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      Tackling the MIT campus’s top energy consumers, building by building

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      When staff in MIT’s Department of Facilities would visualize energy use and carbon-associated emissions by campus buildings, Building 46 always stood out — attributed to its energy intensity, which accounted for 8 percent of MIT’s total campus energy use. This high energy draw was not surprising, as the building is home of the Brain and Cognitive Sciences Complex and a large amount of lab space, but it also made the building a perfect candidate for an energy performance audit to seek out potential energy saving opportunities.

      This audit revealed that several energy efficiency updates to the building mechanical systems infrastructure, including optimization of the room-by-room ventilation rates, could result in an estimated 35 percent reduction of energy use, which would in turn lower MIT’s total greenhouse gas emissions by an estimated 2 percent — driving toward the Institute’s 2026 goal of net-zero and 2050 goal of elimination of direct campus emissions.

      Building energy efficiency projects are not new for MIT. Since 2010, MIT has been engaged in a partnership agreement with utility company Eversource establishing the Efficiency Forward program, empowering MIT to invest in more than 300 energy conservation projects to date and lowering energy consumption on campus for a total calculated savings of approximately 70 million kilowatt hours and 4.2 million therms. But at 418,000 gross square feet, Building 46 is the first energy efficiency project of its size on the campus.

      “We’ve never tackled a whole building like this — it’s the first capital project that is technically an energy project,” explains Siobhan Carr, energy efficiency program manager, who was part of the team overseeing the energy audit and lab ventilation performance assessment in the building. “That gives you an idea of the magnitude and complexity of this.”

      The project started with the full building energy assessment and lab ventilation risk audit. “We had a team go through every corner of the building and look at every possible opportunity to save energy,” explains Jessica Parks, senior project manager for systems performance and turnover in campus construction. “One of the biggest issues we saw was that there’s a lot of dry lab spaces which are basically offices, but they’re all getting the same ventilation as if they were a high-intensity lab.” Higher ventilation and more frequent air exchange rates draw more energy. By optimizing for the required ventilation rates, there was an opportunity to save energy in nearly every space in the building.

      In addition to the optimized ventilation, the project team will convert fume hoods from constant volume to variable volume and install equipment to help the building systems run more efficiently. The team also identified opportunities to work with labs to implement programs such as fume hood hibernation and unoccupied setbacks for temperature and ventilation. As different spaces in the building have varying needs, the energy retrofit will touch all 1,254 spaces in the building — one by one — to implement the different energy measures to reach that estimated 35 percent reduction in energy use.

      Although time-consuming and complex, this room-by-room approach has a big benefit in that it has allowed research to continue in the space largely uninterrupted. With a few exceptions, the occupants of Building 46, which include the Department of Brain and Cognitive Sciences, The McGovern Institute for Brain Research, and The Picower Institute for Learning and Memory, have remained in place for the duration of the project. Partners in the MIT Environment, Health and Safety Office are instrumental to this balance of renovations and keeping the building operational during the optimization efforts and are one of several teams across MIT contributing to building efficiency efforts.

      The completion date of the building efficiency project is set for 2024, but Carr says that some of the impact of this ongoing work may soon be seen. “We should start to see savings as we move through the building, and we expect to fully realize all of our projected savings a year after completion,” she says, noting that the length of time is required for a year-over-year perspective to see the full reduction in energy use.

      The impact of the project goes far beyond the footprint of Building 46 as it offers insights and spurred actions for future projects — including buildings 76 and 68, the number two and three top energy users on campus. Both buildings recently underwent their own energy audits and lab ventilation performance assessments. The energy efficiency team is now crafting a plan for full-building approaches, much like Building 46. “To date, 46 has presented many learning opportunities, such as how to touch every space in a building while research continues, as well as how to overcome challenges encountered when working on existing systems,” explains Parks. “The good news is that we have developed solutions for those challenges and the teams have been proactively implementing those lessons in our other projects.”

      Communication has proven to be another key for these large projects where occupants see the work happening and often play a role in answering questions about their unique space. “People are really engaged, they ask questions about the work, and we ask them about the space they’re in every day,” says Parks. “The Building 46 occupants have been wonderful partners as we worked in all of their spaces, which is paving the way for a successful project.”

      The release of Fast Forward in 2021 has also made communications easier, notes Carr, who says the plan helps to frame these projects as part of the big picture — not just a construction interruption. “Fast Forward has brought a visibility into what we’re doing within [MIT] Facilities on these buildings,” she says. “It brings more eyes and ears, and people understand that these projects are happening throughout campus and not just in their own space — we’re all working to reduce energy and to reduce greenhouse gas across campus.”

      The Energy Efficiency team will continue to apply that big-picture approach as ongoing building efficiency projects on campus are assessed to reach toward a 10 to 15 percent reduction in energy use and corresponding emissions over the next several years. More

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      Pursuing a practical approach to research

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      Koroush Shirvan, the John Clark Hardwick Career Development Professor in the Department of Nuclear Science and Engineering (NSE), knows that the nuclear industry has traditionally been wary of innovations until they are shown to have proven utility. As a result, he has relentlessly focused on practical applications in his research, work that has netted him the 2022 Reactor Technology Award from the American Nuclear Society. “The award has usually recognized practical contributions to the field of reactor design and has not often gone to academia,” Shirvan says.

      One of these “practical contributions” is in the field of accident-tolerant fuels, a program launched by the U.S. Nuclear Regulatory Commission in the wake of the 2011 Fukushima Daiichi incident. The goal within this program, says Shirvan, is to develop new forms of nuclear fuels that can tolerate heat. His team, with students from over 16 countries, is working on numerous possibilities that range in composition and method of production.

      Another aspect of Shirvan’s research focuses on how radiation impacts heat transfer mechanisms in the reactor. The team found fuel corrosion to be the driving force. “[The research] informs how nuclear fuels perform in the reactor, from a practical point of view,” Shirvan says.

      Optimizing nuclear reactor design

      A summer internship when Shirvan was an undergraduate at the University of Florida at Gainesville seeded his drive to focus on practical applications in his studies. A nearby nuclear utility was losing millions because of crud accumulating on fuel rods. Over time, the company was solving the problem by using more fuel, before it had extracted all the life from earlier batches.

      Placement of fuel rods in nuclear reactors is a complex problem with many factors — the life of the fuel, location of hot spots — affecting outcomes. Nuclear reactors change their configuration of fuel rods every 18-24 months to optimize close to 15-20 constraints, leading to roughly 200-800 assemblies. The mind-boggling nature of the problem means that plants have to rely on experienced engineers.

      During his internship, Shirvan optimized the program used to place fuel rods in the reactor. He found that certain rods in assemblies were more prone to the crud deposits, and reworked their configurations, optimizing for these rods’ performance instead of adding assemblies.

      In recent years, Shirvan has applied a branch of artificial intelligence — reinforcement learning — to the configuration problem and created a software program used by the largest U.S. nuclear utility. “This program gives even a layperson the ability to reconfigure the fuels and the reactor without having expert knowledge,” Shirvan says.

      From advanced math to counting jelly beans

      Shirvan’s own expertise in nuclear science and engineering developed quite organically. He grew up in Tehran, Iran, and when he was 14 the family moved to Gainesville, where Shirvan’s aunt and family live. He remembers an awkward couple of years at the new high school where he was grouped in with newly arrived international students, and placed in entry-level classes. “I went from doing advanced mathematics in Iran to counting jelly beans,” he laughs.

      Shirvan applied to the University of Florida for his undergraduate studies since it made economic sense; the school gave full scholarships to Floridian students who received a certain minimum SAT score. Shirvan qualified. His uncle, who was a professor in the nuclear engineering department then, encouraged Shirvan to take classes in the department. Under his uncle’s mentorship, the courses Shirvan took, and his internship, cemented his love of the interdisciplinary approach that the field demanded.

      Having always known that he wanted to teach — he remembers finishing his math tests early in Tehran so he could earn the reward of being class monitor — Shirvan knew graduate school was next. His uncle encouraged him to apply to MIT and to the University of Michigan, home to reputable programs in the field. Shirvan chose MIT because “only at MIT was there a program on nuclear design. There were faculty dedicated to designing new reactors, looking at multiple disciplines, and putting all of that together.” He went on to pursue his master’s and doctoral studies at NSE under the supervision of Professor Mujid Kazimi, focusing on compact pressurized and boiling water reactor designs. When Kazimi passed away suddenly in 2015, Shirvan was a research scientist, and switched to tenure track to guide the professor’s team.

      Another project that Shirvan took in 2015: leadership of MIT’s course on nuclear reactor technology for utility executives. Offered only by the Institute, the program is an introduction to nuclear engineering and safety for personnel who might not have much background in the area. “It’s a great course because you get to see what the real problems are in the energy sector … like grid stability,” Shirvan says.

      A multipronged approach to savings

      Another very real problem nuclear utilities face is cost. Contrary to what one hears on the news, one of the biggest stumbling blocks to building new nuclear facilities in the United States is cost, which today can be up to three times that of renewables, Shirvan says. While many approaches such as advanced manufacturing have been tried, Shirvan believes that the solution to decrease expenditures lies in designing more compact reactors.

      His team has developed an open-source advanced nuclear cost tool and has focused on two different designs: a small water reactor using compact steam technology and a horizontal gas reactor. Compactness also means making fuels more efficient, as Shirvan’s work does, and in improving the heat exchange device. It’s all back to the basics and bringing “commercial viable arguments in with your research,” Shirvan explains.

      Shirvan is excited about the future of the U.S. nuclear industry, and that the 2022 Inflation Reduction Act grants the same subsidies to nuclear as it does for renewables. In this new level playing field, advanced nuclear still has a long way to go in terms of affordability, he admits. “It’s time to push forward with cost-effective design,” Shirvan says, “I look forward to supporting this by continuing to guide these efforts with research from my team.” More

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      A breakthrough on “loss and damage,” but also disappointment, at UN climate conference

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      As the 2022 United Nations climate change conference, known as COP27, stretched into its final hours on Saturday, Nov. 19, it was uncertain what kind of agreement might emerge from two weeks of intensive international negotiations.

      In the end, COP27 produced mixed results: on the one hand, a historic agreement for wealthy countries to compensate low-income countries for “loss and damage,” but on the other, limited progress on new plans for reducing the greenhouse gas emissions that are warming the planet.

      “We need to drastically reduce emissions now — and this is an issue this COP did not address,” said U.N. Secretary-General António Guterres in a statement at the conclusion of COP27. “A fund for loss and damage is essential — but it’s not an answer if the climate crisis washes a small island state off the map — or turns an entire African country to desert.”

      Throughout the two weeks of the conference, a delegation of MIT students, faculty, and staff was at the Sharm El-Sheikh International Convention Center to observe the negotiations, conduct and share research, participate in panel discussions, and forge new connections with researchers, policymakers, and advocates from around the world.

      Loss and damage

      A key issue coming in to COP27 (COP stands for “conference of the parties” to the U.N. Framework Convention on Climate Change, held for the 27th time) was loss and damage: a term used by the U.N. to refer to harms caused by climate change — either through acute catastrophes like extreme weather events or slower-moving impacts like sea level rise — to which communities and countries are unable to adapt. 

      Ultimately, a deal on loss and damage proved to be COP27’s most prominent accomplishment. Negotiators reached an eleventh-hour agreement to “establish new funding arrangements for assisting developing countries that are particularly vulnerable to the adverse effects of climate change.” 

      “Providing financial assistance to developing countries so they can better respond to climate-related loss and damage is not only a moral issue, but also a pragmatic one,” said Michael Mehling, deputy director of the MIT Center for Energy and Environmental Policy Research, who attended COP27 and participated in side events. “Future emissions growth will be squarely centered in the developing world, and offering support through different channels is key to building the trust needed for more robust global cooperation on mitigation.”

      Youssef Shaker, a graduate student in the MIT Technology and Policy Program and a research assistant with the MIT Energy Initiative, attended the second week of the conference, where he followed the negotiations over loss and damage closely. 

      “While the creation of a fund is certainly an achievement,” Shaker said, “significant questions remain to be answered, such as the size of the funding available as well as which countries receive access to it.” A loss-and-damage fund that is not adequately funded, Shaker noted, “would not be an impactful outcome.” 

      The agreement on loss and damage created a new committee, made up of 24 country representatives, to “operationalize” the new funding arrangements, including identifying funding sources. The committee is tasked with delivering a set of recommendations at COP28, which will take place next year in Dubai.

      Advising the U.N. on net zero

      Though the decisions reached at COP27 did not include major new commitments on reducing emissions from the combustion of fossil fuels, the transition to a clean global energy system was nevertheless a key topic of conversation throughout the conference.

      The Council of Engineers for the Energy Transition (CEET), an independent, international body of engineers and energy systems experts formed to provide advice to the U.N. on achieving net-zero emissions globally by 2050, convened for the first time at COP27. Jessika Trancik, a professor in the MIT Institute for Data, Systems, and Society and a member of CEET, spoke on a U.N.-sponsored panel on solutions for the transition to clean energy.

      Trancik noted that the energy transition will look different in different regions of the world. “As engineers, we need to understand those local contexts and design solutions around those local contexts — that’s absolutely essential to support a rapid and equitable energy transition.”

      At the same time, Trancik noted that there is now a set of “low-cost, ready-to-scale tools” available to every region — tools that resulted from a globally competitive process of innovation, stimulated by public policies in different countries, that dramatically drove down the costs of technologies like solar energy and lithium-ion batteries. The key, Trancik said, is for regional transition strategies to “tap into global processes of innovation.”

      Reinventing climate adaptation

      Elfatih Eltahir, the H. M. King Bhumibol Professor of Hydrology and Climate, traveled to COP27 to present plans for the Jameel Observatory Climate Resilience Early Warning System (CREWSnet), one of the five projects selected in April 2022 as a flagship in MIT’s Climate Grand Challenges initiative. CREWSnet focuses on climate adaptation, the term for adapting to climate impacts that are unavoidable.

      The aim of CREWSnet, Eltahir told the audience during a panel discussion, is “nothing short of reinventing the process of climate change adaptation,” so that it is proactive rather than reactive; community-led; data-driven and evidence-based; and so that it integrates different climate risks, from heat waves to sea level rise, rather than treating them individually.

      “However, it’s easy to talk about these changes,” said Eltahir. “The real challenge, which we are now just launching and engaging in, is to demonstrate that on the ground.” Eltahir said that early demonstrations will happen in a couple of key locations, including southwest Bangladesh, where multiple climate risks — rising sea levels, increasing soil salinity, and intensifying heat waves and cyclones — are combining to threaten the area’s agricultural production.

      Building on COP26

      Some members of MIT’s delegation attended COP27 to advance efforts that had been formally announced at last year’s U.N. climate conference, COP26, in Glasgow, Scotland.

      At an official U.N. side event co-organized by MIT on Nov. 11, Greg Sixt, the director of the Food and Climate Systems Transformation (FACT) Alliance led by the Abdul Latif Jameel Water and Food Systems Lab, provided an update on the alliance’s work since its launch at COP26.

      Food systems are a major source of greenhouse gas emissions — and are increasingly vulnerable to climate impacts. The FACT Alliance works to better connect researchers to farmers, food businesses, policymakers, and other food systems stakeholders to make food systems (which include food production, consumption, and waste) more sustainable and resilient. 

      Sixt told the audience that the FACT Alliance now counts over 20 research and stakeholder institutions around the world among its members, but also collaborates with other institutions in an “open network model” to advance work in key areas — such as a new research project exploring how climate scenarios could affect global food supply chains.

      Marcela Angel, research program director for the Environmental Solutions Initiative (ESI), helped convene a meeting at COP27 of the Afro-InterAmerican Forum on Climate Change, which also launched at COP26. The forum works with Afro-descendant leaders across the Americas to address significant environmental issues, including climate risks and biodiversity loss. 

      At the event — convened with the Colombian government and the nonprofit Conservation International — ESI brought together leaders from six countries in the Americas and presented recent work that estimates that there are over 178 million individuals who identify as Afro-descendant living in the Americas, in lands of global environmental importance. 

      “There is a significant overlap between biodiversity hot spots, protected areas, and areas of high Afro-descendant presence,” said Angel. “But the role and climate contributions of these communities is understudied, and often made invisible.”    

      Limiting methane emissions

      Methane is a short-lived but potent greenhouse gas: When released into the atmosphere, it immediately traps about 120 times more heat than carbon dioxide does. More than 150 countries have now signed the Global Methane Pledge, launched at COP26, which aims to reduce methane emissions by at least 30 percent by 2030 compared to 2020 levels.

      Sergey Paltsev, the deputy director of the Joint Program on the Science and Policy of Global Change and a senior research scientist at the MIT Energy Initiative, gave the keynote address at a Nov. 17 event on methane, where he noted the importance of methane reductions from the oil and gas sector to meeting the 2030 goal.

      “The oil and gas sector is where methane emissions reductions could be achieved the fastest,” said Paltsev. “We also need to employ an integrated approach to address methane emissions in all sectors and all regions of the world because methane emissions reductions provide a near-term pathway to avoiding dangerous tipping points in the global climate system.”

      “Keep fighting relentlessly”

      Arina Khotimsky, a senior majoring in materials science and engineering and a co-president of the MIT Energy and Climate Club, attended the first week of COP27. She reflected on the experience in a social media post after returning home. 

      “COP will always have its haters. Is there greenwashing? Of course! Is everyone who should have a say in this process in the room? Not even close,” wrote Khotimsky. “So what does it take for COP to matter? It takes everyone who attended to not only put ‘climate’ on front-page news for two weeks, but to return home and keep fighting relentlessly against climate change. I know that I will.” More

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      Reversing the charge

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      Owners of electric vehicles (EVs) are accustomed to plugging into charging stations at home and at work and filling up their batteries with electricity from the power grid. But someday soon, when these drivers plug in, their cars will also have the capacity to reverse the flow and send electrons back to the grid. As the number of EVs climbs, the fleet’s batteries could serve as a cost-effective, large-scale energy source, with potentially dramatic impacts on the energy transition, according to a new paper published by an MIT team in the journal Energy Advances.

      “At scale, vehicle-to-grid (V2G) can boost renewable energy growth, displacing the need for stationary energy storage and decreasing reliance on firm [always-on] generators, such as natural gas, that are traditionally used to balance wind and solar intermittency,” says Jim Owens, lead author and a doctoral student in the MIT Department of Chemical Engineering. Additional authors include Emre Gençer, a principal research scientist at the MIT Energy Initiative (MITEI), and Ian Miller, a research specialist for MITEI at the time of the study.

      The group’s work is the first comprehensive, systems-based analysis of future power systems, drawing on a novel mix of computational models integrating such factors as carbon emission goals, variable renewable energy (VRE) generation, and costs of building energy storage, production, and transmission infrastructure.

      “We explored not just how EVs could provide service back to the grid — thinking of these vehicles almost like energy storage on wheels — but also the value of V2G applications to the entire energy system and if EVs could reduce the cost of decarbonizing the power system,” says Gençer. “The results were surprising; I personally didn’t believe we’d have so much potential here.”

      Displacing new infrastructure

      As the United States and other nations pursue stringent goals to limit carbon emissions, electrification of transportation has taken off, with the rate of EV adoption rapidly accelerating. (Some projections show EVs supplanting internal combustion vehicles over the next 30 years.) With the rise of emission-free driving, though, there will be increased demand for energy. “The challenge is ensuring both that there’s enough electricity to charge the vehicles and that this electricity is coming from renewable sources,” says Gençer.

      But solar and wind energy is intermittent. Without adequate backup for these sources, such as stationary energy storage facilities using lithium-ion batteries, for instance, or large-scale, natural gas- or hydrogen-fueled power plants, achieving clean energy goals will prove elusive. More vexing, costs for building the necessary new energy infrastructure runs to the hundreds of billions.

      This is precisely where V2G can play a critical, and welcome, role, the researchers reported. In their case study of a theoretical New England power system meeting strict carbon constraints, for instance, the team found that participation from just 13.9 percent of the region’s 8 million light-duty (passenger) EVs displaced 14.7 gigawatts of stationary energy storage. This added up to $700 million in savings — the anticipated costs of building new storage capacity.

      Their paper also described the role EV batteries could play at times of peak demand, such as hot summer days. “V2G technology has the ability to inject electricity back into the system to cover these episodes, so we don’t need to install or invest in additional natural gas turbines,” says Owens. “The way that EVs and V2G can influence the future of our power systems is one of the most exciting and novel aspects of our study.”

      Modeling power

      To investigate the impacts of V2G on their hypothetical New England power system, the researchers integrated their EV travel and V2G service models with two of MITEI’s existing modeling tools: the Sustainable Energy System Analysis Modeling Environment (SESAME) to project vehicle fleet and electricity demand growth, and GenX, which models the investment and operation costs of electricity generation, storage, and transmission systems. They incorporated such inputs as different EV participation rates, costs of generation for conventional and renewable power suppliers, charging infrastructure upgrades, travel demand for vehicles, changes in electricity demand, and EV battery costs.

      Their analysis found benefits from V2G applications in power systems (in terms of displacing energy storage and firm generation) at all levels of carbon emission restrictions, including one with no emissions caps at all. However, their models suggest that V2G delivers the greatest value to the power system when carbon constraints are most aggressive — at 10 grams of carbon dioxide per kilowatt hour load. Total system savings from V2G ranged from $183 million to $1,326 million, reflecting EV participation rates between 5 percent and 80 percent.

      “Our study has begun to uncover the inherent value V2G has for a future power system, demonstrating that there is a lot of money we can save that would otherwise be spent on storage and firm generation,” says Owens.

      Harnessing V2G

      For scientists seeking ways to decarbonize the economy, the vision of millions of EVs parked in garages or in office spaces and plugged into the grid for 90 percent of their operating lives proves an irresistible provocation. “There is all this storage sitting right there, a huge available capacity that will only grow, and it is wasted unless we take full advantage of it,” says Gençer.

      This is not a distant prospect. Startup companies are currently testing software that would allow two-way communication between EVs and grid operators or other entities. With the right algorithms, EVs would charge from and dispatch energy to the grid according to profiles tailored to each car owner’s needs, never depleting the battery and endangering a commute.

      “We don’t assume all vehicles will be available to send energy back to the grid at the same time, at 6 p.m. for instance, when most commuters return home in the early evening,” says Gençer. He believes that the vastly varied schedules of EV drivers will make enough battery power available to cover spikes in electricity use over an average 24-hour period. And there are other potential sources of battery power down the road, such as electric school buses that are employed only for short stints during the day and then sit idle.

      The MIT team acknowledges the challenges of V2G consumer buy-in. While EV owners relish a clean, green drive, they may not be as enthusiastic handing over access to their car’s battery to a utility or an aggregator working with power system operators. Policies and incentives would help.

      “Since you’re providing a service to the grid, much as solar panel users do, you could be paid for your participation, and paid at a premium when electricity prices are very high,” says Gençer.

      “People may not be willing to participate ’round the clock, but if we have blackout scenarios like in Texas last year, or hot-day congestion on transmission lines, maybe we can turn on these vehicles for 24 to 48 hours, sending energy back to the system,” adds Owens. “If there’s a power outage and people wave a bunch of money at you, you might be willing to talk.”

      “Basically, I think this comes back to all of us being in this together, right?” says Gençer. “As you contribute to society by giving this service to the grid, you will get the full benefit of reducing system costs, and also help to decarbonize the system faster and to a greater extent.”

      Actionable insights

      Owens, who is building his dissertation on V2G research, is now investigating the potential impact of heavy-duty electric vehicles in decarbonizing the power system. “The last-mile delivery trucks of companies like Amazon and FedEx are likely to be the earliest adopters of EVs,” Owen says. “They are appealing because they have regularly scheduled routes during the day and go back to the depot at night, which makes them very useful for providing electricity and balancing services in the power system.”

      Owens is committed to “providing insights that are actionable by system planners, operators, and to a certain extent, investors,” he says. His work might come into play in determining what kind of charging infrastructure should be built, and where.

      “Our analysis is really timely because the EV market has not yet been developed,” says Gençer. “This means we can share our insights with vehicle manufacturers and system operators — potentially influencing them to invest in V2G technologies, avoiding the costs of building utility-scale storage, and enabling the transition to a cleaner future. It’s a huge win, within our grasp.”

      The research for this study was funded by MITEI’s Future Energy Systems Center. More

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      With new heat treatment, 3D-printed metals can withstand extreme conditions

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      A new MIT-developed heat treatment transforms the microscopic structure of 3D-printed metals, making the materials stronger and more resilient in extreme thermal environments. The technique could make it possible to 3D print high-performance blades and vanes for power-generating gas turbines and jet engines, which would enable new designs with improved fuel consumption and energy efficiency.

      Today’s gas turbine blades are manufactured through conventional casting processes in which molten metal is poured into complex molds and directionally solidified. These components are made from some of the most heat-resistant metal alloys on Earth, as they are designed to rotate at high speeds in extremely hot gas, extracting work to generate electricity in power plants and thrust in jet engines.

      There is growing interest in manufacturing turbine blades through 3D-printing, which, in addition to its environmental and cost benefits, could allow manufacturers to quickly produce more intricate, energy-efficient blade geometries. But efforts to 3D-print turbine blades have yet to clear a big hurdle: creep.

      In metallurgy, creep refers to a metal’s tendency to permanently deform in the face of persistent mechanical stress and high temperatures. While researchers have explored printing turbine blades, they have found that the printing process produces fine grains on the order of tens to hundreds of microns in size — a microstructure that is especially vulnerable to creep.

      “In practice, this would mean a gas turbine would have a shorter life or less fuel efficiency,” says Zachary Cordero, the Boeing Career Development Professor in Aeronautics and Astronautics at MIT. “These are costly, undesirable outcomes.”

      Cordero and his colleagues found a way to improve the structure of 3D-printed alloys by adding an additional heat-treating step, which transforms the as-printed material’s fine grains into much larger “columnar” grains — a sturdier microstructure that should minimize the material’s creep potential, since the “columns” are aligned with the axis of greatest stress. The researchers say the method, outlined today in Additive Manufacturing, clears the way for industrial 3D-printing of gas turbine blades.

      “In the near future, we envision gas turbine manufacturers will print their blades and vanes at large-scale additive manufacturing plants, then post-process them using our heat treatment,” Cordero says. “3D-printing will enable new cooling architectures that can improve the thermal efficiency of a turbine, so that it produces the same amount of power while burning less fuel and ultimately emits less carbon dioxide.”

      Cordero’s co-authors on the study are lead author Dominic Peachey, Christopher Carter, and Andres Garcia-Jimenez at MIT, Anugrahaprada Mukundan and Marie-Agathe Charpagne of the University of Illinois at Urbana-Champaign, and Donovan Leonard of Oak Ridge National Laboratory.

      Triggering a transformation

      The team’s new method is a form of directional recrystallization — a heat treatment that passes a material through a hot zone at a precisely controlled speed to meld a material’s many microscopic grains into larger, sturdier, and more uniform crystals.

      Directional recrystallization was invented more than 80 years ago and has been applied to wrought materials. In their new study, the MIT team adapted directional recrystallization for 3D-printed superalloys.

      The team tested the method on 3D-printed nickel-based superalloys — metals that are typically cast and used in gas turbines. In a series of experiments, the researchers placed 3D-printed samples of rod-shaped superalloys in a room-temperature water bath placed just below an induction coil. They slowly drew each rod out of the water and through the coil at various speeds, dramatically heating the rods to temperatures varying between 1,200 and 1,245 degrees Celsius.

      They found that drawing the rods at a particular speed (2.5 millimeters per hour) and through a specific temperature (1,235 degrees Celsius) created a steep thermal gradient that triggered a transformation in the material’s printed, fine-grained microstructure.

      “The material starts as small grains with defects called dislocations, that are like a mangled spaghetti,” Cordero explains. “When you heat this material up, those defects can annihilate and reconfigure, and the grains are able to grow. We’re continuously elongating the grains by consuming the defective material and smaller grains — a process termed recrystallization.”

      Creep away

      After cooling the heat-treated rods, the researchers examined their microstructure using optical and electron microscopy, and found that the material’s printed microscopic grains were replaced with “columnar” grains, or long crystal-like regions that were significantly larger than the original grains.

      “We’ve completely transformed the structure,” says lead author Dominic Peachey. “We show we can increase the grain size by orders of magnitude, to massive columnar grains, which theoretically should lead to dramatic improvements in creep properties.”

      The team also showed they could manipulate the draw speed and temperature of the rod samples to tailor the material’s growing grains, creating regions of specific grain size and orientation. This level of control, Cordero says, can enable manufacturers to print turbine blades with site-specific microstructures that are resilient to specific operating conditions.

      Cordero plans to test the heat treatment on 3D-printed geometries that more closely resemble turbine blades. The team is also exploring ways to speed up the draw rate, as well as test a heat-treated structure’s resistance to creep. Then, they envision that the heat treatment could enable the practical application of 3D-printing to produce industrial-grade turbine blades, with more complex shapes and patterns.

      “New blade and vane geometries will enable more energy-efficient land-based gas turbines, as well as, eventually, aeroengines,” Cordero notes. “This could from a baseline perspective lead to lower carbon dioxide emissions, just through improved efficiency of these devices.”

      This research was supported, in part, by the U.S. Office of Naval Research. More

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      How can we reduce the carbon footprint of global computing?

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      The voracious appetite for energy from the world’s computers and communications technology presents a clear threat for the globe’s warming climate. That was the blunt assessment from presenters in the intensive two-day Climate Implications of Computing and Communications workshop held on March 3 and 4, hosted by MIT’s Climate and Sustainability Consortium (MCSC), MIT-IBM Watson AI Lab, and the Schwarzman College of Computing.

      The virtual event featured rich discussions and highlighted opportunities for collaboration among an interdisciplinary group of MIT faculty and researchers and industry leaders across multiple sectors — underscoring the power of academia and industry coming together.

      “If we continue with the existing trajectory of compute energy, by 2040, we are supposed to hit the world’s energy production capacity. The increase in compute energy and demand has been increasing at a much faster rate than the world energy production capacity increase,” said Bilge Yildiz, the Breene M. Kerr Professor in the MIT departments of Nuclear Science and Engineering and Materials Science and Engineering, one of the workshop’s 18 presenters. This computing energy projection draws from the Semiconductor Research Corporations’s decadal report.To cite just one example: Information and communications technology already account for more than 2 percent of global energy demand, which is on a par with the aviation industries emissions from fuel.“We are the very beginning of this data-driven world. We really need to start thinking about this and act now,” said presenter Evgeni Gousev, senior director at Qualcomm.  Innovative energy-efficiency optionsTo that end, the workshop presentations explored a host of energy-efficiency options, including specialized chip design, data center architecture, better algorithms, hardware modifications, and changes in consumer behavior. Industry leaders from AMD, Ericsson, Google, IBM, iRobot, NVIDIA, Qualcomm, Tertill, Texas Instruments, and Verizon outlined their companies’ energy-saving programs, while experts from across MIT provided insight into current research that could yield more efficient computing.Panel topics ranged from “Custom hardware for efficient computing” to “Hardware for new architectures” to “Algorithms for efficient computing,” among others.

      Visual representation of the conversation during the workshop session entitled “Energy Efficient Systems.”

      Image: Haley McDevitt

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      The goal, said Yildiz, is to improve energy efficiency associated with computing by more than a million-fold.“I think part of the answer of how we make computing much more sustainable has to do with specialized architectures that have very high level of utilization,” said Darío Gil, IBM senior vice president and director of research, who stressed that solutions should be as “elegant” as possible.  For example, Gil illustrated an innovative chip design that uses vertical stacking to reduce the distance data has to travel, and thus reduces energy consumption. Surprisingly, more effective use of tape — a traditional medium for primary data storage — combined with specialized hard drives (HDD), can yield a dramatic savings in carbon dioxide emissions.Gil and presenters Bill Dally, chief scientist and senior vice president of research of NVIDIA; Ahmad Bahai, CTO of Texas Instruments; and others zeroed in on storage. Gil compared data to a floating iceberg in which we can have fast access to the “hot data” of the smaller visible part while the “cold data,” the large underwater mass, represents data that tolerates higher latency. Think about digital photo storage, Gil said. “Honestly, are you really retrieving all of those photographs on a continuous basis?” Storage systems should provide an optimized mix of of HDD for hot data and tape for cold data based on data access patterns.Bahai stressed the significant energy saving gained from segmenting standby and full processing. “We need to learn how to do nothing better,” he said. Dally spoke of mimicking the way our brain wakes up from a deep sleep, “We can wake [computers] up much faster, so we don’t need to keep them running in full speed.”Several workshop presenters spoke of a focus on “sparsity,” a matrix in which most of the elements are zero, as a way to improve efficiency in neural networks. Or as Dally said, “Never put off till tomorrow, where you could put off forever,” explaining efficiency is not “getting the most information with the fewest bits. It’s doing the most with the least energy.”Holistic and multidisciplinary approaches“We need both efficient algorithms and efficient hardware, and sometimes we need to co-design both the algorithm and the hardware for efficient computing,” said Song Han, a panel moderator and assistant professor in the Department of Electrical Engineering and Computer Science (EECS) at MIT.Some presenters were optimistic about innovations already underway. According to Ericsson’s research, as much as 15 percent of the carbon emissions globally can be reduced through the use of existing solutions, noted Mats Pellbäck Scharp, head of sustainability at Ericsson. For example, GPUs are more efficient than CPUs for AI, and the progression from 3G to 5G networks boosts energy savings.“5G is the most energy efficient standard ever,” said Scharp. “We can build 5G without increasing energy consumption.”Companies such as Google are optimizing energy use at their data centers through improved design, technology, and renewable energy. “Five of our data centers around the globe are operating near or above 90 percent carbon-free energy,” said Jeff Dean, Google’s senior fellow and senior vice president of Google Research.Yet, pointing to the possible slowdown in the doubling of transistors in an integrated circuit — or Moore’s Law — “We need new approaches to meet this compute demand,” said Sam Naffziger, AMD senior vice president, corporate fellow, and product technology architect. Naffziger spoke of addressing performance “overkill.” For example, “we’re finding in the gaming and machine learning space we can make use of lower-precision math to deliver an image that looks just as good with 16-bit computations as with 32-bit computations, and instead of legacy 32b math to train AI networks, we can use lower-energy 8b or 16b computations.”

      Visual representation of the conversation during the workshop session entitled “Wireless, networked, and distributed systems.”

      Image: Haley McDevitt

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      Other presenters singled out compute at the edge as a prime energy hog.“We also have to change the devices that are put in our customers’ hands,” said Heidi Hemmer, senior vice president of engineering at Verizon. As we think about how we use energy, it is common to jump to data centers — but it really starts at the device itself, and the energy that the devices use. Then, we can think about home web routers, distributed networks, the data centers, and the hubs. “The devices are actually the least energy-efficient out of that,” concluded Hemmer.Some presenters had different perspectives. Several called for developing dedicated silicon chipsets for efficiency. However, panel moderator Muriel Medard, the Cecil H. Green Professor in EECS, described research at MIT, Boston University, and Maynooth University on the GRAND (Guessing Random Additive Noise Decoding) chip, saying, “rather than having obsolescence of chips as the new codes come in and in different standards, you can use one chip for all codes.”Whatever the chip or new algorithm, Helen Greiner, CEO of Tertill (a weeding robot) and co-founder of iRobot, emphasized that to get products to market, “We have to learn to go away from wanting to get the absolute latest and greatest, the most advanced processor that usually is more expensive.” She added, “I like to say robot demos are a dime a dozen, but robot products are very infrequent.”Greiner emphasized consumers can play a role in pushing for more energy-efficient products — just as drivers began to demand electric cars.Dean also sees an environmental role for the end user.“We have enabled our cloud customers to select which cloud region they want to run their computation in, and they can decide how important it is that they have a low carbon footprint,” he said, also citing other interfaces that might allow consumers to decide which air flights are more efficient or what impact installing a solar panel on their home would have.However, Scharp said, “Prolonging the life of your smartphone or tablet is really the best climate action you can do if you want to reduce your digital carbon footprint.”Facing increasing demandsDespite their optimism, the presenters acknowledged the world faces increasing compute demand from machine learning, AI, gaming, and especially, blockchain. Panel moderator Vivienne Sze, associate professor in EECS, noted the conundrum.“We can do a great job in making computing and communication really efficient. But there is this tendency that once things are very efficient, people use more of it, and this might result in an overall increase in the usage of these technologies, which will then increase our overall carbon footprint,” Sze said.Presenters saw great potential in academic/industry partnerships, particularly from research efforts on the academic side. “By combining these two forces together, you can really amplify the impact,” concluded Gousev.Presenters at the Climate Implications of Computing and Communications workshop also included: Joel Emer, professor of the practice in EECS at MIT; David Perreault, the Joseph F. and Nancy P. Keithley Professor of EECS at MIT; Jesús del Alamo, MIT Donner Professor and professor of electrical engineering in EECS at MIT; Heike Riel, IBM Fellow and head science and technology at IBM; and Takashi Ando, principal research staff member at IBM Research. The recorded workshop sessions are available on YouTube. More

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      Building communities, founding a startup with people in mind

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      MIT postdoc Francesco Benedetti admits he wasn’t always a star student. But the people he met along his educational journey inspired him to strive, which led him to conduct research at MIT, launch a startup, and even lead the team that won the 2021 MIT $100K Entrepreneurship Competition. Now he is determined to make sure his company, Osmoses, succeeds in boosting the energy efficiency of traditional and renewable natural gas processing, hydrogen production, and carbon capture — thus helping to address climate change.

      “I can’t be grateful enough to MIT for bringing together a community of people who want to change the world,” Benedetti says. “Now we have a technology that can solve one of the big problems of our society.”

      Benedetti and his team have developed an innovative way to separate molecules using a membrane fine enough to extract impurities such as carbon dioxide or hydrogen sulfide from raw natural gas to obtain higher-quality fuel, fulfilling a crucial need in the energy industry. “Natural gas now provides about 40 percent of the energy used to power homes and industry in the United States,” Benedetti says. Using his team’s technology to upgrade natural gas more efficiently could reduce emissions of greenhouse gases while saving enough energy to power the equivalent of 7 million additional U.S. homes for a year, he adds.

      The MIT community

      Benedetti first came to MIT in 2017 as a visiting student from the University of Bologna in Italy, where he was working on membranes for gas separation for his PhD in chemical engineering. Having completed a master’s thesis on water desalination at the University of Texas (UT) at Austin, he connected with UT alumnus Zachary P. Smith, the Robert N. Noyce Career Development Professor of Chemical Engineering at MIT, and the two discovered they shared a vision. “We found ourselves very much aligned on the need for new technology in industry to lower the energy consumption of separating components,” Benedetti says.

      Although Benedetti had always been interested in making a positive impact on the world, particularly the environment, he says it was his university studies that first sparked his interest in more efficient separation technologies. “When you study chemical engineering, you understand hundreds of ways the field can have a positive impact in the world. But we learn very early that 15 percent of the world’s energy is wasted because of inefficient chemical separation — because we still rely on centuries-old technology,” he says. Most separation processes still use heat or toxic solvents to separate components, he explains.

      Still, Benedetti says, his main drive comes from the joy of working with terrific mentors and colleagues. “It’s the people I’ve met that really inspired me to tackle the biggest challenges and find that intrinsic motivation,” he says.

      To help build his community at MIT and provide support for international students, Benedetti co-founded the MIT Visiting Student Association (VISTA) in September 2017. By February 2018, the organization had hundreds of members and official Institute recognition. In May 2018, the group won two Institute awards, including the Golden Beaver Award for enhancing the campus environment. “VISTA gave me a sense of belonging; I loved it,” Benedetti says.

      Membrane technology

      Benedetti also published two papers on membrane research during his stint as a visiting student at MIT, so he was delighted to return in 2019 for postdoctoral work through the MIT Energy Initiative, where he was a 2019-20 ExxonMobil-MIT Energy Fellow. “I came back because the research was extremely exciting, but also because I got extremely passionate about the energy I found on campus and with the people,” he says.

      Returning to MIT enabled Benedetti to continue his work with Smith and Holden Lai, both of whom helped co-found Osmoses. Lai, a recent Stanford PhD in chemistry who was also a visiting student at MIT in 2018, is now the chief technology officer at Osmoses. Co-founder Katherine Mizrahi Rodriguez ’17, an MIT PhD candidate, joined the team more recently.

      Together, the Osmoses team has developed polymer membranes with microporosities capable of filtering gases by separating out molecules that differ by as little as a fraction of an angstrom — a unit of length equal to one hundred-millionth of a centimeter. “We can get up to five times higher selectivity than commercially available technology for methane upgrading, and this has been observed operating the membranes in industrially relevant environments,” Benedetti says.

      Today, methane upgrading — removing carbon dioxide (CO2) from raw natural gas to obtain a higher-grade fuel — is often accomplished using amine absorption, a process that uses toxic solvents to capture CO2 and burns methane to fuel the regeneration of those solvents for reuse. Using Osmoses’ filters would eliminate the need for such solvents while reducing CO2 emissions by up to 16 million metric tons per year in the United States alone, Benedetti says.

      The technology has a wide range of applications — in oxygen and nitrogen generation, hydrogen purification, and carbon capture, for example — but Osmoses plans to start with the $5 billion market for natural gas upgrading because the need to bring innovation and sustainability to that space is urgent, says Benedetti, who received guidance in bringing technology to market from MIT’s Deshpande Center for Technological Innovation. The Osmoses team has also received support from the MIT Sandbox Innovation Fund Program.

      The next step for the startup is to build an industrial-scale prototype, and Benedetti says the company got a huge boost toward that goal in May when it won the MIT $100K Entrepreneurship Competition, a student-run contest that has launched more than 160 companies since it began in 1990. Ninety teams began the competition by pitching their startup ideas; 20 received mentorship and development funding; then eight finalists presented business plans to compete for the $100,000 prize. “Because of this, we’re getting a lot of interest from venture capital firms, investors, companies, corporate funds, et cetera, that want to partner with us or to use our product,” he says. In June, the Osmoses team received a two-year Activate Fellowship, which will support moving its research to market; in October, it won the Northeast Regional and Carbon Sequestration Prizes at the Cleantech Open Accelerator; and in November, the team closed a $3 million pre-seed round of financing.

      FAIL!

      Naturally, Benedetti hopes Osmoses is on the path to success, but he wants everyone to know that there is no shame in failures that come from best efforts. He admits it took him three years longer than usual to finish his undergraduate and master’s degrees, and he says, “I have experienced the pressure you feel when society judges you like a book by its cover and how much a lack of inspired leaders and a supportive environment can kill creativity and the will to try.”

      That’s why in 2018 he, along with other MIT students and VISTA members, started FAIL!–Inspiring Resilience, an organization that provides a platform for sharing unfiltered stories and the lessons leaders have gleaned from failure. “We wanted to help de-stigmatize failure, appreciate vulnerabilities, and inspire humble leadership, eventually creating better communities,” Benedetti says. “If we can make failures, big and small, less intimidating and all-consuming, individuals with great potential will be more willing to take risks, think outside the box, and try things that may push new boundaries. In this way, more breakthrough discoveries are likely to follow, without compromising anyone’s mental health.”

      Benedetti says he will strive to create a supportive culture at Osmoses, because people are central to success. “What drives me every day is the people. I would have no story without the people around me,” he says. “The moment you lose touch with people, you lose the opportunity to create something special.”

      This article appears in the Autumn 2021 issue of Energy Futures, the magazine of the MIT Energy Initiative. More

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      Chemistry Undergraduate Teaching Lab hibernates fume hoods, drastically reducing energy costs

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      The Department of Chemistry’s state-of-the-art Undergraduate Teaching Lab (UGTL), which opened on the fifth floor of MIT.nano in fall 2018, is home to 69 fume hoods. The hoods, ranging from four to seven feet wide, protect students and staff from potential exposure to hazardous materials while working in the lab. Fume hoods represent a tremendous energy consumption on the MIT campus; in addition to the energy required to operate them, the air that replaces what is exhausted must be heated or cooled. Thus, any lab with a large number of fume hoods is destined to be faced with high operational energy cost.

      “When the UGTL’s fume hoods are in use, the air-change rates — the number of times fresh air is exchanged in the space in a given time frame — averages between 25 and 30 air changes per hour (ACH),” says Nicole Imbergamo, senior sustainability project manager in MIT Campus Construction. “When the lab is unoccupied, that air-change rate averages 11 ACH. For context, in a laboratory with a single fume hood, typically MIT’s EHS [Environment, Health, and Safety] department would require six ACH when occupied and four ACH when unoccupied. Hibernation of the fume hoods allowed us to close the gap between the current unoccupied air-change rate and what is typical on campus in a non-teaching lab environment.”

      Fifty-eight of the 69 fume hoods in the UGTL are consistently unused between the hours of 6:30 p.m. and 12 p.m., as well as all weekend long, totaling 135 hours per week. Based on these numbers, the team determined it was safe to “hibernate” the fume hoods during the off hours, saving the Institute on fan energy and the cost of heating and cooling the air that gets flushed into each hood.

      John Dolhun PhD ’73 is the director of the UGTL. “The project started when MIT Green Labs — a division of the Environment, Health, and Safety Office now known as the Safe & Sustainable Labs Program — contacted the UGTL in October 2018, followed by an initial meeting in November 2018 with all the key players, including Safe and Sustainable Labs, the EHS Office, the Department of Facilities, and the Department of Chemistry,” says Dolhun. “It was during these initial discussions that the UGTL recognized this was something we had to do. The project was completed in April 2021.”

      Now, through a scheduled time clock in the Building Management System (BMS), the 58 fume hoods are flipped into hibernation mode at the end of each day. “In hibernation mode, the exhaust air valves go to their minimum airflow, which is lower than a fume hood minimum required when in use,” says Imbergamo. “As a safety feature, if the sash of a fume hood is opened while it is in standby mode, the valve and hood are automatically released from hibernation until the next scheduled time.” The BMS allows Dolhun and all with access to instantly view the hibernation status of every hood online, at any time, from any location. As an additional safety measure, the lab is equipped with an emergency kill switch that, when activated, instantly takes all 58 fume hoods out of hibernation, increasing the air changes per hour by about 37 percent, at one touch.

      The MIT operations team worked with the building controls vendor to create graphics that allow the UGTL users to easily see the hood sash positions and their current status as either hibernated or in normal operating mode. This virtual visibility allows the UGTL team to confirm the hoods are all closed before leaving the lab at the end of each day, and to confirm the energy reductions. This visual access also lends itself to educating the students on the importance of closing the sash at the end of their lab work, and gives an opportunity for educating the students on relevant fume hood management best practices that will serve them far beyond their undergraduate chemistry classes.

      Since employing the use of hibernation mode, the unoccupied UGTL air change rate has plummeted from 11 ACH to seven ACH, drastically shrinking unnecessary energy outflow, saving MIT an estimated $21,000 per year. The annual utility cost savings of both reduced supply and exhaust fan energy, as well as the heating and cooling required of the supply air to the space, will result in a less-than three-year payback for MIT. The overall success of the hood hibernation program, and the savings that it has afforded the UGTL, is very motivational for the Green Initiative. The highlights of this system will be shared with other labs, both at MIT and beyond, that may also benefit from similar adjustments. More