientific exploitation of the device. It can also be used to tweak and improve even simple data-driven models, which run extremely quickly, allowing researchers to sift through enormous parameter ranges to narrow down possible experiments or possible future machines.

    The research was funded by CFS, with computational support from the National Energy Research Scientific Computing Center, a U.S. Department of Energy Office of Science User Facility. More

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    Using excess heat to improve electrolyzers and fuel cells

    Reducing the use of fossil fuels will have unintended consequences for the power-generation industry and beyond. For example, many industrial chemical processes use fossil-fuel byproducts as precursors to things like asphalt, glycerine, and other important chemicals. One solution to reduce the impact of the loss of fossil fuels on industrial chemical processes is to store and use the heat that nuclear fission produces. New MIT research has dramatically improved a way to put that heat toward generating chemicals through a process called electrolysis. 

    Electrolyzers are devices that use electricity to split water (H2O) and generate molecules of hydrogen (H2) and oxygen (O2). Hydrogen is used in fuel cells to generate electricity and drive electric cars or drones or in industrial operations like the production of steel, ammonia, and polymers. Electrolyzers can also take in water and carbon dioxide (CO2) and produce oxygen and ethylene (C2H4), a chemical used in polymers and elsewhere.

    There are three main types of electrolyzers. One type works at room temperature, but has downsides; they’re inefficient and require rare metals, such as platinum. A second type is more efficient but runs at high temperatures, above 700 degrees Celsius. But metals corrode at that temperature, and the devices need expensive sealing and insulation. The third type would be a Goldilocks solution for nuclear heat if it were perfected, running at 300-600 C and requiring mostly cheap materials like stainless steel. These cells have never been operated as efficiently as theory says they should. The new work, published this month in Nature, both illuminates the problem and offers a solution.

    A sandwich mystery

    The intermediate-temperature devices use what are called protonic ceramic electrochemical cells. Each cell is a sandwich, with a dense electrolyte layered between two porous electrodes. Water vapor is pumped into the top electrode. A wire on the side connects the two electrodes, and externally generated electricity runs from the top to the bottom. The voltage pulls electrons out of the water, which splits the molecule, releasing oxygen. A hydrogen atom without an electron is just a proton. The protons get pulled through the electrolyte to rejoin with the electrons at the bottom electrode and form H2 molecules, which are then collected.

    On its own, the electrolyte in the middle, made mainly of barium, cerium, and zirconium, conducts protons very well. “But when we put the same material into this three-layer device, the proton conductivity of the full cell is pretty bad,” says Yanhao Dong, a postdoc in MIT’s Department of Nuclear Science and Engineering and a paper co-author. “Its conductivity is only about 50 percent of the bulk form’s. We wondered why there’s an inconsistency here.”

    A couple of clues pointed them in the right direction. First, if they don’t prepare the cell very carefully, the top layer, only about 20 microns (.02 millimeters) thick, doesn’t stay attached. “Sometimes if you use just Scotch tape, it will peel off,” Dong says. Second, when they looked at a cross section of a device using a scanning electron microscope, they saw that the top surface of the electrolyte layer was flat, whereas the bottom surface of the porous electrode sitting on it was bumpy, and the two came into contact in only a few places. They didn’t bond well. That precarious interface leads to both structural de-lamination and poor proton passage from the electrode to the electrolyte.

    Acidic solution

    The solution turned out to be simple: researchers roughed up the top of the electrolyte. Specifically, they applied acid for 10 minutes, which etched grooves into the surface. Ju Li, the Battelle Energy Alliance Professor in Nuclear Engineering and professor of materials science and engineering at MIT, and a paper co-author, likens it to sandblasting a surface before applying paint to increase adhesion. Their acid-treated cells produced about 200 percent more hydrogen per area at 1.5 volts at 600 C than did any previous cell of its type, and worked well down to 350 C with very little performance decay over extended operation. 

    “The authors reported a surprisingly simple yet highly effective surface treatment to dramatically improve the interface,” says Liangbing Hu, the director of the Center for Materials Innovation at the Maryland Energy Innovation Institute, who was not involved in the work. He calls the cell performance “exceptional.”

    “We are excited and surprised” by the results, Dong says. “The engineering solution seems quite simple. And that’s actually good, because it makes it very applicable to real applications.” In a practical product, many such cells would be stacked together to form a module. MIT’s partner in the project, Idaho National Laboratory, is very strong in engineering and prototyping, so Li expects to see electrolyzers based on this technology at scale before too long. “At the materials level, this is a breakthrough that shows that at a real-device scale you can work at this sweet spot of temperature of 350 to 600 degrees Celsius for nuclear fission and fusion reactors,” he says.

    “Reduced operating temperature enables cheaper materials for the large-scale assembly, including the stack,” says Idaho National Laboratory researcher and paper co-author Dong Ding. “The technology operates within the same temperature range as several important, current industrial processes, including ammonia production and CO2 reduction. Matching these temperatures will expedite the technology’s adoption within the existing industry.”

    “This is very significant for both Idaho National Lab and us,” Li adds, “because it bridges nuclear energy and renewable electricity.” He notes that the technology could also help fuel cells, which are basically electrolyzers run in reverse, using green hydrogen or hydrocarbons to generate electricity. According to Wei Wu, a materials scientist at Idaho National Laboratory and a paper co-author, “this technique is quite universal and compatible with other solid electrochemical devices.”

    Dong says it’s rare for a paper to advance both science and engineering to such a degree. “We are happy to combine those together and get both very good scientific understanding and also very good real-world performance.”

    This work, done in collaboration with Idaho National Laboratory, New Mexico State University, and the University of Nebraska–Lincoln, was funded, in part, by the U.S. Department of Energy. More

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    What choices does the world need to make to keep global warming below 2 C?

    When the 2015 Paris Agreement set a long-term goal of keeping global warming “well below 2 degrees Celsius, compared to pre-industrial levels” to avoid the worst impacts of climate change, it did not specify how its nearly 200 signatory nations could collectively achieve that goal. Each nation was left to its own devices to reduce greenhouse gas emissions in alignment with the 2 C target. Now a new modeling strategy developed at the MIT Joint Program on the Science and Policy of Global Change that explores hundreds of potential future development pathways provides new insights on the energy and technology choices needed for the world to meet that target.

    Described in a study appearing in the journal Earth’s Future, the new strategy combines two well-known computer modeling techniques to scope out the energy and technology choices needed over the coming decades to reduce emissions sufficiently to achieve the Paris goal.

    The first technique, Monte Carlo analysis, quantifies uncertainty levels for dozens of energy and economic indicators including fossil fuel availability, advanced energy technology costs, and population and economic growth; feeds that information into a multi-region, multi-economic-sector model of the world economy that captures the cross-sectoral impacts of energy transitions; and runs that model hundreds of times to estimate the likelihood of different outcomes. The MIT study focuses on projections through the year 2100 of economic growth and emissions for different sectors of the global economy, as well as energy and technology use.

    The second technique, scenario discovery, uses machine learning tools to screen databases of model simulations in order to identify outcomes of interest and their conditions for occurring. The MIT study applies these tools in a unique way by combining them with the Monte Carlo analysis to explore how different outcomes are related to one another (e.g., do low-emission outcomes necessarily involve large shares of renewable electricity?). This approach can also identify individual scenarios, out of the hundreds explored, that result in specific combinations of outcomes of interest (e.g., scenarios with low emissions, high GDP growth, and limited impact on electricity prices), and also provide insight into the conditions needed for that combination of outcomes.

    Using this unique approach, the MIT Joint Program researchers find several possible patterns of energy and technology development under a specified long-term climate target or economic outcome.

    “This approach shows that there are many pathways to a successful energy transition that can be a win-win for the environment and economy,” says Jennifer Morris, an MIT Joint Program research scientist and the study’s lead author. “Toward that end, it can be used to guide decision-makers in government and industry to make sound energy and technology choices and avoid biases in perceptions of what ’needs’ to happen to achieve certain outcomes.”

    For example, while achieving the 2 C goal, the global level of combined wind and solar electricity generation by 2050 could be less than three times or more than 12 times the current level (which is just over 2,000 terawatt hours). These are very different energy pathways, but both can be consistent with the 2 C goal. Similarly, there are many different energy mixes that can be consistent with maintaining high GDP growth in the United States while also achieving the 2 C goal, with different possible roles for renewables, natural gas, carbon capture and storage, and bioenergy. The study finds renewables to be the most robust electricity investment option, with sizable growth projected under each of the long-term temperature targets explored.

    The researchers also find that long-term climate targets have little impact on economic output for most economic sectors through 2050, but do require each sector to significantly accelerate reduction of its greenhouse gas emissions intensity (emissions per unit of economic output) so as to reach near-zero levels by midcentury.

    “Given the range of development pathways that can be consistent with meeting a 2 degrees C goal, policies that target only specific sectors or technologies can unnecessarily narrow the solution space, leading to higher costs,” says former MIT Joint Program Co-Director John Reilly, a co-author of the study. “Our findings suggest that policies designed to encourage a portfolio of technologies and sectoral actions can be a wise strategy that hedges against risks.”

    The research was supported by the U.S. Department of Energy Office of Science. More

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    At Climate Grand Challenges showcase event, an exploration of how to accelerate breakthrough solutions

    On the eve of Earth Day, more than 300 faculty, researchers, students, government officials, and industry leaders gathered in the Samberg Conference Center, along with thousands more who tuned in online, to celebrate MIT’s first-ever Climate Grand Challenges and the five most promising concepts to emerge from the two-year competition.

    The event began with a climate policy conversation between MIT President L. Rafael Reif and Special Presidential Envoy for Climate John Kerry, followed by presentations from each of the winning flagship teams, and concluded with an expert panel that explored pathways for moving from ideas to impact at scale as quickly as possible.

    “In 2020, when we launched the Climate Grand Challenges, we wanted to focus the daring creativity and pioneering expertise of the MIT community on the urgent problem of climate change,” said President Reif in kicking off the event. “Together these flagship projects will define a transformative new research agenda at MIT, one that has the potential to make meaningful contributions to the global climate response.”

    Reif and Kerry discussed multiple aspects of the climate crisis, including mitigation, adaptation, and the policies and strategies that can help the world avert the worst consequences of climate change and make the United States a leader again in bringing technology into commercial use. Referring to the accelerated wartime research effort that helped turn the tide in World War II, which included work conducted at MIT, Kerry said, “We need about five Manhattan Projects, frankly.”

    “People are now sensing a much greater urgency to finding solutions — new technology — and taking to scale some of the old technologies,” Kerry said. “There are things that are happening that I think are exciting, but the problem is it’s not happening fast enough.”

    Strategies for taking technology from the lab to the marketplace were the basis for the final portion of the event. The panel was moderated by Alicia Barton, president and CEO of FirstLight Power, and included Manish Bapna, president and CEO of the Natural Resources Defense Council; Jack Little, CEO and co-founder of MathWorks; Arati Prabhakar, president of Actuate and former head of the Defense Advanced Research Projects Agency; and Katie Rae, president and managing director of The Engine. The discussion touched upon the importance of marshaling the necessary resources and building the cross-sector partnerships required to scale the technologies being developed by the flagship teams and to deliver them to the world in time to make a difference. 

    “MIT doesn’t sit on its hands ever, and innovation is central to its founding,” said Rae. “The students coming out of MIT at every level, along with the professors, have been committed to these challenges for a long time and therefore will have a big impact. These flagships have always been in process, but now we have an extraordinary moment to commercialize these projects.”

    The panelists weighed in on how to change the mindset around finance, policy, business, and community adoption to scale massive shifts in energy generation, transportation, and other major carbon-emitting industries. They stressed the importance of policies that address the economic, equity, and public health impacts of climate change and of reimagining supply chains and manufacturing to grow and distribute these technologies quickly and affordably. 

    “We are embarking on five adventures, but we do not know yet, cannot know yet, where these projects will take us,” said Maria Zuber, MIT’s vice president for research. “These are powerful and promising ideas. But each one will require focused effort, creative and interdisciplinary teamwork, and sustained commitment and support if they are to become part of the climate and energy revolution that the world urgently needs. This work begins now.” 

    Zuber called for investment from philanthropists and financiers, and urged companies, governments, and others to join this all-of-humanity effort. Associate Provost for International Activities Richard Lester echoed this message in closing the event. 

    “Every one of us needs to put our shoulder to the wheel at the points where our leverage is maximized — where we can do what we’re best at,” Lester said. “For MIT, Climate Grand Challenges is one of those maximum leverage points.” More

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    Developing electricity-powered, low-emissions alternatives to carbon-intensive industrial processes

    On April 11, 2022, MIT announced five multiyear flagship projects in the first-ever Climate Grand Challenges, a new initiative to tackle complex climate problems and deliver breakthrough solutions to the world as quickly as possible. This is the second article in a five-part series highlighting the most promising concepts to emerge from the competition, and the interdisciplinary research teams behind them.

    One of the biggest leaps that humankind could take to drastically lower greenhouse gas emissions globally would be the complete decarbonization of industry. But without finding low-cost, environmentally friendly substitutes for industrial materials, the traditional production of steel, cement, ammonia, and ethylene will continue pumping out billions of tons of carbon annually; these sectors alone are responsible for at least one third of society’s global greenhouse gas emissions. 

    A major problem is that industrial manufacturers, whose success depends on reliable, cost-efficient, and large-scale production methods, are too heavily invested in processes that have historically been powered by fossil fuels to quickly switch to new alternatives. It’s a machine that kicked on more than 100 years ago, and which MIT electrochemical engineer Yet-Ming Chiang says we can’t shut off without major disruptions to the world’s massive supply chain of these materials. What’s needed, Chiang says, is a broader, collaborative clean energy effort that takes “targeted fundamental research, all the way through to pilot demonstrations that greatly lowers the risk for adoption of new technology by industry.”

    This would be a new approach to decarbonization of industrial materials production that relies on largely unexplored but cleaner electrochemical processes. New production methods could be optimized and integrated into the industrial machine to make it run on low-cost, renewable electricity in place of fossil fuels. 

    Recognizing this, Chiang, the Kyocera Professor in the Department of Materials Science and Engineering, teamed with research collaborator Bilge Yildiz, the Breene M. Kerr Professor of Nuclear Science and Engineering and professor of materials science and engineering, with key input from Karthish Manthiram, visiting professor in the Department of Chemical Engineering, to submit a project proposal to the MIT Climate Grand Challenges. Their plan: to create an innovation hub on campus that would bring together MIT researchers individually investigating decarbonization of steel, cement, ammonia, and ethylene under one roof, combining research equipment and directly collaborating on new methods to produce these four key materials.

    Many researchers across MIT have already signed on to join the effort, including Antoine Allanore, associate professor of metallurgy, who specializes in the development of sustainable materials and manufacturing processes, and Elsa Olivetti, the Esther and Harold E. Edgerton Associate Professor in the Department of Materials Science and Engineering, who is an expert in materials economics and sustainability. Other MIT faculty currently involved include Fikile Brushett, Betar Gallant, Ahmed Ghoniem, William Green, Jeffrey Grossman, Ju Li, Yuriy Román-Leshkov, Yang Shao-Horn, Robert Stoner, Yogesh Surendranath, Timothy Swager, and Kripa Varanasi.

    “The team we brought together has the expertise needed to tackle these challenges, including electrochemistry — using electricity to decarbonize these chemical processes — and materials science and engineering, process design and scale-up technoeconomic analysis, and system integration, which is all needed for this to go out from our labs to the field,” says Yildiz.

    Selected from a field of more than 100 proposals, their Center for Electrification and Decarbonization of Industry (CEDI) will be the first such institute worldwide dedicated to testing and scaling the most innovative and promising technologies in sustainable chemicals and materials. CEDI will work to facilitate rapid translation of lab discoveries into affordable, scalable industry solutions, with potential to offset as much as 15 percent of greenhouse gas emissions. The team estimates that some CEDI projects already underway could be commercialized within three years.

    “The real timeline is as soon as possible,” says Chiang.

    To achieve CEDI’s ambitious goals, a physical location is key, staffed with permanent faculty, as well as undergraduates, graduate students, and postdocs. Yildiz says the center’s success will depend on engaging student researchers to carry forward with research addressing the biggest ongoing challenges to decarbonization of industry.

    “We are training young scientists, students, on the learned urgency of the problem,” says Yildiz. “We empower them with the skills needed, and even if an individual project does not find the implementation in the field right away, at least, we would have trained the next generation that will continue to go after them in the field.”

    Chiang’s background in electrochemistry showed him how the efficiency of cement production could benefit from adopting clean electricity sources, and Yildiz’s work on ethylene, the source of plastic and one of industry’s most valued chemicals, has revealed overlooked cost benefits to switching to electrochemical processes with less expensive starting materials. With industry partners, they hope to continue these lines of fundamental research along with Allanore, who is focused on electrifying steel production, and Manthiram, who is developing new processes for ammonia. Olivetti will focus on understanding risks and barriers to implementation. This multilateral approach aims to speed up the timeline to industry adoption of new technologies at the scale needed for global impact.

    “One of the points of emphasis in this whole center is going to be applying technoeconomic analysis of what it takes to be successful at a technical and economic level, as early in the process as possible,” says Chiang.

    The impact of large-scale industry adoption of clean energy sources in these four key areas that CEDI plans to target first would be profound, as these sectors are currently responsible for 7.5 billion tons of emissions annually. There is the potential for even greater impact on emissions as new knowledge is applied to other industrial products beyond the initial four targets of steel, cement, ammonia, and ethylene. Meanwhile, the center will stand as a hub to attract new industry, government stakeholders, and research partners to collaborate on urgently needed solutions, both newly arising and long overdue.

    When Chiang and Yildiz first met to discuss ideas for MIT Climate Grand Challenges, they decided they wanted to build a climate research center that functioned unlike any other to help pivot large industry toward decarbonization. Beyond considering how new solutions will impact industry’s bottom line, CEDI will also investigate unique synergies that could arise from the electrification of industry, like processes that would create new byproducts that could be the feedstock to other industry processes, reducing waste and increasing efficiencies in the larger system. And because industry is so good at scaling, those added benefits would be widespread, finally replacing century-old technologies with critical updates designed to improve production and markedly reduce industry’s carbon footprint sooner rather than later.

    “Everything we do, we’re going to try to do with urgency,” Chiang says. “The fundamental research will be done with urgency, and the transition to commercialization, we’re going to do with urgency.” More

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    Engineers enlist AI to help scale up advanced solar cell manufacturing

    Perovskites are a family of materials that are currently the leading contender to potentially replace today’s silicon-based solar photovoltaics. They hold the promise of panels that are far thinner and lighter, that could be made with ultra-high throughput at room temperature instead of at hundreds of degrees, and that are cheaper and easier to transport and install. But bringing these materials from controlled laboratory experiments into a product that can be manufactured competitively has been a long struggle.

    Manufacturing perovskite-based solar cells involves optimizing at least a dozen or so variables at once, even within one particular manufacturing approach among many possibilities. But a new system based on a novel approach to machine learning could speed up the development of optimized production methods and help make the next generation of solar power a reality.

    The system, developed by researchers at MIT and Stanford University over the last few years, makes it possible to integrate data from prior experiments, and information based on personal observations by experienced workers, into the machine learning process. This makes the outcomes more accurate and has already led to the manufacturing of perovskite cells with an energy conversion efficiency of 18.5 percent, a competitive level for today’s market.

    The research is reported today in the journal Joule, in a paper by MIT professor of mechanical engineering Tonio Buonassisi, Stanford professor of materials science and engineering Reinhold Dauskardt, recent MIT research assistant Zhe Liu, Stanford doctoral graduate Nicholas Rolston, and three others.

    Perovskites are a group of layered crystalline compounds defined by the configuration of the atoms in their crystal lattice. There are thousands of such possible compounds and many different ways of making them. While most lab-scale development of perovskite materials uses a spin-coating technique, that’s not practical for larger-scale manufacturing, so companies and labs around the world have been searching for ways of translating these lab materials into a practical, manufacturable product.

    “There’s always a big challenge when you’re trying to take a lab-scale process and then transfer it to something like a startup or a manufacturing line,” says Rolston, who is now an assistant professor at Arizona State University. The team looked at a process that they felt had the greatest potential, a method called rapid spray plasma processing, or RSPP.

    The manufacturing process would involve a moving roll-to-roll surface, or series of sheets, on which the precursor solutions for the perovskite compound would be sprayed or ink-jetted as the sheet rolled by. The material would then move on to a curing stage, providing a rapid and continuous output “with throughputs that are higher than for any other photovoltaic technology,” Rolston says.

    “The real breakthrough with this platform is that it would allow us to scale in a way that no other material has allowed us to do,” he adds. “Even materials like silicon require a much longer timeframe because of the processing that’s done. Whereas you can think of [this approach as more] like spray painting.”

    Within that process, at least a dozen variables may affect the outcome, some of them more controllable than others. These include the composition of the starting materials, the temperature, the humidity, the speed of the processing path, the distance of the nozzle used to spray the material onto a substrate, and the methods of curing the material. Many of these factors can interact with each other, and if the process is in open air, then humidity, for example, may be uncontrolled. Evaluating all possible combinations of these variables through experimentation is impossible, so machine learning was needed to help guide the experimental process.

    But while most machine-learning systems use raw data such as measurements of the electrical and other properties of test samples, they don’t typically incorporate human experience such as qualitative observations made by the experimenters of the visual and other properties of the test samples, or information from other experiments reported by other researchers. So, the team found a way to incorporate such outside information into the machine learning model, using a probability factor based on a mathematical technique called Bayesian Optimization.

    Using the system, he says, “having a model that comes from experimental data, we can find out trends that we weren’t able to see before.” For example, they initially had trouble adjusting for uncontrolled variations in humidity in their ambient setting. But the model showed them “that we could overcome our humidity challenges by changing the temperature, for instance, and by changing some of the other knobs.”

    The system now allows experimenters to much more rapidly guide their process in order to optimize it for a given set of conditions or required outcomes. In their experiments, the team focused on optimizing the power output, but the system could also be used to simultaneously incorporate other criteria, such as cost and durability — something members of the team are continuing to work on, Buonassisi says.

    The researchers were encouraged by the Department of Energy, which sponsored the work, to commercialize the technology, and they’re currently focusing on tech transfer to existing perovskite manufacturers. “We are reaching out to companies now,” Buonassisi says, and the code they developed has been made freely available through an open-source server. “It’s now on GitHub, anyone can download it, anyone can run it,” he says. “We’re happy to help companies get started in using our code.”

    Already, several companies are gearing up to produce perovskite-based solar panels, even though they are still working out the details of how to produce them, says Liu, who is now at the Northwestern Polytechnical University in Xi’an, China. He says companies there are not yet doing large-scale manufacturing, but instead starting with smaller, high-value applications such as building-integrated solar tiles where appearance is important. Three of these companies “are on track or are being pushed by investors to manufacture 1 meter by 2-meter rectangular modules [comparable to today’s most common solar panels], within two years,” he says.

    ‘The problem is, they don’t have a consensus on what manufacturing technology to use,” Liu says. The RSPP method, developed at Stanford, “still has a good chance” to be competitive, he says. And the machine learning system the team developed could prove to be important in guiding the optimization of whatever process ends up being used.

    “The primary goal was to accelerate the process, so it required less time, less experiments, and less human hours to develop something that is usable right away, for free, for industry,” he says.

    “Existing work on machine-learning-driven perovskite PV fabrication largely focuses on spin-coating, a lab-scale technique,” says Ted Sargent, University Professor at the University of Toronto, who was not associated with this work, which he says demonstrates “a workflow that is readily adapted to the deposition techniques that dominate the thin-film industry. Only a handful of groups have the simultaneous expertise in engineering and computation to drive such advances.” Sargent adds that this approach “could be an exciting advance for the manufacture of a broader family of materials” including LEDs, other PV technologies, and graphene, “in short, any industry that uses some form of vapor or vacuum deposition.” 

    The team also included Austin Flick and Thomas Colburn at Stanford and Zekun Ren at the Singapore-MIT Alliance for Science and Technology (SMART). In addition to the Department of Energy, the work was supported by a fellowship from the MIT Energy Initiative, the Graduate Research Fellowship Program from the National Science Foundation, and the SMART program. More

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    A new heat engine with no moving parts is as efficient as a steam turbine

    Engineers at MIT and the National Renewable Energy Laboratory (NREL) have designed a heat engine with no moving parts. Their new demonstrations show that it converts heat to electricity with over 40 percent efficiency — a performance better than that of traditional steam turbines.

    The heat engine is a thermophotovoltaic (TPV) cell, similar to a solar panel’s photovoltaic cells, that passively captures high-energy photons from a white-hot heat source and converts them into electricity. The team’s design can generate electricity from a heat source of between 1,900 to 2,400 degrees Celsius, or up to about 4,300 degrees Fahrenheit.

    The researchers plan to incorporate the TPV cell into a grid-scale thermal battery. The system would absorb excess energy from renewable sources such as the sun and store that energy in heavily insulated banks of hot graphite. When the energy is needed, such as on overcast days, TPV cells would convert the heat into electricity, and dispatch the energy to a power grid.

    With the new TPV cell, the team has now successfully demonstrated the main parts of the system in separate, small-scale experiments. They are working to integrate the parts to demonstrate a fully operational system. From there, they hope to scale up the system to replace fossil-fuel-driven power plants and enable a fully decarbonized power grid, supplied entirely by renewable energy.

    “Thermophotovoltaic cells were the last key step toward demonstrating that thermal batteries are a viable concept,” says Asegun Henry, the Robert N. Noyce Career Development Professor in MIT’s Department of Mechanical Engineering. “This is an absolutely critical step on the path to proliferate renewable energy and get to a fully decarbonized grid.”

    Henry and his collaborators have published their results today in the journal Nature. Co-authors at MIT include Alina LaPotin, Kevin Schulte, Kyle Buznitsky, Colin Kelsall, Andrew Rohskopf, and Evelyn Wang, the Ford Professor of Engineering and head of the Department of Mechanical Engineering, along with collaborators at NREL in Golden, Colorado.

    Jumping the gap

    More than 90 percent of the world’s electricity comes from sources of heat such as coal, natural gas, nuclear energy, and concentrated solar energy. For a century, steam turbines have been the industrial standard for converting such heat sources into electricity.

    On average, steam turbines reliably convert about 35 percent of a heat source into electricity, with about 60 percent representing the highest efficiency of any heat engine to date. But the machinery depends on moving parts that are temperature- limited. Heat sources higher than 2,000 degrees Celsius, such as Henry’s proposed thermal battery system, would be too hot for turbines.

    In recent years, scientists have looked into solid-state alternatives — heat engines with no moving parts, that could potentially work efficiently at higher temperatures.

    “One of the advantages of solid-state energy converters are that they can operate at higher temperatures with lower maintenance costs because they have no moving parts,” Henry says. “They just sit there and reliably generate electricity.”

    Thermophotovoltaic cells offered one exploratory route toward solid-state heat engines. Much like solar cells, TPV cells could be made from semiconducting materials with a particular bandgap — the gap between a material’s valence band and its conduction band. If a photon with a high enough energy is absorbed by the material, it can kick an electron across the bandgap, where the electron can then conduct, and thereby generate electricity — doing so without moving rotors or blades.

    To date, most TPV cells have only reached efficiencies of around 20 percent, with the record at 32 percent, as they have been made of relatively low-bandgap materials that convert lower-temperature, low-energy photons, and therefore convert energy less efficiently.

    Catching light

    In their new TPV design, Henry and his colleagues looked to capture higher-energy photons from a higher-temperature heat source, thereby converting energy more efficiently. The team’s new cell does so with higher-bandgap materials and multiple junctions, or material layers, compared with existing TPV designs.

    The cell is fabricated from three main regions: a high-bandgap alloy, which sits over a slightly lower-bandgap alloy, underneath which is a mirror-like layer of gold. The first layer captures a heat source’s highest-energy photons and converts them into electricity, while lower-energy photons that pass through the first layer are captured by the second and converted to add to the generated voltage. Any photons that pass through this second layer are then reflected by the mirror, back to the heat source, rather than being absorbed as wasted heat.

    The team tested the cell’s efficiency by placing it over a heat flux sensor — a device that directly measures the heat absorbed from the cell. They exposed the cell to a high-temperature lamp and concentrated the light onto the cell. They then varied the bulb’s intensity, or temperature, and observed how the cell’s power efficiency — the amount of power it produced, compared with the heat it absorbed — changed with temperature. Over a range of 1,900 to 2,400 degrees Celsius, the new TPV cell maintained an efficiency of around 40 percent.

    “We can get a high efficiency over a broad range of temperatures relevant for thermal batteries,” Henry says.

    The cell in the experiments is about a square centimeter. For a grid-scale thermal battery system, Henry envisions the TPV cells would have to scale up to about 10,000 square feet (about a quarter of a football field), and would operate in climate-controlled warehouses to draw power from huge banks of stored solar energy. He points out that an infrastructure exists for making large-scale photovoltaic cells, which could also be adapted to manufacture TPVs.

    “There’s definitely a huge net positive here in terms of sustainability,” Henry says. “The technology is safe, environmentally benign in its life cycle, and can have a tremendous impact on abating carbon dioxide emissions from electricity production.”

    This research was supported, in part, by the U.S. Department of Energy. More

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    Embracing ancient materials and 21st-century challenges

    When Sophia Mittman was 10 years old, she wanted to be an artist. But instead of using paint, she preferred the mud in her backyard. She sculpted it into pots and bowls like the ones she had seen at the archaeological museums, transforming the earthly material into something beautiful.

    Now an MIT senior studying materials science and engineering, Mittman seeks modern applications for sustainable materials in ways that benefit the community around her.

    Growing up in San Diego, California, Mittman was homeschooled, and enjoyed the process of teaching herself new things. After taking a pottery class in seventh grade, she became interested in sculpture, teaching herself how to make fused glass. From there, Mittman began making pottery and jewelry. This passion to create new things out of sustainable materials led her to pursue materials science, a subject she didn’t even know was originally offered at the Institute.

    “I didn’t know the science behind why those materials had the properties they did. And materials science explained it,” she says.

    During her first year at MIT, Mittman took 2.00b (Toy Product Design), which she considers one of her most memorable classes at the Institute. She remembers learning about the mechanical side of building, using drill presses and sanding machines to create things. However, her favorite part was the seminars on the weekends, where she learned how to make things such as stuffed animals or rolling wooden toys. She appreciated the opportunity to learn how to use everyday materials like wood to construct new and exciting gadgets.

    From there, Mittman got involved in the Glass Club, using blowtorches to melt rods of glass to make things like marbles and little fish decorations. She also took a few pottery and ceramics classes on campus, learning how to hone her skills to craft new things. Understanding MIT’s hands-on approach to learning, Mittman was excited to use her newly curated skills in the various workshops on campus to apply them to the real world.

    In the summer after her first year, Mittman became an undergraduate field and conservation science researcher for the Department of Civil and Environmental Engineering. She traveled to various cities across Italy to collaborate with international art restorers, conservation scientists, and museum curators to study archaeological materials and their applications to modern sustainability. One of her favorite parts was restoring the Roman baths, and studying the mosaics on the ground. She did a research project on Egyptian Blue, one of the first synthetic pigments, which has modern applications because of its infrared luminescence, which can be used for detecting fingerprints in crime scenes. The experience was eye-opening for Mittman; she got to directly experience what she had been learning in the classroom about sustainable materials and how she could preserve and use them for modern applications.

    The next year, upon returning to campus, Mittman joined Incredible Foods as a polymeric food science and technology intern. She learned how to create and apply a polymer coating to natural fruit snacks to replicate real berries. “It was fun to see the breadth of material science because I had learned about polymers in my material science classes, but then never thought that it could be applied to making something as fun as fruit snacks,” she says.

    Venturing into yet another new area of materials science, Mittman last year pursued an internship with Phoenix Tailings, which aims to be the world’s first “clean” mining company. In the lab, she helped develop and analyze chemical reactions to physically and chemically extract rare earth metals and oxides from mining waste. She also worked to engineer bright-colored, high-performance pigments using nontoxic chemicals. Mittman enjoyed the opportunity to explore a mineralogically sustainable method for mining, something she hadn’t previously explored as a branch of materials science research.

    “I’m still able to contribute to environmental sustainability and to try to make a greener world, but it doesn’t solely have to be through energy because I’m dealing with dirt and mud,” she says.

    Outside of her academic work, Mittman is involved with the Tech Catholic Community (TCC) on campus. She has held roles as the music director, prayer chair, and social committee chair, organizing and managing social events for over 150 club members. She says the TCC is the most supportive community in her campus life, as she can meet people who have similar interests as her, though are in different majors. “There are a lot of emotional aspects of being at MIT, and there’s a spiritual part that so many students wrestle with. The TCC is where I’ve been able to find so much comfort, support, and encouragement; the closest friends I have are in the Tech Catholic Community,” she says.

    Mittman is also passionate about teaching, which allows her to connect to students and teach them material in new and exciting ways. In the fall of her junior and senior years, she was a teaching assistant for 3.091 (Introduction to Solid State Chemistry), where she taught two recitations of 20 students and offered weekly private tutoring. She enjoyed helping students tackle difficult course material in ways that are enthusiastic and encouraging, as she appreciated receiving the same help in her introductory courses.

    Looking ahead, Mittman plans to work fulltime at Phoenix Tailings as a materials scientist following her graduation. In this way, she feels like she has come full circle: from playing in the mud as a kid to working with it as a materials scientist to extract materials to help build a sustainable future for nearby and international communities.

    “I want to be able to apply what I’m enthusiastic about, which is materials science, by way of mineralogical sustainability, so that it can help mines here in America but also mines in Brazil, Austria, Jamaica — all over the world, because ultimately, I think that will help more people live better lives,” she says. More