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    Startup turns mining waste into critical metals for the U.S.

    At the heart of the energy transition is a metal transition. Wind farms, solar panels, and electric cars require many times more copper, zinc, and nickel than their gas-powered alternatives. They also require more exotic metals with unique properties, known as rare earth elements, which are essential for the magnets that go into things like wind turbines and EV motors.Today, China dominates the processing of rare earth elements, refining around 60 percent of those materials for the world. With demand for such materials forecasted to skyrocket, the Biden administration has said the situation poses national and economic security threats.Substantial quantities of rare earth metals are sitting unused in the United States and many other parts of the world today. The catch is they’re mixed with vast quantities of toxic mining waste.Phoenix Tailings is scaling up a process for harvesting materials, including rare earth metals and nickel, from mining waste. The company uses water and recyclable solvents to collect oxidized metal, then puts the metal into a heated molten salt mixture and applies electricity.The company, co-founded by MIT alumni, says its pilot production facility in Woburn, Massachusetts, is the only site in the world producing rare earth metals without toxic byproducts or carbon emissions. The process does use electricity, but Phoenix Tailings currently offsets that with renewable energy contracts.The company expects to produce more than 3,000 tons of the metals by 2026, which would have represented about 7 percent of total U.S. production last year.Now, with support from the Department of Energy, Phoenix Tailings is expanding the list of metals it can produce and accelerating plans to build a second production facility.For the founding team, including MIT graduates Tomás Villalón ’14 and Michelle Chao ’14 along with Nick Myers and Anthony Balladon, the work has implications for geopolitics and the planet.“Being able to make your own materials domestically means that you’re not at the behest of a foreign monopoly,” Villalón says. “We’re focused on creating critical materials for the next generation of technologies. More broadly, we want to get these materials in ways that are sustainable in the long term.”Tackling a global problemVillalón got interested in chemistry and materials science after taking Course 3.091 (Introduction to Solid-State Chemistry) during his first year at MIT. In his senior year, he got a chance to work at Boston Metal, another MIT spinoff that uses an electrochemical process to decarbonize steelmaking at scale. The experience got Villalón, who majored in materials science and engineering, thinking about creating more sustainable metallurgical processes.But it took a chance meeting with Myers at a 2018 Bible study for Villalón to act on the idea.“We were discussing some of the major problems in the world when we came to the topic of electrification,” Villalón recalls. “It became a discussion about how the U.S. gets its materials and how we should think about electrifying their production. I was finally like, ‘I’ve been working in the space for a decade, let’s go do something about it.’ Nick agreed, but I thought he just wanted to feel good about himself. Then in July, he randomly called me and said, ‘I’ve got [$7,000]. When do we start?’”Villalón brought in Chao, his former MIT classmate and fellow materials science and engineering major, and Myers brought Balladon, a former co-worker, and the founders started experimenting with new processes for producing rare earth metals.“We went back to the base principles, the thermodynamics I learned with MIT professors Antoine Allanore and Donald Sadoway, and understanding the kinetics of reactions,” Villalón says. “Classes like Course 3.022 (Microstructural Evolution in Materials) and 3.07 (Introduction to Ceramics) were also really useful. I touched on every aspect I studied at MIT.”The founders also received guidance from MIT’s Venture Mentoring Service (VMS) and went through the U.S. National Science Foundation’s I-Corps program. Sadoway served as an advisor for the company.After drafting one version of their system design, the founders bought an experimental quantity of mining waste, known as red sludge, and set up a prototype reactor in Villalón’s backyard. The founders ended up with a small amount of product, but they had to scramble to borrow the scientific equipment needed to determine what exactly it was. It turned out to be a small amount of rare earth concentrate along with pure iron.Today, at the company’s refinery in Woburn, Phoenix Tailings puts mining waste rich in rare earth metals into its mixture and heats it to around 1,300 degrees Fahrenheit. When it applies an electric current to the mixture, pure metal collects on an electrode. The process leaves minimal waste behind.“The key for all of this isn’t just the chemistry, but how everything is linked together, because with rare earths, you have to hit really high purities compared to a conventionally produced metal,” Villalón explains. “As a result, you have to be thinking about the purity of your material the entire way through.”From rare earths to nickel, magnesium, and moreVillalón says the process is economical compared to conventional production methods, produces no toxic byproducts, and is completely carbon free when renewable energy sources are used for electricity.The Woburn facility is currently producing several rare earth elements for customers, including neodymium and dysprosium, which are important in magnets. Customers are using the materials for things likewind turbines, electric cars, and defense applications.The company has also received two grants with the U.S. Department of Energy’s ARPA-E program totaling more than $2 million. Its 2023 grant supports the development of a system to extract nickel and magnesium from mining waste through a process that uses carbonization and recycled carbon dioxide. Both nickel and magnesium are critical materials for clean energy applications like batteries.The most recent grant will help the company adapt its process to produce iron from mining waste without emissions or toxic byproducts. Phoenix Tailings says its process is compatible with a wide array of ore types and waste materials, and the company has plenty of material to work with: Mining and processing mineral ores generates about 1.8 billion tons of waste in the U.S. each year.“We want to take our knowledge from processing the rare earth metals and slowly move it into other segments,” Villalón explains. “We simply have to refine some of these materials here. There’s no way we can’t. So, what does that look like from a regulatory perspective? How do we create approaches that are economical and environmentally compliant not just now, but 30 years from now?” More

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    Smart handling of neutrons is crucial to fusion power success

    In fall 2009, when Ethan Peterson ’13 arrived at MIT as an undergraduate, he already had some ideas about possible career options. He’d always liked building things, even as a child, so he imagined his future work would involve engineering of some sort. He also liked physics. And he’d recently become intent on reducing our dependence on fossil fuels and simultaneously curbing greenhouse gas emissions, which made him consider studying solar and wind energy, among other renewable sources.Things crystallized for him in the spring semester of 2010, when he took an introductory course on nuclear fusion, taught by Anne White, during which he discovered that when a deuterium nucleus and a tritium nucleus combine to produce a helium nucleus, an energetic (14 mega electron volt) neutron — traveling at one-sixth the speed of light — is released. Moreover, 1020 (100 billion billion) of these neutrons would be produced every second that a 500-megawatt fusion power plant operates. “It was eye-opening for me to learn just how energy-dense the fusion process is,” says Peterson, who became the Class of 1956 Career Development Professor of nuclear science and engineering in July 2024. “I was struck by the richness and interdisciplinary nature of the fusion field. This was an engineering discipline where I could apply physics to solve a real-world problem in a way that was both interesting and beautiful.”He soon became a physics and nuclear engineering double major, and by the time he graduated from MIT in 2013, the U.S. Department of Energy (DoE) had already decided to cut funding for MIT’s Alcator C-Mod fusion project. In view of that facility’s impending closure, Peterson opted to pursue graduate studies at the University of Wisconsin. There, he acquired a basic science background in plasma physics, which is central not only to nuclear fusion but also to astrophysical phenomena such as the solar wind.When Peterson received his PhD from Wisconsin in 2019, nuclear fusion had rebounded at MIT with the launch, a year earlier, of the SPARC project — a collaborative effort being carried out with the newly founded MIT spinout Commonwealth Fusion Systems. He returned to his alma mater as a postdoc and then a research scientist in the Plasma Science and Fusion Center, taking his time, at first, to figure out how to best make his mark in the field.Minding your neutronsAround that time, Peterson was participating in a community planning process, sponsored by the DoE, that focused on critical gaps that needed to be closed for a successful fusion program. In the course of these discussions, he came to realize that inadequate attention had been paid to the handling of neutrons, which carry 80 percent of the energy coming out of a fusion reaction — energy that needs to be harnessed for electrical generation. However, these neutrons are so energetic that they can penetrate through many tens of centimeters of material, potentially undermining the structural integrity of components and damaging vital equipment such as superconducting magnets. Shielding is also essential for protecting humans from harmful radiation.One goal, Peterson says, is to minimize the number of neutrons that escape and, in so doing, to reduce the amount of lost energy. A complementary objective, he adds, “is to get neutrons to deposit heat where you want them to and to stop them from depositing heat where you don’t want them to.” These considerations, in turn, can have a profound influence on fusion reactor design. This branch of nuclear engineering, called neutronics — which analyzes where neutrons are created and where they end up going — has become Peterson’s specialty.It was never a high-profile area of research in the fusion community — as plasma physics, for example, has always garnered more of the spotlight and more of the funding. That’s exactly why Peterson has stepped up. “The impacts of neutrons on fusion reactor design haven’t been a high priority for a long time,” he says. “I felt that some initiative needed to be taken,” and that prompted him to make the switch from plasma physics to neutronics. It has been his principal focus ever since — as a postdoc, a research scientist, and now as a faculty member.A code to design byThe best way to get a neutron to transfer its energy is to make it collide with a light atom. Lithium, with an atomic number of three, or lithium-containing materials are normally good choices — and necessary for producing tritium fuel. The placement of lithium “blankets,” which are intended to absorb energy from neutrons and produce tritium, “is a critical part of the design of fusion reactors,” Peterson says. High-density materials, such as lead and tungsten, can be used, conversely, to block the passage of neutrons and other types of radiation. “You might want to layer these high- and low-density materials in a complicated way that isn’t immediately intuitive” he adds. Determining which materials to put where — and of what thickness and mass — amounts to a tricky optimization problem, which will affect the size, cost, and efficiency of a fusion power plant.To that end, Peterson has developed modelling tools that can make analyses of these sorts easier and faster, thereby facilitating the design process. “This has traditionally been the step that takes the longest time and causes the biggest holdups,” he says. The models and algorithms that he and his colleagues are devising are general enough, moreover, to be compatible with a diverse range of fusion power plant concepts, including those that use magnets or lasers to confine the plasma.Now that he’s become a professor, Peterson is in a position to introduce more people to nuclear engineering, and to neutronics in particular. “I love teaching and mentoring students, sharing the things I’m excited about,” he says. “I was inspired by all the professors I had in physics and nuclear engineering at MIT, and I hope to give back to the community in the same way.”He also believes that if you are going to work on fusion, there is no better place to be than MIT, “where the facilities are second-to-none. People here are extremely innovative and passionate. And the sheer number of people who excel in their fields is staggering.” Great ideas can sometimes be sparked by off-the-cuff conversations in the hallway — something that happens more frequently than you expect, Peterson remarks. “All of these things taken together makes MIT a very special place.” More

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    Uplifting West African communities, one cashew at a time

    Ever wonder how your favorite snack was sourced? Joshua Reed-Diawuoh thinks more people should.Reed-Diawuoh MBA ’20 is the founder and CEO of GRIA Food Company, which partners with companies that ethically source and process food in West Africa to support local food economies and help communities in the region more broadly.“It’s very difficult for these agribusinesses and producers to start sustainable businesses and build up that value chain in the area,” says Reed-Diawuoh, who started the company as a student in the MIT Sloan School of Management. “We want to support these companies that put in the work to build integrated businesses that are employing people and uplifting communities.”GRIA, which stands for “Grown in Africa,” is currently selling six types of flavored cashews sourced from Benin, Togo, and Burkina Faso. All of the cashews are certified by Fairtrade International, which means in addition to offering sustainable wages, access to financing, and decent working conditions, the companies receive a “Fairtrade Premium” on top of the selling price that allows them to invest in the long-term health of their communities.“That premium is transformational,” Reed-Diawuoh says. “The premium goes to the producer cooperatives, or the farmers working the land, and they can invest that in any way they choose. They can put it back into their business, they can start new community development projects, like building schools or improving wastewater infrastructure, whatever they want.”Cracking the nutReed-Diawuoh’s family is from Ghana, and before coming to MIT Sloan, he worked to support agriculture and food manufacturing for countries in Sub-Saharan Africa, with particular focus on uplifting small-scale farmers. That’s where he learned about difficulties with financing and infrastructure constraints that held many companies back.“I wanted to get my hands dirty and start my own business that contributed to improving agricultural development in West Africa,” Reed-Diawuoh says.He entered MIT Sloan in 2018, taking entrepreneurship classes and exploring several business ideas before deciding to ethically source produce from farmers and sell directly to consumers. He says MIT Sloan’s Sustainability Business Lab offered particularly valuable lessons for how to structure his business.In his second year, Reed-Diawuoh was selected for a fellowship at the Legatum Center, which connected him to other entrepreneurs working in emerging markets around the world.“Legatum was a pivotal milestone for me,” he says. “It provided me with some structure and space to develop this idea. It also gave me an incredible opportunity to take risks and explore different business concepts in a way I couldn’t have done if I was working in industry.”The business model Reed-Diawuoh settled on for GRIA sources product from agribusiness partners in West Africa that adhere to the strictest environmental and labor standards. Reed-Diawuoh decided to start with cashews because they have many manual processing steps — from shelling to peeling and roasting — that are often done after the cashews are shipped out of West Africa, limiting the growth of local food economies and taking wealth out of communities.Each of GRIA’s partners, from the companies harvesting cashews to the processing facilities, works directly with farmer cooperatives and small-scale farmers and is certified by Fairtrade International.“Without proper oversight and regulations, workers oftentimes get exploited, and child labor is a huge problem across the agriculture sector,” Reed-Diawuoh says. “Fairtrade certifications try and take a robust and rigorous approach to auditing all of the businesses and their supply chains, from producers to farmers to processors. They do on-site visits and they audit financial documents. We went through this over the course of a thorough three-month review.”After importing cashew kernels, GRIA flavors and packages them at a production facility in Boston. Reed-Diawuoh started by selling to small independent retailers in Greater Boston before scaling up GRIA’s online sales. He started ramping up production in the beginning of 2023.“Every time we sell our product, if people weren’t already familiar with Fairtrade or ethical sourcing, we provide information on our packaging and all of our collateral,” Reed-Diawuoh says. “We want to spread this message about the importance of ethical sourcing and the importance of building up food manufacturing in West Africa in particular, but also in rising economies throughout the world.”Making ethical sourcing mainstreamGRIA currently imports about a ton of Fairtrade cashews and kernels each quarter, and Reed-Diawuoh hopes to double that number each year for the foreseeable future.“For each pound, we pay premiums for the kernels, and that supports this ecosystem where producers get compensated fairly for their work on the land, and agribusinesses are able to build more robust and profitable business models, because they have an end market for these Fairtrade-certified products.”Reed-Diawuoh is currently trying out different packaging and flavors and is in discussions with partners to expand production capacity and move into Ghana. He’s also exploring corporate collaborations and has provided MIT with product over the past two years for conferences and other events.“We’re experimenting with different growth strategies,” Reed-Diawuoh says. “We’re very much still in startup mode, but really trying to ramp up our sales and production.”As GRIA scales, Reed-Diawuoh hopes it pushes consumers to start asking more of their favorite food brands.“It’s absolutely critical that, if we’re sourcing produce in markets like the U.S. from places like West Africa, we’re hyper-focused on doing it in an ethical manner,” Reed-Diawuoh says. “The overall goal of GRIA is to ensure we are adhering to and promoting strict sourcing standards and being rigorous and thoughtful about the way we import product.” More

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    MIT Energy and Climate Club mobilizes future leaders to address global climate issues

    One of MIT’s missions is helping to solve the world’s greatest problems — with a large focus on one of the most pressing topics facing the world today, climate change.The MIT Energy and Climate Club, (MITEC) formerly known as the MIT Energy Club, has been working since 2004 to inform and educate the entire MIT community about this urgent issue and other related matters.MITEC, one of the largest clubs on campus, has hundreds of active members from every major, including both undergraduate and graduate students. With a broad reach across the Institute, MITEC is the hub for thought leadership and relationship-building across campus.The club’s co-presidents Laurențiu Anton, doctoral candidate in electrical engineering and computer science; Rosie Keller, an MBA student in the MIT Sloan School of Management; and Thomas Lee, doctoral candidate in the Institute for Data, Systems, and Society, say that faculty, staff, and alumni are also welcome to join and interact with the continuously growing club.While they closely collaborate on all aspects of the club, each of the co-presidents has a focus area to support the student managing directors and vice presidents for several of the club’s committees. Keller oversees the External Relations, Social, Launchpad, and Energy and Climate Hackathon leadership teams. Lee supports the leadership team for next spring’s Energy Conference. He also assists the club treasurer on budget and finance and guides the industry Sponsorships team. Anton oversees marketing, community and education as well as the Energy and Climate Night and Energy and Climate Career Fair leadership teams.“We think of MITEC as the umbrella of all things related to energy and climate on campus. Our goal is to share actionable information and not just have discussions. We work with other organizations on campus, including the MIT Environmental Solutions Initiative, to bring awareness,” says Anton. “Our Community and Education team is currently working with the MIT ESI [Environmental Solutions Initiative] to create an ecosystem map that we’re excited to produce for the MIT community.”To share their knowledge and get more people interested in solving climate and energy problems, each year MITEC hosts a variety of events including the MIT Energy and Climate Night, the MIT Energy and Climate Hack, the MIT Energy and Climate Career Fair, and the MIT Energy Conference to be held next spring March 3-4. The club also offers students the opportunity to gain valuable work experience while engaging with top companies, such as Constellation Energy and GE Vernova, on real climate and energy issues through their Launchpad Program.Founded in 2006, the annual MIT Energy Conference is the largest student-run conference in North America focused on energy and climate issues, where hundreds of participants gather every year with the CEOs, policymakers, investors, and scholars at the forefront of the global energy transition.“The 2025 MIT Energy Conference’s theme is ‘Breakthrough to Deployment: Driving Climate Innovation to Market’ — which focuses on the importance of both cutting-edge research innovation as well as large-scale commercial deployment to successfully reach climate goals,” says Lee.Anton notes that the first of four MITEC flagship events the MIT Energy and Climate Night. This research symposium that takes place every year in the fall at the MIT Museum will be held on Nov. 8. The club invites a select number of keynote speakers and several dozen student posters. Guests are allowed to walk around and engage with students, and in return students get practice showcasing their research. The club’s career fair will take place in the spring semester, shortly after Independent Activities Period.MITEC also provides members opportunities to meet with companies that are working to improve the energy sector, which helps to slow down, as well as adapt to, the effects of climate change.“We recently went to Provincetown and toured Eversource’s battery energy storage facility. This helped open doors for club members,” says Keller. “The Provincetown battery helps address grid reliability problems after extreme storms on Cape Cod — which speaks to energy’s connection to both the mitigation and adaptation aspects of climate change,” adds Lee.“MITEC is also a great way to meet other students at MIT that you might not otherwise have a chance to,” says Keller.“We’d always welcome more undergraduate students to join MITEC. There are lots of leadership opportunities within the club for them to take advantage of and build their resumes. We also have good and growing collaboration between different centers on campus such as the Sloan Sustainability Initiative and the MIT Energy Initiative. They support us with resources, introductions, and help amplify what we’re doing. But students are the drivers of the club and set the agendas,” says Lee.All three co-presidents are excited to hear that MIT President Sally Kornbluth wants to bring climate change solutions to the next level, and that she recently launched The Climate Project at MIT to kick off the Institute’s major new effort to accelerate and scale up climate change solutions.“We look forward to connecting with the new directors of the Climate Project at MIT and Interim Vice President for Climate Change Richard Lester in the near future. We are eager to explore how MITEC can support and collaborate with the Climate Project at MIT,” says Anton.Lee, Keller, and Anton want MITEC to continue fostering solutions to climate issues. They emphasized that while individual actions like bringing your own thermos, using public transportation, or recycling are necessary, there’s a bigger picture to consider. They encourage the MIT community to think critically about the infrastructure and extensive supply chains behind the products everyone uses daily.“It’s not just about bringing a thermos; it’s also understanding the life cycle of that thermos, from production to disposal, and how our everyday choices are interconnected with global climate impacts,” says Anton.“Everyone should get involved with this worldwide problem. We’d like to see more people think about how they can use their careers for change. To think how they can navigate the type of role they can play — whether it’s in finance or on the technical side. I think exploring what that looks like as a career is also a really interesting way of thinking about how to get involved with the problem,” says Keller.“MITEC’s newsletter reaches more than 4,000 people. We’re grateful that so many people are interested in energy and climate change,” says Anton. More

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    Tracking emissions to help companies reduce their environmental footprint

    Amidst a global wave of corporate pledges to decarbonize or reach net-zero emissions, a system for verifying actual greenhouse gas reductions has never been more important. Context Labs, founded by former MIT Sloan Fellow and serial entrepreneur Dan Harple SM ’13, is rising to meet that challenge with an analytics platform that brings more transparency to emissions data.The company’s platform adds context to data from sources like equipment sensors and satellites, provides third-party verification, and records all that information on a blockchain. Context Labs also provides an interactive view of emissions across every aspect of a company’s operations, allowing leaders to pinpoint the dirtiest parts of their business.“There’s an old adage: Unless you measure something, you can’t change it,” says Harple, who is the firm’s CEO. “I think of what we’re doing as an AI-driven digital lens into what’s happening across organizations. Our goal is to help the planet get better, faster.”Context Labs is already working with some of the largest energy companies in the world — including EQT, Williams Companies, and Coterra Energy — to verify emissions reductions. A partnership with Microsoft, announced at last year’s COP28 United Nations climate summit, allows any organization on Microsoft’s Azure cloud to integrate their sensor data into Context Lab’s platform to get a granular view of their environmental impact.Harple says the progress enables more informed sustainability initiatives at scale. He also sees the work as a way to combat overly vague statements about sustainable practices that don’t lead to actual emissions reductions, or what’s known as “greenwashing.”“Just producing data isn’t good enough, and our customers realize that, because they know even if they have good intentions to reduce emissions, no one is going to believe them,” Harple says. “One way to think about our platform is as antigreenwashing insurance, because if you get attacked for your emissions, we unbundle the data like it’s in shrink-wrap and roll it back through time on the blockchain. You can click on it and see exactly where and how it was measured, monitored, timestamped, its serial number, everything. It’s really the gold standard of proof.”An unconventional master’sHarple came to MIT as a serial founder whose companies had pioneered several foundational internet technologies, including real-time video streaming technology still used in applications like Zoom and Netflix, as well as some of the core technology for the popular Chinese microblogging website Weibo.Harple’s introduction to MIT started with a paper he wrote for his venture capital contacts in the U.S. to make the case for investment in the Netherlands, where he was living with his family. The paper caught the attention of MIT Professor Stuart Madnick, the John Norris Maguire Professor of Information Technology at the MIT Sloan School of Management, who suggested Harple come to MIT as a Sloan Fellow to further develop his ideas about what makes a strong innovation ecosystem.Having successfully founded and exited multiple companies, Harple was not a typical MIT student when he began the Sloan Fellows program in 2011. At one point, he held a summit at MIT for a group of leading Dutch entrepreneurs and government officials that included tours of major labs and a meeting with former MIT President L. Rafael Reif.“Everyone was super enamored with MIT, and that kicked off what became a course that I started at MIT called REAL, Regional Entrepreneurial Acceleration Lab,” Harple says. REAL was eventually absorbed by what is now REAP — the Regional Entrepreneurship Acceleration Program, which has worked with communities around the world.Harple describes REAL as a framework vehicle to put his theories on supporting innovation into action. Over his time at MIT, which also included collaborating with the Media Lab, he systematized those theories into what he calls pentalytics, which is a way to measure and predict the resilience of innovation ecosystems.“My sense was MIT should be analytical and data-driven,” Harple says. “The thesis I wrote was a framework for AI-driven network graph analytics. So, you can model things using analytics, and you can use AI to do predictive analytics to see where the innovation ecosystem is going to thrive.”Once Harple’s pentalytics theory was established, he wanted to put it to the test with a company. His initial idea for Context Labs was to build a verification platform to combat fake news, deepfakes, and other misinformation on the internet. Around 2018, Harple met climate investor Jeremy Grantham, who he says helped him realize the most important data are about the planet. Harple began to believe that U.S. Environmental Protection Agency (EPA) emissions estimates for things like driving a car or operating an oil rig were just that — estimates — and left room for improvement.“Our approach was very MIT-ish,” Harple says. “We said, ‘Let’s, measure it and let’s monitor it, and then let’s contextualize that data so you can never go back and say they faked it. I think there’s a lot of fakery that’s happened, and that’s why the voluntary carbon markets cratered in the last year. Our view is they cratered because the data wasn’t empirical enough.”Context Labs’ solution starts with a technology platform it calls Immutably that continuously combines disparate data streams, encrypts that information, and records it on a blockchain. Immutably also verifies the information with one or more third parties. (Context Labs has partnered with the global accounting firm KPMG.)On top of Immutably, Context Labs has built applications, including a product called Decarbonization-as-a-Service (DaaS), which uses Immutably’s data to give companies a digital twin of their entire operations. Customers can use DaaS to explore the emissions of their assets and create a certificate of verified CO2-equivalent emissions, which can be used in carbon credit markets.Putting emissions data into contextContext Labs is working with oil and gas companies, utilities, data centers, and large industrial operators, some using the platform to analyze more than 3 billion data points each day. For instance, EQT, the largest natural gas producer in the U.S., uses Context Labs to verify its lower-emission products and create carbon credits. Other customers include the nonprofits Rocky Mountain Institute and the Environmental Defense Fund.“I often get asked how big the total addressable market is,” Harple says. “My view is it’s the largest market in history. Why? Because every country needs a decarbonization plan, along with instrumentation and a digital platform to execute, as does every company.”With its headquarters in Kendall Square in Cambridge, Massachusetts, Context Labs is also serving as a test for Harple’s pentalytics theory for innovation ecosystems. It also has operations in Houston and Amsterdam.“This company is a living lab for pentalytics,” Harple says. “I believe Kendall Square 1.0 was factory buildings, Kendall Square 2.0 is biotech, and Kendall Square 3.0 will be climate tech.” More

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    Pioneering the future of materials extraction

    The next time you cook pasta, imagine that you are cooking spaghetti, rigatoni, and seven other varieties all together, and they need to be separated onto 10 different plates before serving. A colander can remove the water — but you still have a mound of unsorted noodles. Now imagine that this had to be done for thousands of tons of pasta a day. That gives you an idea of the scale of the problem facing Brendan Smith PhD ’18, co-founder and CEO of SiTration, a startup formed out of MIT’s Department of Materials Science and Engineering (DMSE) in 2020. SiTration, which raised $11.8 million in seed capital led by venture capital firm 2150 earlier this month, is revolutionizing the extraction and refining of copper, cobalt, nickel, lithium, precious metals, and other materials critical to manufacturing clean-energy technologies such as electric motors, wind turbines, and batteries. Its initial target applications are recovering the materials from complex mining feed streams, spent lithium-ion batteries from electric vehicles, and various metals refining processes. The company’s breakthrough lies in a new silicon membrane technology that can be adjusted to efficiently recover disparate materials, providing a more sustainable and economically viable alternative to conventional, chemically intensive processes. Think of a colander with adjustable pores to strain different types of pasta. SiTration’s technology has garnered interest from industry players, including mining giant Rio Tinto. Some observers may question whether targeting such different industries could cause the company to lose focus. “But when you dig into these markets, you discover there is actually a significant overlap in how all of these materials are recovered, making it possible for a single solution to have impact across verticals,” Smith says.Powering up materials recoveryConventional methods of extracting critical materials in mining, refining, and recycling lithium-ion batteries involve heavy use of chemicals and heat, which harm the environment. Typically, raw ore from mines or spent batteries are ground into fine particles before being dissolved in acid or incinerated in a furnace. Afterward, they undergo intensive chemical processing to separate and purify the valuable materials. “It requires as much as 10 tons of chemical input to produce one ton of critical material recovered from the mining or battery recycling feedstock,” says Smith. Operators can then sell the recaptured materials back into the supply chain, but suffer from wide swings in profitability due to uncertain market prices. Lithium prices have been the most volatile, having surged more than 400 percent before tumbling back to near-original levels in the past two years. Despite their poor economics and negative environmental impact, these processes remain the state of the art today. By contrast, SiTration is electrifying the critical-materials recovery process, improving efficiency, producing less chemical waste, and reducing the use of chemicals and heat. What’s more, the company’s processing technology is built to be highly adaptable, so it can handle all kinds of materials. The core technology is based on work done at MIT to develop a novel type of membrane made from silicon, which is durable enough to withstand harsh chemicals and high temperatures while conducting electricity. It’s also highly tunable, meaning it can be modified or adjusted to suit different conditions or target specific materials. SiTration’s technology also incorporates electro-extraction, a technique that uses electrochemistry to further isolate and extract specific target materials. This powerful combination of methods in a single system makes it more efficient and effective at isolating and recovering valuable materials, Smith says. So depending on what needs to be separated or extracted, the filtration and electro-extraction processes are adjusted accordingly. “We can produce membranes with pore sizes from the molecular scale up to the size of a human hair in diameter, and everything in between. Combined with the ability to electrify the membrane and separate based on a material’s electrochemical properties, this tunability allows us to target a vast array of different operations and separation applications across industrial fields,” says Smith. Efficient access to materials like lithium, cobalt, and copper — and precious metals like platinum, gold, silver, palladium, and rare-earth elements — is key to unlocking innovation in business and sustainability as the world moves toward electrification and away from fossil fuels.“This is an era when new materials are critical,” says Professor Jeffrey Grossman, co-founder and chief scientist of SiTration and the Morton and Claire Goulder and Family Professor in Environmental Systems at DMSE. “For so many technologies, they’re both the bottleneck and the opportunity, offering tremendous potential for non-incremental advances. And the role they’re having in commercialization and in entrepreneurship cannot be overstated.”SiTration’s commercial frontierSmith became interested in separation technology in 2013 as a PhD student in Grossman’s DMSE research group, which has focused on the design of new membrane materials for a range of applications. The two shared a curiosity about separation of critical materials and a hunger to advance the technology. After years of study under Grossman’s mentorship, and with support from several MIT incubators and foundations including the Abdul Latif Jameel Water and Food Systems Lab’s Solutions Program, the Deshpande Center for Technological Innovation, the Kavanaugh Fellowship, MIT Sandbox, and Venture Mentoring Service, Smith was ready to officially form SiTration in 2020. Grossman has a seat on the board and plays an active role as a strategic and technical advisor. Grossman is involved in several MIT spinoffs and embraces the different imperatives of research versus commercialization. “At SiTration, we’re driving this technology to work at scale. There’s something super exciting about that goal,” he says. “The challenges that come with scaling are very different than the challenges that come in a university lab.” At the same time, although not every research breakthrough becomes a commercial product, open-ended, curiosity-driven knowledge pursuit holds its own crucial value, he adds.It has been rewarding for Grossman to see his technically gifted student and colleague develop a host of other skills the role of CEO demands. Getting out to the market and talking about the technology with potential partners, putting together a dynamic team, discovering the challenges facing industry, drumming up support, early on — those became the most pressing activities on Smith’s agenda. “What’s most fun to me about being a CEO of an early-stage startup is that there are 100 different factors, most people-oriented, that you have to navigate every day. Each stakeholder has different motivations and objectives. And you basically try to fit that all together, to create value for our partners and customers, the company, and for society,” says Smith. “You start with just an idea, and you have to keep leveraging that to form a more and more tangible product, to multiply and progress commercial relationships, and do it all at an ever-expanding scale.” MIT DNA runs deep in the nine-person company, with DMSE grad and former Grossman student Jatin Patil as director of product; Ahmed Helal, from MIT’s Department of Mechanical Engineering, as vice president of research and development; Daniel Bregante, from the Department of Chemistry, as VP of technology; and Sarah Melvin, from the departments of Physics and Political Science, as VP of strategy and operations. Melvin is the first hire devoted to business development. Smith plans to continue expanding the team following the closing of the company’s seed round.  Strategic alliancesBeing a good communicator was important when it came to securing funding, Smith says. SiTration received $2.35 million in pre-seed funding in 2022 led by Azolla Ventures, which reserves its $239 million in investment capital for startups that would not otherwise easily obtain funding. “We invest only in solution areas that can achieve gigaton-scale climate impact by 2050,” says Matthew Nordan, a general partner at Azolla and now SiTration board member. The MIT-affiliated E14 Fund also contributed to the pre-seed round; Azolla and E14 both participated in the recent seed funding round. “Brendan demonstrated an extraordinary ability to go from being a thoughtful scientist to a business leader and thinker who has punched way above his weight in engaging with customers and recruiting a well-balanced team and navigating tricky markets,” says Nordan. One of SiTration’s first partnerships is with Rio Tinto, one of the largest mining companies in the world. As SiTration evaluated various uses cases in its early days, identifying critical materials as its target market, Rio Tinto was looking for partners to recover valuable metals such as cobalt and copper from the wastewater generated at mines. These metals were typically trapped in the water, creating harmful waste and resulting in lost revenue. “We thought this was a great innovation challenge and posted it on our website to scout for companies to partner with who can help us solve this water challenge,” said Nick Gurieff, principal advisor for mine closure, in an interview with MIT’s Industrial Liaison Program in 2023. At SiTration, mining was not yet a market focus, but Smith couldn’t help noticing that Rio Tinto’s needs were in alignment with what his young company offered. SiTration submitted its proposal in August 2022. Gurieff said SiTration’s tunable membrane set it apart. The companies formed a business partnership in June 2023, with SiTration adjusting its membrane to handle mine wastewater and incorporating Rio Tinto feedback to refine the technology. After running tests with water from mine sites, SiTration will begin building a small-scale critical-materials recovery unit, followed by larger-scale systems processing up to 100 cubic meters of water an hour.SiTration’s focused technology development with Rio Tinto puts it in a good position for future market growth, Smith says. “Every ounce of effort and resource we put into developing our product is geared towards creating real-world value. Having an industry-leading partner constantly validating our progress is a tremendous advantage.”It’s a long time from the days when Smith began tinkering with tiny holes in silicon in Grossman’s DMSE lab. Now, they work together as business partners who are scaling up technology to meet a global need. Their joint passion for applying materials innovation to tough problems has served them well. “Materials science and engineering is an engine for a lot of the innovation that is happening today,” Grossman says. “When you look at all of the challenges we face to make the transition to a more sustainable planet, you realize how many of these are materials challenges.” More

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    Startup aims to transform the power grid with superconducting transmission lines

    Last year in Woburn, Massachusetts, a power line was deployed across a 100-foot stretch of land. Passersby wouldn’t have found much interesting about the installation: The line was supported by standard utility poles, the likes of which most of us have driven by millions of times. In fact, the familiarity of the sight is a key part of the technology’s promise.The lines are designed to transport five to 10 times the amount of power of conventional transmission lines, using essentially the same footprint and voltage level. That will be key to helping them overcome the regulatory hurdles and community opposition that has made increasing transmission capacity nearly impossible across large swaths of the globe, particularly in America and Europe, where new power distribution systems play a vital role in the shift to renewable energy and the resilience of the grid.The lines are the product of years of work by the startup VEIR, which was co-founded by Tim Heidel ’05, SM ’06, SM ’09, PhD ’10. They make use of superconducting cables and a proprietary cooling system that will enable initial transmission capacity up to 400 megawatts and, in future versions, up to several gigawatts.“We can deploy much higher power levels at much lower voltage, and so we can deploy the same high power but with a footprint and visual impact that is far less intrusive, and therefore can overcome a lot of the public opposition as well as siting and permitting barriers,” Heidel says.VEIR’s solution comes at a time when more than 10,000 renewable energy projects at various stages of development are seeking permission to connect to U.S. grids. The White House has said the U.S. must more than double existing regional transmission capacity in order to reach 2035 decarbonization goals.All of this comes as electricity demand is skyrocketing amid the increasing use of data centers and AI, and the electrification of everything from passenger vehicles to home heating systems.Despite those trends, building high-power transmission lines remains stubbornly difficult.“Building high-power transmission infrastructure can take a decade or more, and there’s been quite a few examples of projects that folks have had to abandon because they realize that there’s just so much opposition, or there’s too much complexity to pull it off cost effectively,” Heidel says. “We can drop down in voltage but carry the same amount of power because we can build systems that operate at much higher current levels, and that’s how our lines are able to melt into the background and avoid the same opposition.”Heidel says VEIR has built a pipeline of interested customers including utilities, data center operators, industrial companies, and renewable energy developers. VEIR is aiming to complete its first commercial-scale pilot carrying high power in 2026.A career in energyOver more than a decade at MIT, Heidel went from learning about the fundamentals of electrical engineering to studying the electric grid and the power sector more broadly. That journey included earning a bachelor’s, master’s, and PhD from MIT’s Department of Electrical Engineering and Computer Science as well as a master’s in MIT’s Technology and Policy Program, which he earned while working toward his PhD.“I got the energy bug and started to focus exclusively on energy and climate in graduate school,” Heidel says.Following his PhD, Heidel was named research director of MIT’s Future of the Electric Grid study, which was completed in 2011.“That was a fantastic opportunity at the outset of my career to survey the entire landscape and understand challenges facing the power grid and the power sector more broadly,” Heidel says. “It gave me a good foundation for understanding the grid, how it works, who’s involved, how decisions get made, how expansion works, and it looked out over the next 30 years.”After leaving MIT, Heidel worked at the Department of Energy’s Advanced Research Projects Agency-Energy (ARPA-E) and then at Bill Gates’ Breakthrough Energy Ventures (BEV) investment firm, where he continued studying transmission.“Just about every single decarbonization scenario and study that’s been published in the last two decades concludes that to achieve aggressive greenhouse gas emissions reductions, we’re going to have to double or triple the scale of power grids around the world,” Heidel says. “But when we looked at the data on how fast grids were being expanded, the ease with which transmission lines could be built, the cost of building new transmission, just about every indicator was heading in the wrong direction. Transmission was getting more expensive over time and taking longer to build. We desperately need to find a new solution.”Unlike traditional transmission lines made from steel and aluminum, VEIR’s transmission lines leverage decades of progress in the development of high-temperature superconducting tapes and other materials. Some of that progress has been driven by the nuclear fusion industry, which incorporates superconducting materials into some of their nuclear reactor designs.But the core innovation at VEIR is the cooling system. VEIR co-founder and advisor Steve Ashworth developed the rough idea for the cooling system more than 15 years ago at Los Alamos National Laboratory as part of a larger Department of Energy-funded research project. When the project was shut down, the idea was largely forgotten.Heidel and others at Breakthrough Energy Ventures became aware of the innovation in 2019 while researching transmission. Today VEIR’s system is passively cooled with nitrogen, which runs through a vacuum-insulated pipe that surrounds a superconducting cable. Heat exchange units are also used on some transmission towers.Heidel says transmission lines designed to carry that much power are typically far bigger than VEIR’s design, and other attempts at shrinking the footprint of high-power lines were limited to short distances underground.“High power requires high voltage, and high voltage requires tall towers and wide right of ways, and those tall towers and those wide right of ways are deeply unpopular,” Heidel says. “That is a universal truth across just about the entire world.”Moving power around the worldVEIR’s first alternating current (AC) overhead product line is capable of transmission capacities up to 400 megawatts and voltages of up to 69 kilovolts, and the company plans to scale to higher voltage and higher-power products in the future, including direct current (DC) lines.VEIR will sell its equipment to the companies installing transmission lines, with a primary focus on the U.S. market.In the longer term, Heidel believes VEIR’s technology is needed as soon as possible to meet rising electricity demands and new renewable energy projects around the globe. 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    Making steel with electricity

    Steel is one of the most useful materials on the planet. A backbone of modern life, it’s used in skyscrapers, cars, airplanes, bridges, and more. Unfortunately, steelmaking is an extremely dirty process.The most common way it’s produced involves mining iron ore, reducing it in a blast furnace through the addition of coal, and then using an oxygen furnace to burn off excess carbon and other impurities. That’s why steel production accounts for around 7 to 9 percent of humanity’s greenhouse gas emissions worldwide, making it one of the dirtiest industries on the planet.Now Boston Metal is seeking to clean up the steelmaking industry using an electrochemical process called molten oxide electrolysis (MOE), which eliminates many steps in steelmaking and releases oxygen as its sole byproduct.The company, which was founded by MIT Professor Emeritus Donald Sadoway, Professor Antoine Allanore, and James Yurko PhD ’01, is already using MOE to recover high-value metals from mining waste at its Brazilian subsidiary, Boston Metal do Brasil. That work is helping Boston Metal’s team deploy its technology at commercial scale and establish key partnerships with mining operators. It has also built a prototype MOE reactor to produce green steel at its headquarters in Woburn, Massachusetts.And despite its name, Boston Metal has global ambitions. The company has raised more than $370 million to date from organizations across Europe, Asia, the Americas, and the Middle East, and its leaders expect to scale up rapidly to transform steel production in every corner of the world.“There’s a worldwide recognition that we need to act rapidly, and that’s going to happen through technology solutions like this that can help us move away from incumbent technologies,” Boston Metal Chief Scientist and former MIT postdoc Guillaume Lambotte says. “More and more, climate change is a part of our lives, so the pressure is on everyone to act fast.”To the moon and backThe origins of Boston Metal’s technology start on the moon. In the mid 2000s, Sadoway, who is the John F. Elliott Professor Emeritus of Materials Chemistry in MIT’s Department of Materials Science, received a grant from NASA to explore ways to produce oxygen for future lunar bases. Sadoway and other MIT researchers explored the idea of sending an electric current through the iron oxide rock on the moon’s surface, using rock from an old asteroid in Arizona for their experiments. The reaction produced oxygen, with metal as a byproduct.The research stuck with Sadoway, who noticed that down here on Earth, that metal byproduct would be of interest. To help make the electrolysis reaction he studied more viable, he joined forces with Allanore, who is a professor of metallurgy at MIT and the Lechtman Chair in the Department of Materials Science and Engineering. The professors were able to identify a less expensive anode and partnered with Yurko, a former student, to found Boston Metal.“All of the fundamental studies and the initial technologies came out of MIT,” Lambotte says. “We spun out of research that was patented at MIT and licensed from MIT’s Technology Licensing Office.”Lambotte joined the company shortly after Boston Metal’s team published a 2013 paper in Nature describing the MOE platform.“That’s when it went from the lab, with a coffee cup-sized experiment to prove the fundamentals and produce a few grams, to a company that can produce hundreds of kilograms, and soon, tons of metal,” Lambotte says.

    Boston Metal’s process takes place in modular MOE cells the size of a school bus. Here is a schematic of the process.

    Boston Metal’s molten oxide electrolysis process takes place in modular MOE cells the size of a school bus. Iron ore rock is fed into the cell, which contains the cathode (the negative terminal of the MOE cell) and an anode immersed in a liquid electrolyte. The anode is inert, meaning it doesn’t dissolve in the electrolyte or take part in the reaction other than serving as the positive terminal. When electricity runs between the anode and cathode and the cell reaches around 1,600 degrees Celsius, the iron oxide bonds in the ore are split, producing pure liquid metal at the bottom that can be tapped. The byproduct of the reaction is oxygen, and the process doesn’t require water, hazardous chemicals, or precious-metal catalysts.The production of each cell depends on the size of its current. Lambotte says with about 600,000 amps, each cell could produce up to 10 tons of metal every day. Steelmakers would license Boston Metal’s technology and deploy as many cells as needed to reach their production targets.Boston Metal is already using MOE to help mining companies recover high-value metals from their mining waste, which usually needs to undergo costly treatment or storage. Lambotte says it could also be used to produce many other kinds of metals down the line, and Boston Metal was recently selected to negotiate grant funding to produce chromium metal — critical for a number of clean energy applications — in West Virginia.“If you look around the world, a lot of the feedstocks for metal are oxides, and if it’s an oxide, then there’s a chance we can work with that feedstock,” Lambotte says. “There’s a lot of excitement because everyone needs a solution capable of decarbonizing the metal industry, so a lot of people are interested to understand where MOE fits in their own processes.”Gigatons of potentialBoston Metal’s steel decarbonization technology is currently slated to reach commercial-scale in 2026, though its Brazil plant is already introducing the industry to MOE.“I think it’s a window for the metal industry to get acquainted with MOE and see how it works,” Lambotte says. “You need people in the industry to grasp this technology. It’s where you form connections and how new technology spreads.”The Brazilian plant runs on 100 percent renewable energy.“We can be the beneficiary of this tremendous worldwide push to decarbonize the energy sector,” Lambotte says. “I think our approach goes hand in hand with that. Fully green steel requires green electricity, and I think what you’ll see is deployment of this technology where [clean electricity] is already readily available.”Boston Metal’s team is excited about MOE’s application across the metals industry but is focused first and foremost on eliminating the gigatons of emissions from steel production.“Steel produces around 10 percent of global emissions, so that is our north star,” Lambotte says. “Everyone is pledging carbon reductions, emissions reductions, and making net zero goals, so the steel industry is really looking hard for viable technology solutions. People are ready for new approaches.” More