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    A new approach could fractionate crude oil using much less energy

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    Separating crude oil into products such as gasoline, diesel, and heating oil is an energy-intensive process that accounts for about 6 percent of the world’s CO2 emissions. Most of that energy goes into the heat needed to separate the components by their boiling point.In an advance that could dramatically reduce the amount of energy needed for crude oil fractionation, MIT engineers have developed a membrane that filters the components of crude oil by their molecular size.“This is a whole new way of envisioning a separation process. Instead of boiling mixtures to purify them, why not separate components based on shape and size? The key innovation is that the filters we developed can separate very small molecules at an atomistic length scale,” says Zachary P. Smith, an associate professor of chemical engineering at MIT and the senior author of the new study.The new filtration membrane can efficiently separate heavy and light components from oil, and it is resistant to the swelling that tends to occur with other types of oil separation membranes. The membrane is a thin film that can be manufactured using a technique that is already widely used in industrial processes, potentially allowing it to be scaled up for widespread use.Taehoon Lee, a former MIT postdoc who is now an assistant professor at Sungkyunkwan University in South Korea, is the lead author of the paper, which appears today in Science.Oil fractionationConventional heat-driven processes for fractionating crude oil make up about 1 percent of global energy use, and it has been estimated that using membranes for crude oil separation could reduce the amount of energy needed by about 90 percent. For this to succeed, a separation membrane needs to allow hydrocarbons to pass through quickly, and to selectively filter compounds of different sizes.Until now, most efforts to develop a filtration membrane for hydrocarbons have focused on polymers of intrinsic microporosity (PIMs), including one known as PIM-1. Although this porous material allows the fast transport of hydrocarbons, it tends to excessively absorb some of the organic compounds as they pass through the membrane, leading the film to swell, which impairs its size-sieving ability.To come up with a better alternative, the MIT team decided to try modifying polymers that are used for reverse osmosis water desalination. Since their adoption in the 1970s, reverse osmosis membranes have reduced the energy consumption of desalination by about 90 percent — a remarkable industrial success story.The most commonly used membrane for water desalination is a polyamide that is manufactured using a method known as interfacial polymerization. During this process, a thin polymer film forms at the interface between water and an organic solvent such as hexane. Water and hexane do not normally mix, but at the interface between them, a small amount of the compounds dissolved in them can react with each other.In this case, a hydrophilic monomer called MPD, which is dissolved in water, reacts with a hydrophobic monomer called TMC, which is dissolved in hexane. The two monomers are joined together by a connection known as an amide bond, forming a polyamide thin film (named MPD-TMC) at the water-hexane interface.While highly effective for water desalination, MPD-TMC doesn’t have the right pore sizes and swelling resistance that would allow it to separate hydrocarbons.To adapt the material to separate the hydrocarbons found in crude oil, the researchers first modified the film by changing the bond that connects the monomers from an amide bond to an imine bond. This bond is more rigid and hydrophobic, which allows hydrocarbons to quickly move through the membrane without causing noticeable swelling of the film compared to the polyamide counterpart.“The polyimine material has porosity that forms at the interface, and because of the cross-linking chemistry that we have added in, you now have something that doesn’t swell,” Smith says. “You make it in the oil phase, react it at the water interface, and with the crosslinks, it’s now immobilized. And so those pores, even when they’re exposed to hydrocarbons, no longer swell like other materials.”The researchers also introduced a monomer called triptycene. This shape-persistent, molecularly selective molecule further helps the resultant polyimines to form pores that are the right size for hydrocarbons to fit through.This approach represents “an important step toward reducing industrial energy consumption,” says Andrew Livingston, a professor of chemical engineering at Queen Mary University of London, who was not involved in the study.“This work takes the workhorse technology of the membrane desalination industry, interfacial polymerization, and creates a new way to apply it to organic systems such as hydrocarbon feedstocks, which currently consume large chunks of global energy,” Livingston says. “The imaginative approach using an interfacial catalyst coupled to hydrophobic monomers leads to membranes with high permeance and excellent selectivity, and the work shows how these can be used in relevant separations.”Efficient separationWhen the researchers used the new membrane to filter a mixture of toluene and triisopropylbenzene (TIPB) as a benchmark for evaluating separation performance, it was able to achieve a concentration of toluene 20 times greater than its concentration in the original mixture. They also tested the membrane with an industrially relevant mixture consisting of naphtha, kerosene, and diesel, and found that it could efficiently separate the heavier and lighter compounds by their molecular size.If adapted for industrial use, a series of these filters could be used to generate a higher concentration of the desired products at each step, the researchers say.“You can imagine that with a membrane like this, you could have an initial stage that replaces a crude oil fractionation column. You could partition heavy and light molecules and then you could use different membranes in a cascade to purify complex mixtures to isolate the chemicals that you need,” Smith says.Interfacial polymerization is already widely used to create membranes for water desalination, and the researchers believe it should be possible to adapt those processes to mass produce the films they designed in this study.“The main advantage of interfacial polymerization is it’s already a well-established method to prepare membranes for water purification, so you can imagine just adopting these chemistries into existing scale of manufacturing lines,” Lee says.The research was funded, in part, by ExxonMobil through the MIT Energy Initiative.  More

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      Study: Burning heavy fuel oil with scrubbers is the best available option for bulk maritime shipping

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      When the International Maritime Organization enacted a mandatory cap on the sulfur content of marine fuels in 2020, with an eye toward reducing harmful environmental and health impacts, it left shipping companies with three main options.They could burn low-sulfur fossil fuels, like marine gas oil, or install cleaning systems to remove sulfur from the exhaust gas produced by burning heavy fuel oil. Biofuels with lower sulfur content offer another alternative, though their limited availability makes them a less feasible option.While installing exhaust gas cleaning systems, known as scrubbers, is the most feasible and cost-effective option, there has been a great deal of uncertainty among firms, policymakers, and scientists as to how “green” these scrubbers are.Through a novel lifecycle assessment, researchers from MIT, Georgia Tech, and elsewhere have now found that burning heavy fuel oil with scrubbers in the open ocean can match or surpass using low-sulfur fuels, when a wide variety of environmental factors is considered.The scientists combined data on the production and operation of scrubbers and fuels with emissions measurements taken onboard an oceangoing cargo ship.They found that, when the entire supply chain is considered, burning heavy fuel oil with scrubbers was the least harmful option in terms of nearly all 10 environmental impact factors they studied, such as greenhouse gas emissions, terrestrial acidification, and ozone formation.“In our collaboration with Oldendorff Carriers to broadly explore reducing the environmental impact of shipping, this study of scrubbers turned out to be an unexpectedly deep and important transitional issue,” says Neil Gershenfeld, an MIT professor, director of the Center for Bits and Atoms (CBA), and senior author of the study.“Claims about environmental hazards and policies to mitigate them should be backed by science. You need to see the data, be objective, and design studies that take into account the full picture to be able to compare different options from an apples-to-apples perspective,” adds lead author Patricia Stathatou, an assistant professor at Georgia Tech, who began this study as a postdoc in the CBA.Stathatou is joined on the paper by Michael Triantafyllou, the Henry L. and Grace Doherty and others at the National Technical University of Athens in Greece and the maritime shipping firm Oldendorff Carriers. The research appears today in Environmental Science and Technology.Slashing sulfur emissionsHeavy fuel oil, traditionally burned by bulk carriers that make up about 30 percent of the global maritime fleet, usually has a sulfur content around 2 to 3 percent. This is far higher than the International Maritime Organization’s 2020 cap of 0.5 percent in most areas of the ocean and 0.1 percent in areas near population centers or environmentally sensitive regions.Sulfur oxide emissions contribute to air pollution and acid rain, and can damage the human respiratory system.In 2018, fewer than 1,000 vessels employed scrubbers. After the cap went into place, higher prices of low-sulfur fossil fuels and limited availability of alternative fuels led many firms to install scrubbers so they could keep burning heavy fuel oil.Today, more than 5,800 vessels utilize scrubbers, the majority of which are wet, open-loop scrubbers.“Scrubbers are a very mature technology. They have traditionally been used for decades in land-based applications like power plants to remove pollutants,” Stathatou says.A wet, open-loop marine scrubber is a huge, metal, vertical tank installed in a ship’s exhaust stack, above the engines. Inside, seawater drawn from the ocean is sprayed through a series of nozzles downward to wash the hot exhaust gases as they exit the engines.The seawater interacts with sulfur dioxide in the exhaust, converting it to sulfates — water-soluble, environmentally benign compounds that naturally occur in seawater. The washwater is released back into the ocean, while the cleaned exhaust escapes to the atmosphere with little to no sulfur dioxide emissions.But the acidic washwater can contain other combustion byproducts like heavy metals, so scientists wondered if scrubbers were comparable, from a holistic environmental point of view, to burning low-sulfur fuels.Several studies explored toxicity of washwater and fuel system pollution, but none painted a full picture.The researchers set out to fill that scientific gap.A “well-to-wake” analysisThe team conducted a lifecycle assessment using a global environmental database on production and transport of fossil fuels, such as heavy fuel oil, marine gas oil, and very-low sulfur fuel oil. Considering the entire lifecycle of each fuel is key, since producing low-sulfur fuel requires extra processing steps in the refinery, causing additional emissions of greenhouse gases and particulate matter.“If we just look at everything that happens before the fuel is bunkered onboard the vessel, heavy fuel oil is significantly more low-impact, environmentally, than low-sulfur fuels,” she says.The researchers also collaborated with a scrubber manufacturer to obtain detailed information on all materials, production processes, and transportation steps involved in marine scrubber fabrication and installation.“If you consider that the scrubber has a lifetime of about 20 years, the environmental impacts of producing the scrubber over its lifetime are negligible compared to producing heavy fuel oil,” she adds.For the final piece, Stathatou spent a week onboard a bulk carrier vessel in China to measure emissions and gather seawater and washwater samples. The ship burned heavy fuel oil with a scrubber and low-sulfur fuels under similar ocean conditions and engine settings.Collecting these onboard data was the most challenging part of the study.“All the safety gear, combined with the heat and the noise from the engines on a moving ship, was very overwhelming,” she says.Their results showed that scrubbers reduce sulfur dioxide emissions by 97 percent, putting heavy fuel oil on par with low-sulfur fuels according to that measure. The researchers saw similar trends for emissions of other pollutants like carbon monoxide and nitrous oxide.In addition, they tested washwater samples for more than 60 chemical parameters, including nitrogen, phosphorus, polycyclic aromatic hydrocarbons, and 23 metals.The concentrations of chemicals regulated by the IMO were far below the organization’s requirements. For unregulated chemicals, the researchers compared the concentrations to the strictest limits for industrial effluents from the U.S. Environmental Protection Agency and European Union.Most chemical concentrations were at least an order of magnitude below these requirements.In addition, since washwater is diluted thousands of times as it is dispersed by a moving vessel, the concentrations of such chemicals would be even lower in the open ocean.These findings suggest that the use of scrubbers with heavy fuel oil can be considered as equal to or more environmentally friendly than low-sulfur fuels across many of the impact categories the researchers studied.“This study demonstrates the scientific complexity of the waste stream of scrubbers. Having finally conducted a multiyear, comprehensive, and peer-reviewed study, commonly held fears and assumptions are now put to rest,” says Scott Bergeron, managing director at Oldendorff Carriers and co-author of the study.“This first-of-its-kind study on a well-to-wake basis provides very valuable input to ongoing discussion at the IMO,” adds Thomas Klenum, executive vice president of innovation and regulatory affairs at the Liberian Registry, emphasizing the need “for regulatory decisions to be made based on scientific studies providing factual data and conclusions.”Ultimately, this study shows the importance of incorporating lifecycle assessments into future environmental impact reduction policies, Stathatou says.“There is all this discussion about switching to alternative fuels in the future, but how green are these fuels? We must do our due diligence to compare them equally with existing solutions to see the costs and benefits,” she adds.This study was supported, in part, by Oldendorff Carriers. More

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      in Energy

      Taking the “training wheels” off clean energy

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      Renewable power sources have seen unprecedented levels of investment in recent years. But with political uncertainty clouding the future of subsidies for green energy, these technologies must begin to compete with fossil fuels on equal footing, said participants at the 2025 MIT Energy Conference.“What these technologies need less is training wheels, and more of a level playing field,” said Brian Deese, an MIT Institute Innovation Fellow, during a conference-opening keynote panel.The theme of the two-day conference, which is organized each year by MIT students, was “Breakthrough to deployment: Driving climate innovation to market.” Speakers largely expressed optimism about advancements in green technology, balanced by occasional notes of alarm about a rapidly changing regulatory and political environment.Deese defined what he called “the good, the bad, and the ugly” of the current energy landscape. The good: Clean energy investment in the United States hit an all-time high of $272 billion in 2024. The bad: Announcements of future investments have tailed off. And the ugly: Macro conditions are making it more difficult for utilities and private enterprise to build out the clean energy infrastructure needed to meet growing energy demands.“We need to build massive amounts of energy capacity in the United States,” Deese said. “And the three things that are the most allergic to building are high uncertainty, high interest rates, and high tariff rates. So that’s kind of ugly. But the question … is how, and in what ways, that underlying commercial momentum can drive through this period of uncertainty.”A shifting clean energy landscapeDuring a panel on artificial intelligence and growth in electricity demand, speakers said that the technology may serve as a catalyst for green energy breakthroughs, in addition to putting strain on existing infrastructure. “Google is committed to building digital infrastructure responsibly, and part of that means catalyzing the development of clean energy infrastructure that is not only meeting the AI need, but also benefiting the grid as a whole,” said Lucia Tian, head of clean energy and decarbonization technologies at Google.Across the two days, speakers emphasized that the cost-per-unit and scalability of clean energy technologies will ultimately determine their fate. But they also acknowledged the impact of public policy, as well as the need for government investment to tackle large-scale issues like grid modernization.Vanessa Chan, a former U.S. Department of Energy (DoE) official and current vice dean of innovation and entrepreneurship at the University of Pennsylvania School of Engineering and Applied Sciences, warned of the “knock-on” effects of the move to slash National Institutes of Health (NIH) funding for indirect research costs, for example. “In reality, what you’re doing is undercutting every single academic institution that does research across the nation,” she said.During a panel titled “No clean energy transition without transmission,” Maria Robinson, former director of the DoE’s Grid Deployment Office, said that ratepayers alone will likely not be able to fund the grid upgrades needed to meet growing power demand. “The amount of investment we’re going to need over the next couple of years is going to be significant,” she said. “That’s where the federal government is going to have to play a role.”David Cohen-Tanugi, a clean energy venture builder at MIT, noted that extreme weather events have changed the climate change conversation in recent years. “There was a narrative 10 years ago that said … if we start talking about resilience and adaptation to climate change, we’re kind of throwing in the towel or giving up,” he said. “I’ve noticed a very big shift in the investor narrative, the startup narrative, and more generally, the public consciousness. There’s a realization that the effects of climate change are already upon us.”“Everything on the table”The conference featured panels and keynote addresses on a range of emerging clean energy technologies, including hydrogen power, geothermal energy, and nuclear fusion, as well as a session on carbon capture.Alex Creely, a chief engineer at Commonwealth Fusion Systems, explained that fusion (the combining of small atoms into larger atoms, which is the same process that fuels stars) is safer and potentially more economical than traditional nuclear power. Fusion facilities, he said, can be powered down instantaneously, and companies like his are developing new, less-expensive magnet technology to contain the extreme heat produced by fusion reactors.By the early 2030s, Creely said, his company hopes to be operating 400-megawatt power plants that use only 50 kilograms of fuel per year. “If you can get fusion working, it turns energy into a manufacturing product, not a natural resource,” he said.Quinn Woodard Jr., senior director of power generation and surface facilities at geothermal energy supplier Fervo Energy, said his company is making the geothermal energy more economical through standardization, innovation, and economies of scale. Traditionally, he said, drilling is the largest cost in producing geothermal power. Fervo has “completely flipped the cost structure” with advances in drilling, Woodard said, and now the company is focused on bringing down its power plant costs.“We have to continuously be focused on cost, and achieving that is paramount for the success of the geothermal industry,” he said.One common theme across the conference: a number of approaches are making rapid advancements, but experts aren’t sure when — or, in some cases, if — each specific technology will reach a tipping point where it is capable of transforming energy markets.“I don’t want to get caught in a place where we often descend in this climate solution situation, where it’s either-or,” said Peter Ellis, global director of nature climate solutions at The Nature Conservancy. “We’re talking about the greatest challenge civilization has ever faced. We need everything on the table.”The road aheadSeveral speakers stressed the need for academia, industry, and government to collaborate in pursuit of climate and energy goals. Amy Luers, senior global director of sustainability for Microsoft, compared the challenge to the Apollo spaceflight program, and she said that academic institutions need to focus more on how to scale and spur investments in green energy.“The challenge is that academic institutions are not currently set up to be able to learn the how, in driving both bottom-up and top-down shifts over time,” Luers said. “If the world is going to succeed in our road to net zero, the mindset of academia needs to shift. And fortunately, it’s starting to.”During a panel called “From lab to grid: Scaling first-of-a-kind energy technologies,” Hannan Happi, CEO of renewable energy company Exowatt, stressed that electricity is ultimately a commodity. “Electrons are all the same,” he said. “The only thing [customers] care about with regards to electrons is that they are available when they need them, and that they’re very cheap.”Melissa Zhang, principal at Azimuth Capital Management, noted that energy infrastructure development cycles typically take at least five to 10 years — longer than a U.S. political cycle. However, she warned that green energy technologies are unlikely to receive significant support at the federal level in the near future. “If you’re in something that’s a little too dependent on subsidies … there is reason to be concerned over this administration,” she said.World Energy CEO Gene Gebolys, the moderator of the lab-to-grid panel, listed off a number of companies founded at MIT. “They all have one thing in common,” he said. “They all went from somebody’s idea, to a lab, to proof-of-concept, to scale. It’s not like any of this stuff ever ends. It’s an ongoing process.” More

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      in Energy

      Collaboration between MIT and GE Vernova aims to develop and scale sustainable energy systems

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      MIT and GE Vernova today announced the creation of the MIT-GE Vernova Energy and Climate Alliance to help develop and scale sustainable energy systems across the globe.The alliance launches a five-year collaboration between MIT and GE Vernova, a global energy company that spun off from General Electric’s energy business in 2024. The endeavor will encompass research, education, and career opportunities for students, faculty, and staff across MIT’s five schools and the MIT Schwarzman College of Computing. It will focus on three main themes: decarbonization, electrification, and renewables acceleration.“This alliance will provide MIT students and researchers with a tremendous opportunity to work on energy solutions that could have real-world impact,” says Anantha Chandrakasan, MIT’s chief innovation and strategy officer and dean of the School of Engineering. “GE Vernova brings domain knowledge and expertise deploying these at scale. When our researchers develop new innovative technologies, GE Vernova is strongly positioned to bring them to global markets.”Through the alliance, GE Vernova is sponsoring research projects at MIT and providing philanthropic support for MIT research fellowships. The company will also engage with MIT’s community through participation in corporate membership programs and professional education.“It’s a privilege to combine forces with MIT’s world-class faculty and students as we work together to realize an optimistic, innovation-driven approach to solving the world’s most pressing challenges,” says Scott Strazik, GE Vernova CEO. “Through this alliance, we are proud to be able to help drive new technologies while at the same time inspire future leaders to play a meaningful role in deploying technology to improve the planet at companies like GE Vernova.”“This alliance embodies the spirit of the MIT Climate Project — combining cutting-edge research, a shared drive to tackle today’s toughest energy challenges, and a deep sense of optimism about what we can achieve together,” says Sally Kornbluth, president of MIT. “With the combined strengths of MIT and GE Vernova, we have a unique opportunity to make transformative progress in the flagship areas of electrification, decarbonization, and renewables acceleration.”The alliance, comprising a $50 million commitment, will operate within MIT’s Office of Innovation and Strategy. It will fund approximately 12 annual research projects relating to the three themes, as well as three master’s student projects in MIT’s Technology and Policy Program. The research projects will address challenges like developing and storing clean energy, as well as the creation of robust system architectures that help sustainable energy sources like solar, wind, advanced nuclear reactors, green hydrogen, and more compete with carbon-emitting sources.The projects will be selected by a joint steering committee composed of representatives from MIT and GE Vernova, following an annual Institute-wide call for proposals.The collaboration will also create approximately eight endowed GE Vernova research fellowships for MIT students, to be selected by faculty and beginning in the fall. There will also be 10 student internships that will span GE Vernova’s global operations, and GE Vernova will also sponsor programming through MIT’s New Engineering Education Transformation (NEET), which equips students with career-oriented experiential opportunities. Additionally, the alliance will create professional education programming for GE Vernova employees.“The internships and fellowships will be designed to bring students into our ecosystem,” says GE Vernova Chief Corporate Affairs Officer Roger Martella. “Students will walk our factory floor, come to our labs, be a part of our management teams, and see how we operate as business leaders. They’ll get a sense for how what they’re learning in the classroom is being applied in the real world.”Philanthropic support from GE Vernova will also support projects in MIT’s Human Insight Collaborative (MITHIC), which launched last fall to elevate human-centered research and teaching. The projects will allow faculty to explore how areas like energy and cybersecurity influence human behavior and experiences.In connection with the alliance, GE Vernova is expected to join several MIT consortia and membership programs, helping foster collaborations and dialogue between industry experts and researchers and educators across campus.With operations across more than 100 countries, GE Vernova designs, manufactures, and services technologies to generate, transfer, and store electricity with a mission to decarbonize the world. The company is headquartered in Kendall Square, right down the road from MIT, which its leaders say is not a coincidence.“We’re really good at taking proven technologies and commercializing them and scaling them up through our labs,” Martella says. “MIT excels at coming up with those ideas and being a sort of time machine that thinks outside the box to create the future. That’s why this such a great fit: We both have a commitment to research, innovation, and technology.”The alliance is the latest in MIT’s rapidly growing portfolio of research and innovation initiatives around sustainable energy systems, which also includes the Climate Project at MIT. Separate from, but complementary to, the MIT-GE Vernova Alliance, the Climate Project is a campus-wide effort to develop technological, behavioral, and policy solutions to some of the toughest problems impeding an effective global climate response. More

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      in Environment

      Technology developed by MIT engineers makes pesticides stick to plant leaves

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      Reducing the amount of agricultural sprays used by farmers — including fertilizers, pesticides and herbicides — could cut down the amount of polluting runoff that ends up in the environment while at the same time reducing farmers’ costs and perhaps even enhancing their productivity. A classic win-win-win.A team of researchers at MIT and a spinoff company they launched has developed a system to do just that. Their technology adds a thin coating around droplets as they are being sprayed onto a field, greatly reducing their tendency to bounce off leaves and end up wasted on the ground. Instead, the coated droplets stick to the leaves as intended.The research is described today in the journal Soft Matter, in a paper by recent MIT alumni Vishnu Jayaprakash PhD ’22 and Sreedath Panat PhD ’23, graduate student Simon Rufer, and MIT professor of mechanical engineering Kripa Varanasi.A recent study found that if farmers didn’t use pesticides, they would lose 78 percent of fruit, 54 percent of vegetable, and 32 percent of cereal production. Despite their importance, a lack of technology that monitors and optimizes sprays has forced farmers to rely on personal experience and rules of thumb to decide how to apply these chemicals. As a result, these chemicals tend to be over-sprayed, leading to runoff and chemicals ending up in waterways or building up in the soil.Pesticides take a significant toll on global health and the environment, the researchers point out. A recent study found that 31 percent of agricultural soils around the world were at high risk from pesticide pollution. And agricultural chemicals are a major expense for farmers: In the U.S., they spend $16 billion a year just on pesticides.Making spraying more efficient is one of the best ways to make food production more sustainable and economical. Agricultural spraying essentially boils down to mixing chemicals into water and spraying water droplets onto plant leaves, which are often inherently water-repellent. “Over more than a decade of research in my lab at MIT, we have developed fundamental understandings of spraying and the interaction between droplets and plants — studying when they bounce and all the ways we have to make them stick better and enhance coverage,” Varanasi says.The team had previously found a way to reduce the amount of sprayed liquid that bounces away from the leaves it strikes, which involved using two spray nozzles instead of one and spraying mixtures with opposite electrical charges. But they found that farmers were reluctant to take on the expense and effort of converting their spraying equipment to a two-nozzle system. So, the team looked for a simpler alternative.They discovered they could achieve the same improvement in droplet retention using a single-nozzle system that can be easily adapted to existing sprayers. Instead of giving the droplets of pesticide an electric charge, they coat each droplet with a vanishingly thin layer of an oily material.In their new study, they conducted lab experiments with high-speed cameras. When they sprayed droplets with no special treatment onto a water-repelling (hydrophobic) surface similar to that of many plant leaves, the droplets initially spread out into a pancake-like disk, then rebounded back into a ball and bounced away. But when the researchers coated the surface of the droplets with a tiny amount of oil — making up less than 1 percent of the droplet’s liquid — the droplets spread out and then stayed put. The treatment improved the droplets’ “stickiness” by as much as a hundredfold.“When these droplets are hitting the surface and as they expand, they form this oil ring that essentially pins the droplet to the surface,” Rufer says. The researchers tried a wide variety of conditions, he says, explaining that they conducted hundreds of experiments, “with different impact velocities, different droplet sizes, different angles of inclination, all the things that fully characterize this phenomenon.” Though different oils varied in their effectiveness, all of them were effective. “Regardless of the impact velocity and the oils, we saw that the rebound height was significantly lower,” he says.The effect works with remarkably small amounts of oil. In their initial tests they used 1 percent oil compared to the water, then they tried a 0.1 percent, and even .01. The improvement in droplets sticking to the surface continued at a 0.1 percent, but began to break down beyond that. “Basically, this oil film acts as a way to trap that droplet on the surface, because oil is very attracted to the surface and sort of holds the water in place,” Rufer says.In the researchers’ initial tests they used soybean oil for the coating, figuring this would be a familiar material for the farmers they were working with, many of whom were growing soybeans. But it turned out that though they were producing the beans, the oil was not part of their usual supply chain for use on the farm. In further tests, the researchers found that several chemicals that farmers were already routinely using in their spraying, called surfactants and adjuvants, could be used instead, and that some of these provided the same benefits in keeping the droplets stuck on the leaves.“That way,” Varanasi says, “we’re not introducing a new chemical or changed chemistries into their field, but they’re using things they’ve known for a long time.”Varanasi and Jayaprakash formed a company called AgZen to commercialize the system. In order to prove how much their coating system improves the amount of spray that stays on the plant, they first had to develop a system to monitor spraying in real time. That system, which they call RealCoverage, has been deployed on farms ranging in size from a few dozen acres to hundreds of thousands of acres, and many different crop types, and has saved farmers 30 to 50 percent on their pesticide expenditures, just by improving the controls on the existing sprays. That system is being deployed to 920,000 acres of crops in 2025, the company says, including some in California, Texas, the Midwest, France and Italy. Adding the cloaking system using new nozzles, the researchers say, should yield at least another doubling of efficiency.“You could give back a billion dollars to U.S. growers if you just saved 6 percent of their pesticide budget,” says Jayaprakash, lead author of the research paper and CEO of AgZen. “In the lab we got 300 percent of extra product on the plant. So that means we could get orders of magnitude reductions in the amount of pesticides that farmers are spraying.”Farmers had already been using these surfactant and adjuvant chemicals as a way to enhance spraying effectiveness, but they were mixing it with a water solution. For it to have any effect, they had to use much more of these materials, risking causing burns to the plants. The new coating system reduces the amount of these materials needed, while improving their effectiveness.In field tests conducted by AgZen, “we doubled the amount of product on kale and soybeans just by changing where the adjuvant was,” from mixed in to being a coating, Jayaprakash says. It’s convenient for farmers because “all they’re doing is changing their nozzle. They’re getting all their existing chemicals to work better, and they’re getting more product on the plant.”And it’s not just for pesticides. “The really cool thing is this is useful for every chemistry that’s going on the leaf, be it an insecticide, a herbicide, a fungicide, or foliar nutrition,” Varanasi says. This year, they plan to introduce the new spray system on about 30,000 acres of cropland.Varanasi says that with projected world population growth, “the amount of food production has got to double, and we are limited in so many resources, for example we cannot double the arable land. … This means that every acre we currently farm must become more efficient and able to do more with less.” These improved spraying technologies, for both monitoring the spraying and coating the droplets, Varanasi says, “I think is fundamentally changing agriculture.”AgZen has recently raised $10 million in venture financing to support rapid commercial deployment of these technologies that can improve the control of chemical inputs into agriculture. “The knowledge we are gathering from every leaf, combined with our expertise in interfacial science and fluid mechanics, is giving us unparalleled insights into how chemicals are used and developed — and it’s clear that we can deliver value across the entire agrochemical supply chain,” Varanasi says  “Our mission is to use these technologies to deliver improved outcomes and reduced costs for the ag industry.”  More

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      in Environment

      J-WAFS: Supporting food and water research across MIT

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      MIT’s Abdul Latif Jameel Water and Food Systems Lab (J-WAFS) has transformed the landscape of water and food research at MIT, driving faculty engagement and catalyzing new research and innovation in these critical areas. With philanthropic, corporate, and government support, J-WAFS’ strategic approach spans the entire research life cycle, from support for early-stage research to commercialization grants for more advanced projects.Over the past decade, J-WAFS has invested approximately $25 million in direct research funding to support MIT faculty pursuing transformative research with the potential for significant impact. “Since awarding our first cohort of seed grants in 2015, it’s remarkable to look back and see that over 10 percent of the MIT faculty have benefited from J-WAFS funding,” observes J-WAFS Executive Director Renee J. Robins ’83. “Many of these professors hadn’t worked on water or food challenges before their first J-WAFS grant.” By fostering interdisciplinary collaborations and supporting high-risk, high-reward projects, J-WAFS has amplified the capacity of MIT faculty to pursue groundbreaking research that addresses some of the world’s most pressing challenges facing our water and food systems.Drawing MIT faculty to water and food researchJ-WAFS open calls for proposals enable faculty to explore bold ideas and develop impactful approaches to tackling critical water and food system challenges. Professor Patrick Doyle’s work in water purification exemplifies this impact. “Without J-WAFS, I would have never ventured into the field of water purification,” Doyle reflects. While previously focused on pharmaceutical manufacturing and drug delivery, exposure to J-WAFS-funded peers led him to apply his expertise in soft materials to water purification. “Both the funding and the J-WAFS community led me to be deeply engaged in understanding some of the key challenges in water purification and water security,” he explains.Similarly, Professor Otto Cordero of the Department of Civil and Environmental Engineering (CEE) leveraged J-WAFS funding to pivot his research into aquaculture. Cordero explains that his first J-WAFS seed grant “has been extremely influential for my lab because it allowed me to take a step in a new direction, with no preliminary data in hand.” Cordero’s expertise is in microbial communities. He was previous unfamiliar with aquaculture, but he saw the relevance of microbial communities the health of farmed aquatic organisms.Supporting early-career facultyNew assistant professors at MIT have particularly benefited from J-WAFS funding and support. J-WAFS has played a transformative role in shaping the careers and research trajectories of many new faculty members by encouraging them to explore novel research areas, and in many instances providing their first MIT research grant.Professor Ariel Furst reflects on how pivotal J-WAFS’ investment has been in advancing her research. “This was one of the first grants I received after starting at MIT, and it has truly shaped the development of my group’s research program,” Furst explains. With J-WAFS’ backing, her lab has achieved breakthroughs in chemical detection and remediation technologies for water. “The support of J-WAFS has enabled us to develop the platform funded through this work beyond the initial applications to the general detection of environmental contaminants and degradation of those contaminants,” she elaborates. Karthish Manthiram, now a professor of chemical engineering and chemistry at Caltech, explains how J-WAFS’ early investment enabled him and other young faculty to pursue ambitious ideas. “J-WAFS took a big risk on us,” Manthiram reflects. His research on breaking the nitrogen triple bond to make ammonia for fertilizer was initially met with skepticism. However, J-WAFS’ seed funding allowed his lab to lay the groundwork for breakthroughs that later attracted significant National Science Foundation (NSF) support. “That early funding from J-WAFS has been pivotal to our long-term success,” he notes. These stories underscore the broad impact of J-WAFS’ support for early-career faculty, and its commitment to empowering them to address critical global challenges and innovate boldly.Fueling follow-on funding J-WAFS seed grants enable faculty to explore nascent research areas, but external funding for continued work is usually necessary to achieve the full potential of these novel ideas. “It’s often hard to get funding for early stage or out-of-the-box ideas,” notes J-WAFS Director Professor John H. Lienhard V. “My hope, when I founded J-WAFS in 2014, was that seed grants would allow PIs [principal investigators] to prove out novel ideas so that they would be attractive for follow-on funding. And after 10 years, J-WAFS-funded research projects have brought more than $21 million in subsequent awards to MIT.”Professor Retsef Levi led a seed study on how agricultural supply chains affect food safety, with a team of faculty spanning the MIT schools Engineering and Science as well as the MIT Sloan School of Management. The team parlayed their seed grant research into a multi-million-dollar follow-on initiative. Levi reflects, “The J-WAFS seed funding allowed us to establish the initial credibility of our team, which was key to our success in obtaining large funding from several other agencies.”Dave Des Marais was an assistant professor in the Department of CEE when he received his first J-WAFS seed grant. The funding supported his research on how plant growth and physiology are controlled by genes and interact with the environment. The seed grant helped launch his lab’s work addressing enhancing climate change resilience in agricultural systems. The work led to his Faculty Early Career Development (CAREER) Award from the NSF, a prestigious honor for junior faculty members. Now an associate professor, Des Marais’ ongoing project to further investigate the mechanisms and consequences of genomic and environmental interactions is supported by the five-year, $1,490,000 NSF grant. “J-WAFS providing essential funding to get my new research underway,” comments Des Marais.Stimulating interdisciplinary collaborationDes Marais’ seed grant was also key to developing new collaborations. He explains, “the J-WAFS grant supported me to develop a collaboration with Professor Caroline Uhler in EECS/IDSS [the Department of Electrical Engineering and Computer Science/Institute for Data, Systems, and Society] that really shaped how I think about framing and testing hypotheses. One of the best things about J-WAFS is facilitating unexpected connections among MIT faculty with diverse yet complementary skill sets.”Professors A. John Hart of the Department of Mechanical Engineering and Benedetto Marelli of CEE also launched a new interdisciplinary collaboration with J-WAFS funding. They partnered to join expertise in biomaterials, microfabrication, and manufacturing, to create printed silk-based colorimetric sensors that detect food spoilage. “The J-WAFS Seed Grant provided a unique opportunity for multidisciplinary collaboration,” Hart notes.Professors Stephen Graves in the MIT Sloan School of Management and Bishwapriya Sanyal in the Department of Urban Studies and Planning (DUSP) partnered to pursue new research on agricultural supply chains. With field work in Senegal, their J-WAFS-supported project brought together international development specialists and operations management experts to study how small firms and government agencies influence access to and uptake of irrigation technology by poorer farmers. “We used J-WAFS to spur a collaboration that would have been improbable without this grant,” they explain. Being part of the J-WAFS community also introduced them to researchers in Professor Amos Winter’s lab in the Department of Mechanical Engineering working on irrigation technologies for low-resource settings. DUSP doctoral candidate Mark Brennan notes, “We got to share our understanding of how irrigation markets and irrigation supply chains work in developing economies, and then we got to contrast that with their understanding of how irrigation system models work.”Timothy Swager, professor of chemistry, and Rohit Karnik, professor of mechanical engineering and J-WAFS associate director, collaborated on a sponsored research project supported by Xylem, Inc. through the J-WAFS Research Affiliate program. The cross-disciplinary research, which targeted the development of ultra-sensitive sensors for toxic PFAS chemicals, was conceived following a series of workshops hosted by J-WAFS. Swager and Karnik were two of the participants, and their involvement led to the collaborative proposal that Xylem funded. “J-WAFS funding allowed us to combine Swager lab’s expertise in sensing with my lab’s expertise in microfluidics to develop a cartridge for field-portable detection of PFAS,” says Karnik. “J-WAFS has enriched my research program in so many ways,” adds Swager, who is now working to commercialize the technology.Driving global collaboration and impactJ-WAFS has also helped MIT faculty establish and advance international collaboration and impactful global research. By funding and supporting projects that connect MIT researchers with international partners, J-WAFS has not only advanced technological solutions, but also strengthened cross-cultural understanding and engagement.Professor Matthew Shoulders leads the inaugural J-WAFS Grand Challenge project. In response to the first J-WAFS call for “Grand Challenge” proposals, Shoulders assembled an interdisciplinary team based at MIT to enhance and provide climate resilience to agriculture by improving the most inefficient aspect of photosynthesis, the notoriously-inefficient carbon dioxide-fixing plant enzyme RuBisCO. J-WAFS funded this high-risk/high-reward project following a competitive process that engaged external reviewers through a several rounds of iterative proposal development. The technical feedback to the team led them to researchers with complementary expertise from the Australian National University. “Our collaborative team of biochemists and synthetic biologists, computational biologists, and chemists is deeply integrated with plant biologists and field trial experts, yielding a robust feedback loop for enzyme engineering,” Shoulders says. “Together, this team will be able to make a concerted effort using the most modern, state-of-the-art techniques to engineer crop RuBisCO with an eye to helping make meaningful gains in securing a stable crop supply, hopefully with accompanying improvements in both food and water security.”Professor Leon Glicksman and Research Engineer Eric Verploegen’s team designed a low-cost cooling chamber to preserve fruits and vegetables harvested by smallholder farmers with no access to cold chain storage. J-WAFS’ guidance motivated the team to prioritize practical considerations informed by local collaborators, ensuring market competitiveness. “As our new idea for a forced-air evaporative cooling chamber was taking shape, we continually checked that our solution was evolving in a direction that would be competitive in terms of cost, performance, and usability to existing commercial alternatives,” explains Verploegen. Following the team’s initial seed grant, the team secured a J-WAFS Solutions commercialization grant, which Verploegen say “further motivated us to establish partnerships with local organizations capable of commercializing the technology earlier in the project than we might have done otherwise.” The team has since shared an open-source design as part of its commercialization strategy to maximize accessibility and impact.Bringing corporate sponsored research opportunities to MIT facultyJ-WAFS also plays a role in driving private partnerships, enabling collaborations that bridge industry and academia. Through its Research Affiliate Program, for example, J-WAFS provides opportunities for faculty to collaborate with industry on sponsored research, helping to convert scientific discoveries into licensable intellectual property (IP) that companies can turn into commercial products and services.J-WAFS introduced professor of mechanical engineering Alex Slocum to a challenge presented by its research affiliate company, Xylem: how to design a more energy-efficient pump for fluctuating flows. With centrifugal pumps consuming an estimated 6 percent of U.S. electricity annually, Slocum and his then-graduate student Hilary Johnson SM ’18, PhD ’22 developed an innovative variable volute mechanism that reduces energy usage. “Xylem envisions this as the first in a new category of adaptive pump geometry,” comments Johnson. The research produced a pump prototype and related IP that Xylem is working on commercializing. Johnson notes that these outcomes “would not have been possible without J-WAFS support and facilitation of the Xylem industry partnership.” Slocum adds, “J-WAFS enabled Hilary to begin her work on pumps, and Xylem sponsored the research to bring her to this point … where she has an opportunity to do far more than the original project called for.”Swager speaks highly of the impact of corporate research sponsorship through J-WAFS on his research and technology translation efforts. His PFAS project with Karnik described above was also supported by Xylem. “Xylem was an excellent sponsor of our research. Their engagement and feedback were instrumental in advancing our PFAS detection technology, now on the path to commercialization,” Swager says.Looking forwardWhat J-WAFS has accomplished is more than a collection of research projects; a decade of impact demonstrates how J-WAFS’ approach has been transformative for many MIT faculty members. As Professor Mathias Kolle puts it, his engagement with J-WAFS “had a significant influence on how we think about our research and its broader impacts.” He adds that it “opened my eyes to the challenges in the field of water and food systems and the many different creative ideas that are explored by MIT.” This thriving ecosystem of innovation, collaboration, and academic growth around water and food research has not only helped faculty build interdisciplinary and international partnerships, but has also led to the commercialization of transformative technologies with real-world applications. C. Cem Taşan, the POSCO Associate Professor of Metallurgy who is leading a J-WAFS Solutions commercialization team that is about to launch a startup company, sums it up by noting, “Without J-WAFS, we wouldn’t be here at all.”  As J-WAFS looks to the future, its continued commitment — supported by the generosity of its donors and partners — builds on a decade of success enabling MIT faculty to advance water and food research that addresses some of the world’s most pressing challenges. More

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      in Security

      Pivot Bio is using microbial nitrogen to make agriculture more sustainable

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      The Haber-Bosch process, which converts atmospheric nitrogen to make ammonia fertilizer, revolutionized agriculture and helped feed the world’s growing population, but it also created huge environmental problems. It is one of the most energy-intensive chemical processes in the world, responsible for 1-2 percent of global energy consumption. It also releases nitrous oxide, a potent greenhouse gas that harms the ozone layer. Excess nitrogen also routinely runs off farms into waterways, harming marine life and polluting groundwater.In place of synthetic fertilizer, Pivot Bio has engineered nitrogen-producing microbes to make farming more sustainable. The company, which was co-founded by Professor Chris Voigt, Karsten Temme, and Alvin Tamsir, has engineered its microbes to grow on plant roots, where they feed on the root’s sugars and precisely deliver nitrogen in return.Pivot’s microbial colonies grow with the plant and produce more nitrogen at exactly the time the plant needs it, minimizing nitrogen runoff.“The way we have delivered nutrients to support plant growth historically is fertilizer, but that’s an inefficient way to get all the nutrients you need,” says Temme, Pivot’s chief innovation officer. “We have the ability now to help farmers be more efficient and productive with microbes.”Farmers can replace up to 40 pounds per acre of traditional nitrogen with Pivot’s product, which amounts to about a quarter of the total nitrogen needed for a crop like corn.Pivot’s products are already being used to grow corn, wheat, barley, oats, and other grains across millions of acres of American farmland, eliminating hundreds of thousands of tons of CO2 equivalent in the process. The company’s impact is even more striking given its unlikely origins, which trace back to one of the most challenging times of Voigt’s career.A Pivot from despairThe beginning of every faculty member’s career can be a sink-or-swim moment, and by Voigt’s own account, he was drowning. As a freshly minted assistant professor at the University of California at San Francisco, Voigt was struggling to stand up his lab, attract funding, and get experiments started.Around 2008, Voigt joined a research group out of the University of California at Berkeley that was writing a grant proposal focused on photovoltaic materials. His initial role was minor, but a senior researcher pulled out of the group a week before the proposal had to be submitted, so Voigt stepped up.“I said ‘I’ll finish this section in a week,’” Voigt recalls. “It was my big chance.”For the proposal, Voigt detailed an ambitious plan to rearrange the genetics of biologic photosynthetic systems to make them more efficient. He barely submitted it in time.A few months went by, then the proposal reviews finally came back. Voigt hurried to the meeting with some of the most senior researchers at UC Berkeley to discuss the responses.“My part of the proposal got completely slammed,” Voigt says. “There were something like 15 reviews on it — they were longer than the actual grant — and it’s just one after another tearing into my proposal. All the most famous people are in this meeting, future energy secretaries, future leaders of the university, and it was totally embarrassing. After that meeting, I was considering leaving academia.”A few discouraging months later, Voigt got a call from Paul Ludden, the dean of the School of Science at UC Berkeley. He wanted to talk.“As I walk into Paul’s office, he’s reading my proposal,” Voigt recalls. “He sits me down and says, ‘Everybody’s telling me how terrible this is.’ I’m thinking, ‘Oh my God.’ But then he says, ‘I think there’s something here. Your idea is good, you just picked the wrong system.’”Ludden went on to explain to Voigt that he should apply his gene-swapping idea to nitrogen fixation. He even offered to send Voigt a postdoc from his lab, Dehua Zhao, to help. Voigt paired Zhao with Temme, and sure enough, the resulting 2011 paper of their work was well-received by the nitrogen fixation community.“Nitrogen fixation has been a holy grail for scientists, agronomists, and farmers for almost a century, ever since somebody discovered the first microbe that can fix nitrogen for legumes like soybeans,” Temme says. “Everybody always said that someday we’ll be able to do this for the cereal crops. The excitement with Pivot was this is the first time that technology became accessible.”Voigt had moved to MIT in 2010. When the paper came out, he founded Pivot Bio with Temme and another Berkeley researcher, Alvin Tamsir. Since then, Voigt, who is the Daniel I.C. Wang Professor at MIT and the head of the Department of Biological Engineering, has continued collaborating with Pivot on things like increasing nitrogen production, making strains more stable, and making them inducible to different signals from the plant. Pivot has licensed technology from MIT, and the research has also received support from MIT’s Abdul Latif Jameel Water and Food Systems Lab (J-WAFS).Pivot’s first goals were to gain regulatory approval and prove themselves in the marketplace. To gain approval in the U.S., Pivot’s team focused on using DNA from within the same organism rather than bringing in totally new DNA, which simplified the approval process. It also partnered with independent corn seed dealers to get its product to farms. Early deployments occurred in 2019.Farmers apply Pivot’s product at planting, either as a liquid that gets sprayed on the soil or as a dry powder that is rehydrated and applied to the seeds as a coating. The microbes live on the surface of the growing root system, eating plant sugars and releasing nitrogen throughout the plant’s life cycle.“Today, our microbes colonize just a fraction of the total sugars provided by the plant,” Temme explains. “They’re also sharing ammonia with the plant, and all of those things are just a portion of what’s possible technically. Our team is always trying to figure out how to make those microbes more efficient at getting the energy they need to grow or at fixing nitrogen and sharing it with the crop.”In 2023, Pivot started the N-Ovator program to connect companies with growers who practice sustainable farming using Pivot’s microbial nitrogen. Through the program, companies buy nitrogen credits and farmers can get paid by verifying their practices. The program was named one of the Inventions of the Year by Time Magazine last year and has paid out millions of dollars to farmers to date.Microbial nitrogen and beyondPivot is currently selling to farmers across the U.S. and working with smallholder farmers in Kenya. It’s also hoping to gain approval for its microbial solution in Brazil and Canada, which it hopes will be its next markets.”How do we get the economics to make sense for everybody — the farmers, our partners, and the company?” Temme says of Pivot’s mission. “Because this truly can be a deflationary technology that upends the very expensive traditional way of making fertilizer.”Pivot’s team is also extending the product to cotton, and Temme says microbes can be a nitrogen source for any type of plant on the planet. Further down the line, the company believes it can help farmers with other nutrients essential to help their crops grow.“Now that we’ve established our technology, how can Pivot help farmers overcome all the other limitations they face with crop nutrients to maximize yields?” Temme asks. “That really starts to change the way a farmer thinks about managing the entire acre from a price, productivity, and sustainability perspective.” More

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      in Energy

      Puzzling out climate change

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      Shreyaa Raghavan’s journey into solving some of the world’s toughest challenges started with a simple love for puzzles. By high school, her knack for problem-solving naturally drew her to computer science. Through her participation in an entrepreneurship and leadership program, she built apps and twice made it to the semifinals of the program’s global competition.Her early successes made a computer science career seem like an obvious choice, but Raghavan says a significant competing interest left her torn.“Computer science sparks that puzzle-, problem-solving part of my brain,” says Raghavan ’24, an Accenture Fellow and a PhD candidate in MIT’s Institute for Data, Systems, and Society. “But while I always felt like building mobile apps was a fun little hobby, it didn’t feel like I was directly solving societal challenges.”Her perspective shifted when, as an MIT undergraduate, Raghavan participated in an Undergraduate Research Opportunity in the Photovoltaic Research Laboratory, now known as the Accelerated Materials Laboratory for Sustainability. There, she discovered how computational techniques like machine learning could optimize materials for solar panels — a direct application of her skills toward mitigating climate change.“This lab had a very diverse group of people, some from a computer science background, some from a chemistry background, some who were hardcore engineers. All of them were communicating effectively and working toward one unified goal — building better renewable energy systems,” Raghavan says. “It opened my eyes to the fact that I could use very technical tools that I enjoy building and find fulfillment in that by helping solve major climate challenges.”With her sights set on applying machine learning and optimization to energy and climate, Raghavan joined Cathy Wu’s lab when she started her PhD in 2023. The lab focuses on building more sustainable transportation systems, a field that resonated with Raghavan due to its universal impact and its outsized role in climate change — transportation accounts for roughly 30 percent of greenhouse gas emissions.“If we were to throw all of the intelligent systems we are exploring into the transportation networks, by how much could we reduce emissions?” she asks, summarizing a core question of her research.Wu, an associate professor in the Department of Civil and Environmental Engineering, stresses the value of Raghavan’s work.“Transportation is a critical element of both the economy and climate change, so potential changes to transportation must be carefully studied,” Wu says. “Shreyaa’s research into smart congestion management is important because it takes a data-driven approach to add rigor to the broader research supporting sustainability.”Raghavan’s contributions have been recognized with the Accenture Fellowship, a cornerstone of the MIT-Accenture Convergence Initiative for Industry and Technology. As an Accenture Fellow, she is exploring the potential impact of technologies for avoiding stop-and-go traffic and its emissions, using systems such as networked autonomous vehicles and digital speed limits that vary according to traffic conditions — solutions that could advance decarbonization in the transportation section at relatively low cost and in the near term.Raghavan says she appreciates the Accenture Fellowship not only for the support it provides, but also because it demonstrates industry involvement in sustainable transportation solutions.“It’s important for the field of transportation, and also energy and climate as a whole, to synergize with all of the different stakeholders,” she says. “I think it’s important for industry to be involved in this issue of incorporating smarter transportation systems to decarbonize transportation.”Raghavan has also received a fellowship supporting her research from the U.S. Department of Transportation.“I think it’s really exciting that there’s interest from the policy side with the Department of Transportation and from the industry side with Accenture,” she says.Raghavan believes that addressing climate change requires collaboration across disciplines. “I think with climate change, no one industry or field is going to solve it on its own. It’s really got to be each field stepping up and trying to make a difference,” she says. “I don’t think there’s any silver-bullet solution to this problem. It’s going to take many different solutions from different people, different angles, different disciplines.”With that in mind, Raghavan has been very active in the MIT Energy and Climate Club since joining about three years ago, which, she says, “was a really cool way to meet lots of people who were working toward the same goal, the same climate goals, the same passions, but from completely different angles.”This year, Raghavan is on the community and education team, which works to build the community at MIT that is working on climate and energy issues. As part of that work, Raghavan is launching a mentorship program for undergraduates, pairing them with graduate students who help the undergrads develop ideas about how they can work on climate using their unique expertise.“I didn’t foresee myself using my computer science skills in energy and climate,” Raghavan says, “so I really want to give other students a clear pathway, or a clear sense of how they can get involved.”Raghavan has embraced her area of study even in terms of where she likes to think.“I love working on trains, on buses, on airplanes,” she says. “It’s really fun to be in transit and working on transportation problems.”Anticipating a trip to New York to visit a cousin, she holds no dread for the long train trip.“I know I’m going to do some of my best work during those hours,” she says. “Four hours there. Four hours back.” More

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      in Environment

      Cleaning up critical minerals and materials production, using microwave plasma

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      The push to bring manufacturing back to the U.S. is running up against an unfortunate truth: The processes for making many critical materials today create toxic byproducts and other environmental hazards. That’s true for commonly used industrial metals like nickel and titanium, as well as specialty minerals, materials, and coatings that go into batteries, advanced electronics, and defense applications.Now 6K, founded by former MIT research scientist Kamal Hadidi, is using a new production process to bring critical materials production back to America without the toxic byproducts.The company is actively scaling its microwave plasma technology, which it calls UniMelt, to transform the way critical minerals are processed, creating new domestic supply chains in the process. UniMelt uses beams of tightly controlled thermal plasma to melt or vaporize precursor materials into particles with precise sizes and crystalline phases.The technology converts metals, such as titanium, nickel, and refractory alloys, into particles optimized for additive manufacturing for a range of industrial applications. It is also being used to create battery materials for electric vehicles, grid infrastructure, and data centers.“The markets and critical materials we are focused on are important for not just economic reasons but also U.S. national security, because the bulk of these materials are manufactured today in nonfriendly countries,” 6K CEO Saurabh Ullal says. “Now, the [U.S. government] and our growing customer base can leverage this technology invented at MIT to make the U.S. less dependent on these nonfriendly countries, ensuring supply chain independence now and in the future.”Named after the 6,000-degree temperature of its plasma, 6K is currently selling its high-performance metal powders to parts manufacturers as well as defense, automotive, medical, and oil and gas companies for use in applications from engine components and medical implants to rockets. To scale its battery materials business, 6K is also building a 100,000-square-foot production facility in Jackson, Tennessee, which will begin construction later this year.A weekend projectBetween 1994 and 2007, Hadidi worked at the Plasma Science and Fusion Center (PFSC), where he developed plasma technologies for a range of applications, including hydrogen production, fuel reforming, and detecting environmental toxins. His first company was founded in 2000 out of the PFSC to detect mercury in coal-fired power plants’ smokestacks.“I loved working at MIT,” Hadidi says. “It’s an amazing place that really challenges you. Just being there is so stimulating because everyone’s trying to come up with new solutions and connect dots between different fields.”Hadidi also began using high-frequency microwave plasmas to create nanomaterials for use in optical applications. He wasn’t a materials expert, so he collaborated with Professor Eric Jordan, a materials synthesis expert from the University of Connecticut, and the researchers started working on nights and weekends in the PSFC to develop the idea further, eventually patenting the technology.Hadidi officially founded the company as Amastan in 2007, exploring the use of his microwave plasma technology, later named UniMelt for “uniform melt state process,” to make a host of different materials as part of a government grant he and Jordan received.The researchers soon realized the microwave plasma technology had several advantages over traditional production techniques for certain materials. For one, it could eliminate several high-energy steps of conventional processes, reducing production times from days to hours in some cases. For batteries and certain critical minerals, the process also works with recycled feedstocks. Amastan was renamed 6K in 2019.Early on, Hadidi produced metal powders used in additive manufacturing through a process called spheroidization, which results in dense, spherical powders that flow well and make high-performance 3D-printed parts.Following another grant, Hadidi explored methods for producing a type of battery cathode made from lithium, nickel, manganese, and cobalt (NMC). The standard process for making NMCs involved chemical synthesis, precipitation, heat treatment, and a lot of water. 6K is able to reduce many of those steps, speeding up production and lowering costs while also being more sustainable.“Our technology completely eliminates toxic waste and recycles all of the byproducts back through the process to utilize everything, including water,” Ullal says.Scaling domestic productionToday, 6K’s additive manufacturing arm operates out of a factory in Pennsylvania. The company’s critical minerals processing, refining, and recycling systems can produce about 400 tons of material per year and can be used to make more than a dozen types of metal powders. The company also has 33,000-square-foot battery center in North Andover, Massachusetts, where it produces battery cathode materials for its energy storage and mobility customers.The Tennessee facility will be used to produce battery cathode materials and represents a massive step up in throughput. The company says it will be able to produce 13,000 tons of material annually when construction is complete next year.“I’m happy if what I started brings something positive to society, and I’m extremely thankful to all the people that helped me,” says Hadidi, who left the company in 2019. “I’m an entrepreneur at heart. I like to make things. But that doesn’t mean I always succeed. It’s personally very satisfying to see this make an impact.”The 6K team says its technology can also create a variety of specialty ceramics, advanced coatings, and nanoengineered materials. They say it may also be used to eliminate PFAS, or “forever chemicals,” though that work is at an early stage.The company recently received a grant to demonstrate a process for recycling critical materials from military depots to produce aerospace and defense products, creating a new value stream for these materials that would otherwise deteriorate or go to landfill. That work is consistent with the company’s motto, “We take nothing from the ground and put nothing into the ground.”The company’s additive division recently received a $23.4 Defense Production Act grant “that will enable us to double processing capacity in the next three years,” Ullal says. “The next step is to scale battery materials production to the tens of thousands of tons per year. At this point, it’s a scale-up of known processes, and we just need to execute. The idea of creating a circular economy is near and dear to us because that’s how we’ve built this company and that’s how we generate value: addressing our U.S. national security concerns and protecting the planet as well.” More