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    Building better batteries, faster

    To help combat climate change, many car manufacturers are racing to add more electric vehicles in their lineups. But to convince prospective buyers, manufacturers need to improve how far these cars can go on a single charge. One of their main challenges? Figuring out how to make extremely powerful but lightweight batteries.

    Typically, however, it takes decades for scientists to thoroughly test new battery materials, says Pablo Leon, an MIT graduate student in materials science. To accelerate this process, Leon is developing a machine-learning tool for scientists to automate one of the most time-consuming, yet key, steps in evaluating battery materials.

    With his tool in hand, Leon plans to help search for new materials to enable the development of powerful and lightweight batteries. Such batteries would not only improve the range of EVs, but they could also unlock potential in other high-power systems, such as solar energy systems that continuously deliver power, even at night.

    From a young age, Leon knew he wanted to pursue a PhD, hoping to one day become a professor of engineering, like his father. Growing up in College Station, Texas, home to Texas A&M University, where his father worked, many of Leon’s friends also had parents who were professors or affiliated with the university. Meanwhile, his mom worked outside the university, as a family counselor in a neighboring city.

    In college, Leon followed in his father’s and older brother’s footsteps to become a mechanical engineer, earning his bachelor’s degree at Texas A&M. There, he learned how to model the behaviors of mechanical systems, such as a metal spring’s stiffness. But he wanted to delve deeper, down to the level of atoms, to understand exactly where these behaviors come from.

    So, when Leon applied to graduate school at MIT, he switched fields to materials science, hoping to satisfy his curiosity. But the transition to a different field was “a really hard process,” Leon says, as he rushed to catch up to his peers.

    To help with the transition, Leon sought out a congenial research advisor and found one in Rafael Gómez-Bombarelli, an assistant professor in the Department of Materials Science and Engineering (DMSE). “Because he’s from Spain and my parents are Peruvian, there’s a cultural ease with the way we talk,” Leon says. According to Gómez-Bombarelli, sometimes the two of them even discuss research in Spanish — a “rare treat.” That connection has empowered Leon to freely brainstorm ideas or talk through concerns with his advisor, enabling him to make significant progress in his research.

    Leveraging machine learning to research battery materials

    Scientists investigating new battery materials generally use computer simulations to understand how different combinations of materials perform. These simulations act as virtual microscopes for batteries, zooming in to see how materials interact at an atomic level. With these details, scientists can understand why certain combinations do better, guiding their search for high-performing materials.

    But building accurate computer simulations is extremely time-intensive, taking years and sometimes even decades. “You need to know how every atom interacts with every other atom in your system,” Leon says. To create a computer model of these interactions, scientists first make a rough guess at a model using complex quantum mechanics calculations. They then compare the model with results from real-life experiments, manually tweaking different parts of the model, including the distances between atoms and the strength of chemical bonds, until the simulation matches real life.

    With well-studied battery materials, the simulation process is somewhat easier. Scientists can buy simulation software that includes pre-made models, Leon says, but these models often have errors and still require additional tweaking.

    To build accurate computer models more quickly, Leon is developing a machine-learning-based tool that can efficiently guide the trial-and-error process. “The hope with our machine learning framework is to not have to rely on proprietary models or do any hand-tuning,” he says. Leon has verified that for well-studied materials, his tool is as accurate as the manual method for building models.

    With this system, scientists will have a single, standardized approach for building accurate models in lieu of the patchwork of approaches currently in place, Leon says.

    Leon’s tool comes at an opportune time, when many scientists are investigating a new paradigm of batteries: solid-state batteries. Compared to traditional batteries, which contain liquid electrolytes, solid-state batteries are safer, lighter, and easier to manufacture. But creating versions of these batteries that are powerful enough for EVs or renewable energy storage is challenging.

    This is largely because in battery chemistry, ions dislike flowing through solids and instead prefer liquids, in which atoms are spaced further apart. Still, scientists believe that with the right combination of materials, solid-state batteries can provide enough electricity for high-power systems, such as EVs. 

    Leon plans to use his machine-learning tool to help look for good solid-state battery materials more quickly. After he finds some powerful candidates in simulations, he’ll work with other scientists to test out the new materials in real-world experiments.

    Helping students navigate graduate school

    To get to where he is today, doing exciting and impactful research, Leon credits his community of family and mentors. Because of his upbringing, Leon knew early on which steps he would need to take to get into graduate school and work toward becoming a professor. And he appreciates the privilege of his position, even more so as a Peruvian American, given that many Latino students are less likely to have access to the same resources. “I understand the academic pipeline in a way that I think a lot of minority groups in academia don’t,” he says.

    Now, Leon is helping prospective graduate students from underrepresented backgrounds navigate the pipeline through the DMSE Application Assistance Program. Each fall, he mentors applicants for the DMSE PhD program at MIT, providing feedback on their applications and resumes. The assistance program is student-run and separate from the admissions process.

    Knowing firsthand how invaluable mentorship is from his relationship with his advisor, Leon is also heavily involved in mentoring junior PhD students in his department. This past year, he served as the academic chair on his department’s graduate student organization, the Graduate Materials Council. With MIT still experiencing disruptions from Covid-19, Leon noticed a problem with student cohesiveness. “I realized that traditional [informal] modes of communication across [incoming class] years had been cut off,” he says, making it harder for junior students to get advice from their senior peers. “They didn’t have any community to fall back on.”

    To help fix this problem, Leon served as a go-to mentor for many junior students. He helped second-year PhD students prepare for their doctoral qualification exam, an often-stressful rite of passage. He also hosted seminars for first-year students to teach them how to make the most of their classes and help them acclimate to the department’s fast-paced classes. For fun, Leon organized an axe-throwing event to further facilitate student cameraderie.

    Leon’s efforts were met with success. Now, “newer students are building back the community,” he says, “so I feel like I can take a step back” from being academic chair. He will instead continue mentoring junior students through other programs within the department. He also plans to extend his community-building efforts among faculty and students, facilitating opportunities for students to find good mentors and work on impactful research. With these efforts, Leon hopes to help others along the academic pipeline that he’s become familiar with, journeying together over their PhDs. More

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    Donald Sadoway wins European Inventor Award for liquid metal batteries

    MIT Professor Donald Sadoway has won the 2022 European Inventor Award, in the category for Non-European Patent Office Countries, for his work on liquid metal batteries that could enable the long-term storage of renewable energy.

    Sadoway is the John F. Elliott Professor of Materials Chemistry in MIT’s Department of Materials Science and Engineering, and a longtime supporter and friend of the Materials Research Laboratory.

    “By enabling the large-scale storage of renewable energy, Donald Sadoway’s invention is a huge step towards the deployment of carbon-free electricity generation,” says António Campinos, president of the European Patent Office. “He has spent his career studying electrochemistry and has transformed this expertise into an invention that represents a huge step forward in the transition to green energy.”

    Sadoway was honored at the 2022 European Inventor Award ceremony on June 21. The award is one of Europe’s most prestigious innovation prizes and is presented annually to outstanding inventors from Europe and beyond who have made an exceptional contribution to society, technological progress, and economic growth.

    When accepting the award in Munich, Sadoway told the audience:

    “I am astonished. When I look at all the patented technologies that are represented at this event I see an abundance of excellence, all of them solutions to pressing problems. I wonder if the judges are assessing not only degrees of excellence but degrees of urgency. The liquid metal battery addresses an existential threat to the health of our atmosphere which is related to climate change.

    “By hosting this event the EPO celebrates invention. The thread that connects all the inventors is their efforts to make the world a better place. In my judgment there is no nobler pursuit. So perhaps this is a celebration of nobility.”

    Sadoway’s liquid metal batteries consist of three liquid layers of different densities, which naturally separate in the same way as oil and vinegar do in a salad dressing. The top and bottom layers are made from molten metals, with a middle layer of molten liquid salt.

    To keep the metals liquid, the batteries need to operate at extremely high temperatures, so Sadoway designed a system that is self-heating and insulated, requiring no external heating or cooling. They have a lifespan of more than 20 years, can maintain 99 percent of their capacity over 5,000 charging cycles, and have no combustible materials, meaning there is no fire risk.

    In 2010, with a patent for his invention and support from Bill Gates, Sadoway co-founded Ambri, based in Marlborough, Massachusetts just outside Boston, to develop a commercial product. The company will soon install a unit on a 3,700-acre development for a data center in Nevada. This battery will store energy from a reported 500 megawatts of on-site renewable generation, the same output as a natural gas power plant.

    Born in 1950 into a family of Ukrainian immigrants in Canada, Sadoway studied chemical metallurgy specializing in what he calls “extreme electrochemistry” — chemical reactions in molten salts and liquid metals that have been heated to over 500 degrees Celsius. After earning his BASc, MASc, and PhD, all from the University of Toronto, he joined the faculty at MIT in 1978. More

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    Expanding energy access in rural Lesotho

    Matt Orosz’s mission for the last 20 years can be explained with a single picture: a satellite image of the world at night, with major cities blazing with light and large swaths of land shrouded in darkness.

    The image reminds Orosz SM ’03, SM ’06, PhD ’12 of what he’s trying to change. Orosz is the CEO of OnePower, an MIT spinout building networks of minigrids powered by solar energy to bring electricity to rural regions of Lesotho.

    There are other companies building minigrids in Africa, but OnePower is the only one to have accomplished the feat in Lesotho, and it’s not hard to understand why. Known as the kingdom in the sky, Lesotho is a small, developing country crossed by mountain ranges and rivers, making it difficult to get electricity to rural regions. Recent estimates suggest that less than half of all households have electricity.

    OnePower’s first minigrid is a small system that has been serving around 200 customers for more than a year. The operation is part of an eight-minigrid project that will provide reliable electricity for the first time to more than 30,000 people, 13 health clinics, 25 schools, and over 100 small businesses.

    Construction on those sites is underway, and Orosz is currently working on a power transmission and road crossing over the Senqu river, the largest in southern Africa. During the project, the operators of a health clinic on the off-grid side of the river let Orosz stay there on the condition that he fix their diesel generator. He got the generator working again, but if everything goes according to plan, the clinic won’t need it for much longer.

    “If you don’t have power, then you don’t have lights, you don’t have computers, you don’t have communications,” Orosz says. “That means hospitals can’t refer patients or get expert opinions or run equipment, and schools can’t get internet. When the fundamental institutions for health and education don’t have power, their effectiveness is pretty limited, which affects quality of life for everybody that lives in the area.”

    Finding a spark

    The health clinic Orosz is staying in isn’t far from where he first learned about energy access problems in rural Africa. Between 2000 and 2002, Orosz lived in Lesotho, without electricity, as a member of the Peace Corps. The experience inspired him to help, but without an engineering background, he knew he’d need to gain more skills first.

    “I applied to MIT so that I could gain some knowledge and experience and apply it in this setting,” Orosz says, noting he spent a lot longer at MIT than he initially intended.

    Orosz first joined the research lab of Harry Hemond, the William E Leonhard Professor of Civil and Environmental Engineering, learning about topics like physics and fluid mechanics as part of his first year at MIT. After that, he enrolled in another master’s program in technology and policy. In 2007, he began a PhD at MIT studying solar thermal and photovoltaic hybrid power generation.

    The education wasn’t the only reason Orosz stayed at MIT. Throughout his time on campus, he also took advantage of funding opportunities presented by the IDEAS Social Innovation Challenge and the MIT $100K Entrepreneurship Competition (the $50K at the time). Orosz was also awarded a Fulbright scholarship while at MIT, and was selected for grants from the World Bank and the Environmental Protection Agency.

    Orosz also aligned himself closely with MIT D-Lab. During his second master’s, he led trips to Lesotho with other D-Lab students. Between his master’s and his PhD, Orosz spent a year living in Lesotho exploring energy solutions with three other MIT students, including Amy Mueller ’02, SM ’03, PhD ’12, who is currently chief financial officer of OnePower.

    In 2015, Orosz moved to Lesotho to work on OnePower full-time. The move coincided with OnePower’s successful bid to develop the first utility-scale solar project in Lesotho, a 20-megawatt project that will sell electricity to Lesotho’s central grid in addition to OnePower’s minigrid work. OnePower expects that project, named Neo 1, to start delivering power to Lesotho’s central electric grid next year.

    “It takes quite a lot of time and money to develop utility scale solar projects, but we’ve been told by investors and partners that seven years is not unusual,” Orosz says. “It kind of reminds me of the time it took to get a PhD — surprisingly long, but corroborated by others’ experiences.”

    In conjunction with the grid-scale project, OnePower also piloted the first privately financed, fully licensed minigrid in Lesotho. The company has also set up minigrids to help power six health care centers in the mountains of Lesotho.

    OnePower’s grid-scale project and its minigrids use industry standard, large-format bifacial solar panels, mounted on single axis tracking substructures designed and built in Lesotho by OnePower, but the minigrids send energy to a powerhouse filled with lithium-ion batteries. From there, transmission lines bring the electricity to different villages, where it powers homes, businesses, schools, health clinics, police stations, churches, and more. A smart meter at each customer’s building tracks electricity usage, and customers use a phone app to pay for their electricity.

    OnePower secured funding for the projects from a network of private investors rather than through grants and donations. By paying the investors back, Orosz says OnePower will be showing that funding such projects can be a profitable investment in addition to an impactful one.

    That’s important because grants and donations will only take minigrid operators so far. Orosz says in order to provide reliable electricity to the entire continent of Africa, a huge amount of private investment is needed.

    “The goal is ultimately to prove that you can make this work: that you can generate electricity and sell it to a customer in Africa, and that revenue enables you to pay back the financier that helped you build the infrastructure in the first place,” Orosz says. “Once you close that loop, then it can scale. That’s the holy grail of minigrids.”

    Orosz believes OnePower is differentiated from other minigrid companies in that it develops and owns more of the value chain, like the tracking substructures that allow solar panels to adjust with the sun, which has helped the company continue operations during the pandemic. The technical innovations his team developed at MIT ultimately help OnePower offer lower electricity prices to people in Lesotho.

    Turning the lights on

    OnePower has doubled its employees over the last year as construction on the eight minigrids ramps up. As his team stays busy rolling those projects out, Orosz is already exploring options for the next cluster of minigrids OnePower will build.

    “If we can solve the economics and logistics in Lesotho, then it should be a lot easier to replicate this in other markets,” Orosz says.

    The goal is to bring OnePower’s minigrids to the rural communities that would benefit from them the most. As the satellite image of earth at night shows, that includes many unelectrified community across sub-Saharan Africa.

    “We think Africans in rural areas should have the same quality of power as Africans in urban areas, and that should be the same quality power as everywhere else in the world,” Orosz says. More

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    Energy storage important to creating affordable, reliable, deeply decarbonized electricity systems

    In deeply decarbonized energy systems utilizing high penetrations of variable renewable energy (VRE), energy storage is needed to keep the lights on and the electricity flowing when the sun isn’t shining and the wind isn’t blowing — when generation from these VRE resources is low or demand is high. The MIT Energy Initiative’s Future of Energy Storage study makes clear the need for energy storage and explores pathways using VRE resources and storage to reach decarbonized electricity systems efficiently by 2050.

    “The Future of Energy Storage,” a new multidisciplinary report from the MIT Energy Initiative (MITEI), urges government investment in sophisticated analytical tools for planning, operation, and regulation of electricity systems in order to deploy and use storage efficiently. Because storage technologies will have the ability to substitute for or complement essentially all other elements of a power system, including generation, transmission, and demand response, these tools will be critical to electricity system designers, operators, and regulators in the future. The study also recommends additional support for complementary staffing and upskilling programs at regulatory agencies at the state and federal levels. 

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    Why is energy storage so important?

    The MITEI report shows that energy storage makes deep decarbonization of reliable electric power systems affordable. “Fossil fuel power plant operators have traditionally responded to demand for electricity — in any given moment — by adjusting the supply of electricity flowing into the grid,” says MITEI Director Robert Armstrong, the Chevron Professor of Chemical Engineering and chair of the Future of Energy Storage study. “But VRE resources such as wind and solar depend on daily and seasonal variations as well as weather fluctuations; they aren’t always available to be dispatched to follow electricity demand. Our study finds that energy storage can help VRE-dominated electricity systems balance electricity supply and demand while maintaining reliability in a cost-effective manner — that in turn can support the electrification of many end-use activities beyond the electricity sector.”

    The three-year study is designed to help government, industry, and academia chart a path to developing and deploying electrical energy storage technologies as a way of encouraging electrification and decarbonization throughout the economy, while avoiding excessive or inequitable burdens.

    Focusing on three distinct regions of the United States, the study shows the need for a varied approach to energy storage and electricity system design in different parts of the country. Using modeling tools to look out to 2050, the study team also focuses beyond the United States, to emerging market and developing economy (EMDE) countries, particularly as represented by India. The findings highlight the powerful role storage can play in EMDE nations. These countries are expected to see massive growth in electricity demand over the next 30 years, due to rapid overall economic expansion and to increasing adoption of electricity-consuming technologies such as air conditioning. In particular, the study calls attention to the pivotal role battery storage can play in decarbonizing grids in EMDE countries that lack access to low-cost gas and currently rely on coal generation.

    The authors find that investment in VRE combined with storage is favored over new coal generation over the medium and long term in India, although existing coal plants may linger unless forced out by policy measures such as carbon pricing. 

    “Developing countries are a crucial part of the global decarbonization challenge,” says Robert Stoner, the deputy director for science and technology at MITEI and one of the report authors. “Our study shows how they can take advantage of the declining costs of renewables and storage in the coming decades to become climate leaders without sacrificing economic development and modernization.”

    The study examines four kinds of storage technologies: electrochemical, thermal, chemical, and mechanical. Some of these technologies, such as lithium-ion batteries, pumped storage hydro, and some thermal storage options, are proven and available for commercial deployment. The report recommends that the government focus R&D efforts on other storage technologies, which will require further development to be available by 2050 or sooner — among them, projects to advance alternative electrochemical storage technologies that rely on earth-abundant materials. It also suggests government incentives and mechanisms that reward success but don’t interfere with project management. The report calls for the federal government to change some of the rules governing technology demonstration projects to enable more projects on storage. Policies that require cost-sharing in exchange for intellectual property rights, the report argues, discourage the dissemination of knowledge. The report advocates for federal requirements for demonstration projects that share information with other U.S. entities.

    The report says many existing power plants that are being shut down can be converted to useful energy storage facilities by replacing their fossil fuel boilers with thermal storage and new steam generators. This retrofit can be done using commercially available technologies and may be attractive to plant owners and communities — using assets that would otherwise be abandoned as electricity systems decarbonize.  

    The study also looks at hydrogen and concludes that its use for storage will likely depend on the extent to which hydrogen is used in the overall economy. That broad use of hydrogen, the report says, will be driven by future costs of hydrogen production, transportation, and storage — and by the pace of innovation in hydrogen end-use applications. 

    The MITEI study predicts the distribution of hourly wholesale prices or the hourly marginal value of energy will change in deeply decarbonized power systems — with many more hours of very low prices and more hours of high prices compared to today’s wholesale markets. So the report recommends systems adopt retail pricing and retail load management options that reward all consumers for shifting electricity use away from times when high wholesale prices indicate scarcity, to times when low wholesale prices signal abundance. 

    The Future of Energy Storage study is the ninth in MITEI’s “Future of” series, exploring complex and vital issues involving energy and the environment. Previous studies have focused on nuclear power, solar energy, natural gas, geothermal energy, and coal (with capture and sequestration of carbon dioxide emissions), as well as on systems such as the U.S. electric power grid. The Alfred P. Sloan Foundation and the Heising-Simons Foundation provided core funding for MITEI’s Future of Energy Storage study. MITEI members Equinor and Shell provided additional support.  More

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    Team creates map for production of eco-friendly metals

    In work that could usher in more efficient, eco-friendly processes for producing important metals like lithium, iron, and cobalt, researchers from MIT and the SLAC National Accelerator Laboratory have mapped what is happening at the atomic level behind a particularly promising approach called metal electrolysis.

    By creating maps for a wide range of metals, they not only determined which metals should be easiest to produce using this approach, but also identified fundamental barriers behind the efficient production of others. As a result, the researchers’ map could become an important design tool for optimizing the production of all these metals.

    The work could also aid the development of metal-air batteries, cousins of the lithium-ion batteries used in today’s electric vehicles.

    Most of the metals key to society today are produced using fossil fuels. These fuels generate the high temperatures necessary to convert the original ore into its purified metal. But that process is a significant source of greenhouse gases — steel alone accounts for some 7 percent of carbon dioxide emissions globally. As a result, researchers from around the world are working to identify more eco-friendly ways for the production of metals.

    One promising approach is metal electrolysis, in which a metal oxide, the ore, is zapped with electricity to create pure metal with oxygen as the byproduct. That is the reaction explored at the atomic level in new research reported in the April 8 issue of the journal Chemistry of Materials.

    Donald Siegel is department chair and professor of mechanical engineering at the University of Texas at Austin. Says Siegel, who was not involved in the Chemistry of Materials study: “This work is an important contribution to improving the efficiency of metal production from metal oxides. It clarifies our understanding of low-carbon electrolysis processes by tracing the underlying thermodynamics back to elementary metal-oxygen interactions. I expect that this work will aid in the creation of design rules that will make these industrially important processes less reliant on fossil fuels.”

    Yang Shao-Horn, the JR East Professor of Engineering in MIT’s Department of Materials Science and Engineering (DMSE) and Department of Mechanical Engineering, is a leader of the current work, with Michal Bajdich of SLAC.

    “Here we aim to establish some basic understanding to predict the efficiency of electrochemical metal production and metal-air batteries from examining computed thermodynamic barriers for the conversion between metal and metal oxides,” says Shao-Horn, who is on the research team for MIT’s new Center for Electrification and Decarbonization of Industry, a winner of the Institute’s first-ever Climate Grand Challenges competition. Shao-Horn is also affiliated with MIT’s Materials Research Laboratory and Research Laboratory of Electronics.

    In addition to Shao-Horn and Bajdich, other authors of the Chemistry of Materials paper are Jaclyn R. Lunger, first author and a DMSE graduate student; mechanical engineering senior Naomi Lutz; and DMSE graduate student Jiayu Peng.

    Other applications

    The work could also aid in developing metal-air batteries such as lithium-air, aluminum-air, and zinc-air batteries. These cousins of the lithium-ion batteries used in today’s electric vehicles have the potential to electrify aviation because their energy densities are much higher. However, they are not yet on the market due to a variety of problems including inefficiency.

    Charging metal-air batteries also involves electrolysis. As a result, the new atomic-level understanding of these reactions could not only help engineers develop efficient electrochemical routes for metal production, but also design more efficient metal-air batteries.

    Learning from water splitting

    Electrolysis is also used to split water into oxygen and hydrogen, which stores the resulting energy. That hydrogen, in turn, could become an eco-friendly alternative to fossil fuels. Since much more is known about water electrolysis, the focus of Bajdich’s work at SLAC, than the electrolysis of metal oxides, the team compared the two processes for the first time.

    The result: “Slowly, we uncovered the elementary steps involved in metal electrolysis,” says Bajdich. The work was challenging, says Lunger, because “it was unclear to us what those steps are. We had to figure out how to get from A to B,” or from a metal oxide to metal and oxygen.

    All of the work was conducted with supercomputer simulations. “It’s like a sandbox of atoms, and then we play with them. It’s a little like Legos,” says Bajdich. More specifically, the team explored different scenarios for the electrolysis of several metals. Each involved different catalysts, molecules that boost the speed of a reaction.

    Says Lunger, “To optimize the reaction, you want to find the catalyst that makes it most efficient.” The team’s map is essentially a guide for designing the best catalysts for each different metal.

    What’s next? Lunger noted that the current work focused on the electrolysis of pure metals. “I’m interested in seeing what happens in more complex systems involving multiple metals. Can you make the reaction more efficient if there’s sodium and lithium present, or cadmium and cesium?”

    This work was supported by a U.S. Department of Energy Office of Science Graduate Student Research award. It was also supported by an MIT Energy Initiative fellowship, the Toyota Research Institute through the Accelerated Materials Design and Discovery Program, the Catalysis Science Program of Department of Energy, Office of Basic Energy Sciences, and by the Differentiate Program through the U.S. Advanced Research Projects Agency — Energy.  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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    Selective separation could help alleviate critical metals shortage

    New processing methods developed by MIT researchers could help ease looming shortages of the essential metals that power everything from phones to automotive batteries, by making it easier to separate these rare metals from mining ores and recycled materials.

    Selective adjustments within a chemical process called sulfidation allowed professor of metallurgy Antoine Allanore and his graduate student Caspar Stinn to successfully target and separate rare metals, such as the cobalt in a lithium-ion battery, from mixed-metal materials.

    As they report in the journal Nature, their processing techniques allow the metals to remain in solid form and be separated without dissolving the material. This avoids traditional but costly liquid separation methods that require significant energy. The researchers developed processing conditions for 56 elements and tested these conditions on 15 elements.

    Their sulfidation approach, they write in the paper, could reduce the capital costs of metal separation between 65 and 95 percent from mixed-metal oxides. Their selective processing could also reduce greenhouse gas emissions by 60 to 90 percent compared to traditional liquid-based separation.

    “We were excited to find replacements for processes that had really high levels of water usage and greenhouse gas emissions, such as lithium-ion battery recycling, rare-earth magnet recycling, and rare-earth separation,” says Stinn. “Those are processes that make materials for sustainability applications, but the processes themselves are very unsustainable.”

    The findings offer one way to alleviate a growing demand for minor metals like cobalt, lithium, and rare earth elements that are used in “clean” energy products like electric cars, solar cells, and electricity-generating windmills. According to a 2021 report by the International Energy Agency, the average amount of minerals needed for a new unit of power generation capacity has risen by 50 percent since 2010, as renewable energy technologies using these metals expand their reach.

    Opportunity for selectivity

    For more than a decade, the Allanore group has been studying the use of sulfide materials in developing new electrochemical routes for metal production. Sulfides are common materials, but the MIT scientists are experimenting with them under extreme conditions like very high temperatures — from 800 to 3,000 degrees Fahrenheit — that are used in manufacturing plants but not in a typical university lab.

    “We are looking at very well-established materials in conditions that are uncommon compared to what has been done before,” Allanore explains, “and that is why we are finding new applications or new realities.”

    In the process of synthetizing high-temperature sulfide materials to support electrochemical production, Stinn says, “we learned we could be very selective and very controlled about what products we made. And it was with that understanding that we realized, ‘OK, maybe there’s an opportunity for selectivity in separation here.’”

    The chemical reaction exploited by the researchers reacts a material containing a mix of metal oxides to form new metal-sulfur compounds or sulfides. By altering factors like temperature, gas pressure, and the addition of carbon in the reaction process, Stinn and Allanore found that they could selectively create a variety of sulfide solids that can be physically separated by a variety of methods, including crushing the material and sorting different-sized sulfides or using magnets to separate different sulfides from one another.

    Current methods of rare metal separation rely on large quantities of energy, water, acids, and organic solvents which have costly environmental impacts, says Stinn. “We are trying to use materials that are abundant, economical, and readily available for sustainable materials separation, and we have expanded that domain to now include sulfur and sulfides.”

    Stinn and Allanore used selective sulfidation to separate out economically important metals like cobalt in recycled lithium-ion batteries. They also used their techniques to separate dysprosium — a rare-earth element used in applications ranging from data storage devices to optoelectronics — from rare-earth-boron magnets, or from the typical mixture of oxides available from mining minerals such as bastnaesite.

    Leveraging existing technology

    Metals like cobalt and rare earths are only found in small amounts in mined materials, so industries must process large volumes of material to retrieve or recycle enough of these metals to be economically viable, Allanore explains. “It’s quite clear that these processes are not efficient. Most of the emissions come from the lack of selectivity and the low concentration at which they operate.”

    By eliminating the need for liquid separation and the extra steps and materials it requires to dissolve and then reprecipitate individual elements, the MIT researchers’ process significantly reduces the costs incurred and emissions produced during separation.

    “One of the nice things about separating materials using sulfidation is that a lot of existing technology and process infrastructure can be leveraged,” Stinn says. “It’s new conditions and new chemistries in established reactor styles and equipment.”

    The next step is to show that the process can work for large amounts of raw material — separating out 16 elements from rare-earth mining streams, for example. “Now we have shown that we can handle three or four or five of them together, but we have not yet processed an actual stream from an existing mine at a scale to match what’s required for deployment,” Allanore says.

    Stinn and colleagues in the lab have built a reactor that can process about 10 kilograms of raw material per day, and the researchers are starting conversations with several corporations about the possibilities.

    “We are discussing what it would take to demonstrate the performance of this approach with existing mineral and recycling streams,” Allanore says.

    This research was supported by the U.S. Department of Energy and the U.S. National Science Foundation. More

  • in

    An energy-storage solution that flows like soft-serve ice cream

    Batteries made from an electrically conductive mixture the consistency of molasses could help solve a critical piece of the decarbonization puzzle. An interdisciplinary team from MIT has found that an electrochemical technology called a semisolid flow battery can be a cost-competitive form of energy storage and backup for variable renewable energy (VRE) sources such as wind and solar. The group’s research is described in a paper published in Joule.

    “The transition to clean energy requires energy storage systems of different durations for when the sun isn’t shining and the wind isn’t blowing,” says Emre Gençer, a research scientist with the MIT Energy Initiative (MITEI) and a member of the team. “Our work demonstrates that a semisolid flow battery could be a lifesaving as well as economical option when these VRE sources can’t generate power for a day or longer — in the case of natural disasters, for instance.”

    The rechargeable zinc-manganese dioxide (Zn-MnO2) battery the researchers created beat out other long-duration energy storage contenders. “We performed a comprehensive, bottom-up analysis to understand how the battery’s composition affects performance and cost, looking at all the trade-offs,” says Thaneer Malai Narayanan SM ’18, PhD ’21. “We showed that our system can be cheaper than others, and can be scaled up.”

    Narayanan, who conducted this work at MIT as part of his doctorate in mechanical engineering, is the lead author of the paper. Additional authors include Gençer, Yunguang Zhu, a postdoc in the MIT Electrochemical Energy Lab; Gareth McKinley, the School of Engineering Professor of Teaching Innovation and professor of mechanical engineering at MIT; and Yang Shao-Horn, the JR East Professor of Engineering, a professor of mechanical engineering and of materials science and engineering, and a member of the Research Laboratory of Electronics (RLE), who directs the MIT Electrochemical Energy Lab.

    Going with the flow

    In 2016, Narayanan began his graduate studies, joining the Electrochemical Energy Lab, a hotbed of research and exploration of solutions to mitigate climate change, which is centered on innovative battery chemistry and decarbonizing fuels and chemicals. One exciting opportunity for the lab: developing low- and no-carbon backup energy systems suitable for grid-scale needs when VRE generation flags.                                                  

    While the lab cast a wide net, investigating energy conversion and storage using solid oxide fuel cells, lithium-ion batteries, and metal-air batteries, among others, Narayanan took a particular interest in flow batteries. In these systems, two different chemical (electrolyte) solutions with either negative or positive ions are pumped from separate tanks, meeting across a membrane (called the stack). Here, the ion streams react, converting electrical energy to chemical energy — in effect, charging the battery. When there is demand for this stored energy, the solution gets pumped back to the stack to convert chemical energy into electrical energy again.

    The duration of time that flow batteries can discharge, releasing the stored electricity, is determined by the volume of positively and negatively charged electrolyte solutions streaming through the stack. In theory, as long as these solutions keep flowing, reacting, and converting the chemical energy to electrical energy, the battery systems can provide electricity.

    “For backup lasting more than a day, the architecture of flow batteries suggests they can be a cheap option,” says Narayanan. “You recharge the solution in the tanks from sun and wind power sources.” This renders the entire system carbon free.

    But while the promise of flow battery technologies has beckoned for at least a decade, the uneven performance and expense of materials required for these battery systems has slowed their implementation. So, Narayanan set out on an ambitious journey: to design and build a flow battery that could back up VRE systems for a day or more, storing and discharging energy with the same or greater efficiency than backup rivals; and to determine, through rigorous cost analysis, whether such a system could prove economically viable as a long-duration energy option.

    Multidisciplinary collaborators

    To attack this multipronged challenge, Narayanan’s project brought together, in his words, “three giants, scientists all well-known in their fields”:  Shao-Horn, who specializes in chemical physics and electrochemical science, and design of materials; Gençer, who creates detailed economic models of emergent energy systems at MITEI; and McKinley, an expert in rheology, the physics of flow. These three also served as his thesis advisors.

    “I was excited to work in such an interdisciplinary team, which offered a unique opportunity to create a novel battery architecture by designing charge transfer and ion transport within flowable semi-solid electrodes, and to guide battery engineering using techno-economics of such flowable batteries,” says Shao-Horn.

    While other flow battery systems in contention, such as the vanadium redox flow battery, offer the storage capacity and energy density to back up megawatt and larger power systems, they depend on expensive chemical ingredients that make them bad bets for long duration purposes. Narayanan was on the hunt for less-pricey chemical components that also feature rich energy potential.

    Through a series of bench experiments, the researchers came up with a novel electrode (electrical conductor) for the battery system: a mixture containing dispersed manganese dioxide (MnO2) particles, shot through with an electrically conductive additive, carbon black. This compound reacts with a conductive zinc solution or zinc plate at the stack, enabling efficient electrochemical energy conversion. The fluid properties of this battery are far removed from the watery solutions used by other flow batteries.

    “It’s a semisolid — a slurry,” says Narayanan. “Like thick, black paint, or perhaps a soft-serve ice cream,” suggests McKinley. The carbon black adds the pigment and the electric punch. To arrive at the optimal electrochemical mix, the researchers tweaked their formula many times.

    “These systems have to be able to flow under reasonable pressures, but also have a weak yield stress so that the active MnO2 particles don’t sink to the bottom of the flow tanks when the system isn’t being used, as well as not separate into a battery/oily clear fluid phase and a dense paste of carbon particles and MnO2,” says McKinley.

    This series of experiments informed the technoeconomic analysis. By “connecting the dots between composition, performance, and cost,” says Narayanan, he and Gençer were able to make system-level cost and efficiency calculations for the Zn-MnO2 battery.

    “Assessing the cost and performance of early technologies is very difficult, and this was an example of how to develop a standard method to help researchers at MIT and elsewhere,” says Gençer. “One message here is that when you include the cost analysis at the development stage of your experimental work, you get an important early understanding of your project’s cost implications.”

    In their final round of studies, Gençer and Narayanan compared the Zn-MnO2 battery to a set of equivalent electrochemical battery and hydrogen backup systems, looking at the capital costs of running them at durations of eight, 24, and 72 hours. Their findings surprised them: For battery discharges longer than a day, their semisolid flow battery beat out lithium-ion batteries and vanadium redox flow batteries. This was true even when factoring in the heavy expense of pumping the MnO2 slurry from tank to stack. “I was skeptical, and not expecting this battery would be competitive, but once I did the cost calculation, it was plausible,” says Gençer.

    But carbon-free battery backup is a very Goldilocks-like business: Different situations require different-duration solutions, whether an anticipated overnight loss of solar power, or a longer-term, climate-based disruption in the grid. “Lithium-ion is great for backup of eight hours and under, but the materials are too expensive for longer periods,” says Gençer. “Hydrogen is super expensive for very short durations, and good for very long durations, and we will need all of them.” This means it makes sense to continue working on the Zn-MnO2 system to see where it might fit in.

    “The next step is to take our battery system and build it up,” says Narayanan, who is working now as a battery engineer. “Our research also points the way to other chemistries that could be developed under the semi-solid flow battery platform, so we could be seeing this kind of technology used for energy storage in our lifetimes.”

    This research was supported by Eni S.p.A. through MITEI. Thaneer Malai Narayanan received an Eni-sponsored MIT Energy Fellowship during his work on the project. More