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      MIT Solar Electric Vehicle Team wins 2021 American Solar Challenge

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      After three years of hard work, the MIT Solar Electric Vehicle Team took first place at the 2021 American Solar Challenge (ASC) on August 7 in the Single Occupancy Vehicle (SOV) category. During the five-day race, their solar car, Nimbus — designed and built entirely by students — beat eight other SOVs from schools across the country, traversing 1,109 miles and maintaining an average speed of 38.4 miles per hour.

      Held every two years, the ASC has traditionally been a timed event. This year, however, the race was based on the total distance traveled. Each team followed the same prescribed route, from Independence, Missouri, to Las Vegas, New Mexico. But teams could drive additional miles within each of the three stages — if their battery had enough juice to continue. Nimbus surpassed the closest runner-up, the University of Kentucky, by over 100 miles.

      “It’s still a little surreal,” says SEVT captain Aditya Mehrotra, a rising senior in electrical engineering and computer science. “We were all hopeful, but I don’t think you ever go into racing like, ‘We got this.’ It’s more like, ‘We’re going to do our best and see how we fare.’ In this case, we were fortunate enough to do really well. The car worked beautifully, and — more importantly — the team worked beautifully and we learned a lot.”

      Team work makes the dream work

      Two weeks before the ASC race, each solar car was put through its paces in the Formula Sun Grand Prix at Heartland Motorsports Park in Topeka, Kansas. First, vehicles had to perform a series of qualifying challenges, called “scrutineering.” Cars that passed could participate in a track race in hopes of qualifying for ASC. Nimbus placed second, completing a total of 239 laps around the track over three days (equivalent to 597.5 miles).

      In the process, SEVT member and rising junior in mechanical engineering Cameron Kokesh tied the Illinois State driver for the fastest single lap time around the track, clocking in at three minutes and 19 seconds. She’s not one to rest on her laurels, though. “It would be fun to see if we could beat that time at the next race,” she says with a smile.

      Nimbus’s performance at the Formula Sun Grand Prix and ASC is a manifestation of team’s proficiency in not only designing and building a superior solar vehicle, but other skills, as well, including managing logistics, communications, and teamwork. “It’s a huge operation,” says Mehrotra. “It’s not like we drive the car straight down the highway during the race.”

      Indeed, Nimbus travels with an impressive caravan of seven vehicles manned by about two dozen SEVT members. A scout vehicle is at the front, monitoring road and weather conditions, followed by a lead car that oversees navigation. Nimbus is third in the caravan, trailed by a chase vehicle, in which the strategy team manages tasks like monitoring telemetry data, calculating how much power the solar panels are generating and the remaining travel distance, and setting target speeds. Bringing up the rear are the transport truck and trailer, a media car, and “Cupcake,” a support vehicle with food, supplies, and camping gear.

      Leading up to the three-week event, the team devoted three years to designing, building, refining, and testing Nimbus. (The ASC was scheduled for 2020, but it was postponed until this year due to the Covid-19 pandemic.) They spent countless hours in the MIT Edgerton Center’s machine shop in Building N51, making, building, and iterating. They drove the car in the greater-Boston area, up to Salem, Massachusetts, and to Cape Cod. In the spring, they traveled to Palmer Motorsports Park in Palmer, Massachusetts, to practice various components of the race. They performed scrutineering tasks like the slalom test and figure eight test, conducted team operations training to optimize the caravan’s performance, and, of course, the “shakedown.” 

      “Shakedown is just, you drive the car around the track and you basically see what falls off and then you know what you need to fix,” Mehrotra explains. “Hopefully nothing too major falls off!”

      The road ahead

      At the conclusion of the race, Mehotra officially stepped down and handed SEVT’s reins to its new leaders: Kotesh will take the helm as team captain, and rising sophomore Sydney Kim, an ocean engineering major, will serve as vice-captain. The long drive back from the Midwest gave them time to reflect on the win and future plans.

      Although Nimbus performed well, there were a few instructive glitches here and there, mostly during scrutineering. But there was nothing the team couldn’t handle. For example, the canopy latch didn’t always hold, so the clear acrylic bubble covering the driver would pop open. (A little spring adjustment and tape did the trick.) In addition, Nimbus had a tendency to skid when the driver slammed on the brakes. (Driver training, and letting some air out of the tires, improved the traction.)

      Then there were the unpredictable variables, beyond the team’s control. On one day, with little sun, Nimbus had to chug along the highway at a mere 15 miles per hour. And there was the time that the Kansas State Police pulled the entire caravan over. “They didn’t realize we were coming through,” Mehrotra explains.

      Kim thinks one of the keys to the team’s success is that Nimbus is quite reliable. “We didn’t have wheels falling off on the road. Once we got the car rolling, things didn’t go wrong mechanically or electrically. Also, it’s very energy efficient because it’s lightweight and the shape of the vehicle is very aerodynamic. On a nice sunny day, it allows us to drive 40 miles per hour energy-neutral — the battery stays at the same amount of charge as we drive,” she says.

      The next ASC will take place in 2022, so this year the team will focus on refining Nimbus to race it again next summer. Also, they’ve set their sights on building a car to enter in the Multiple Occupancy Vehicle (MOV) class in the 2024 race — something the team has never done. “It will definitely take the three years to build a good car to compete,” Kotesh muses. “But it’s a really good transition period, after doing so well on this race, so our team is excited about it.”

      “It will be challenging for them, but I wouldn’t put it anything past them,” says Patrick McAtamney, the Edgerton Center technical instructor and shop manager who works with all the student clubs and teams, from solar vehicles to Formula race cars to rockets. He attended ASC, too, and has the utmost admiration for SEVT. “It’s totally student-run. They do all the designing and machining themselves. I always tell people that sometimes I feel like my only job is to make sure they have 10 fingers when they leave the shop.”

      In the meantime, before the school year begins, SEVT has another challenge: deciding where to put the trophy. “It’s huge,” McAtamney says. “It’s about the size of the Stanley Cup!” More

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      Using aluminum and water to make clean hydrogen fuel — when and where it’s needed

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      As the world works to move away from fossil fuels, many researchers are investigating whether clean hydrogen fuel can play an expanded role in sectors from transportation and industry to buildings and power generation. It could be used in fuel cell vehicles, heat-producing boilers, electricity-generating gas turbines, systems for storing renewable energy, and more.

      But while using hydrogen doesn’t generate carbon emissions, making it typically does. Today, almost all hydrogen is produced using fossil fuel-based processes that together generate more than 2 percent of all global greenhouse gas emissions. In addition, hydrogen is often produced in one location and consumed in another, which means its use also presents logistical challenges.

      A promising reaction

      Another option for producing hydrogen comes from a perhaps surprising source: reacting aluminum with water. Aluminum metal will readily react with water at room temperature to form aluminum hydroxide and hydrogen. That reaction doesn’t typically take place because a layer of aluminum oxide naturally coats the raw metal, preventing it from coming directly into contact with water.

      Using the aluminum-water reaction to generate hydrogen doesn’t produce any greenhouse gas emissions, and it promises to solve the transportation problem for any location with available water. Simply move the aluminum and then react it with water on-site. “Fundamentally, the aluminum becomes a mechanism for storing hydrogen — and a very effective one,” says Douglas P. Hart, professor of mechanical engineering at MIT. “Using aluminum as our source, we can ‘store’ hydrogen at a density that’s 10 times greater than if we just store it as a compressed gas.”

      Two problems have kept aluminum from being employed as a safe, economical source for hydrogen generation. The first problem is ensuring that the aluminum surface is clean and available to react with water. To that end, a practical system must include a means of first modifying the oxide layer and then keeping it from re-forming as the reaction proceeds.

      The second problem is that pure aluminum is energy-intensive to mine and produce, so any practical approach needs to use scrap aluminum from various sources. But scrap aluminum is not an easy starting material. It typically occurs in an alloyed form, meaning that it contains other elements that are added to change the properties or characteristics of the aluminum for different uses. For example, adding magnesium increases strength and corrosion-resistance, adding silicon lowers the melting point, and adding a little of both makes an alloy that’s moderately strong and corrosion-resistant.

      Despite considerable research on aluminum as a source of hydrogen, two key questions remain: What’s the best way to prevent the adherence of an oxide layer on the aluminum surface, and how do alloying elements in a piece of scrap aluminum affect the total amount of hydrogen generated and the rate at which it is generated?

      “If we’re going to use scrap aluminum for hydrogen generation in a practical application, we need to be able to better predict what hydrogen generation characteristics we’re going to observe from the aluminum-water reaction,” says Laureen Meroueh PhD ’20, who earned her doctorate in mechanical engineering.

      Since the fundamental steps in the reaction aren’t well understood, it’s been hard to predict the rate and volume at which hydrogen forms from scrap aluminum, which can contain varying types and concentrations of alloying elements. So Hart, Meroueh, and Thomas W. Eagar, a professor of materials engineering and engineering management in the MIT Department of Materials Science and Engineering, decided to examine — in a systematic fashion — the impacts of those alloying elements on the aluminum-water reaction and on a promising technique for preventing the formation of the interfering oxide layer.

      To prepare, they had experts at Novelis Inc. fabricate samples of pure aluminum and of specific aluminum alloys made of commercially pure aluminum combined with either 0.6 percent silicon (by weight), 1 percent magnesium, or both — compositions that are typical of scrap aluminum from a variety of sources. Using those samples, the MIT researchers performed a series of tests to explore different aspects of the aluminum-water reaction.

      Pre-treating the aluminum

      The first step was to demonstrate an effective means of penetrating the oxide layer that forms on aluminum in the air. Solid aluminum is made up of tiny grains that are packed together with occasional boundaries where they don’t line up perfectly. To maximize hydrogen production, researchers would need to prevent the formation of the oxide layer on all those interior grain surfaces.

      Research groups have already tried various ways of keeping the aluminum grains “activated” for reaction with water. Some have crushed scrap samples into particles so tiny that the oxide layer doesn’t adhere. But aluminum powders are dangerous, as they can react with humidity and explode. Another approach calls for grinding up scrap samples and adding liquid metals to prevent oxide deposition. But grinding is a costly and energy-intensive process.

      To Hart, Meroueh, and Eagar, the most promising approach — first introduced by Jonathan Slocum ScD ’18 while he was working in Hart’s research group — involved pre-treating the solid aluminum by painting liquid metals on top and allowing them to permeate through the grain boundaries.

      To determine the effectiveness of that approach, the researchers needed to confirm that the liquid metals would reach the internal grain surfaces, with and without alloying elements present. And they had to establish how long it would take for the liquid metal to coat all of the grains in pure aluminum and its alloys.

      They started by combining two metals — gallium and indium — in specific proportions to create a “eutectic” mixture; that is, a mixture that would remain in liquid form at room temperature. They coated their samples with the eutectic and allowed it to penetrate for time periods ranging from 48 to 96 hours. They then exposed the samples to water and monitored the hydrogen yield (the amount formed) and flow rate for 250 minutes. After 48 hours, they also took high-magnification scanning electron microscope (SEM) images so they could observe the boundaries between adjacent aluminum grains.

      Based on the hydrogen yield measurements and the SEM images, the MIT team concluded that the gallium-indium eutectic does naturally permeate and reach the interior grain surfaces. However, the rate and extent of penetration vary with the alloy. The permeation rate was the same in silicon-doped aluminum samples as in pure aluminum samples but slower in magnesium-doped samples.

      Perhaps most interesting were the results from samples doped with both silicon and magnesium — an aluminum alloy often found in recycling streams. Silicon and magnesium chemically bond to form magnesium silicide, which occurs as solid deposits on the internal grain surfaces. Meroueh hypothesized that when both silicon and magnesium are present in scrap aluminum, those deposits can act as barriers that impede the flow of the gallium-indium eutectic.

      The experiments and images confirmed her hypothesis: The solid deposits did act as barriers, and images of samples pre-treated for 48 hours showed that permeation wasn’t complete. Clearly, a lengthy pre-treatment period would be critical for maximizing the hydrogen yield from scraps of aluminum containing both silicon and magnesium.

      Meroueh cites several benefits to the process they used. “You don’t have to apply any energy for the gallium-indium eutectic to work its magic on aluminum and get rid of that oxide layer,” she says. “Once you’ve activated your aluminum, you can drop it in water, and it’ll generate hydrogen — no energy input required.” Even better, the eutectic doesn’t chemically react with the aluminum. “It just physically moves around in between the grains,” she says. “At the end of the process, I could recover all of the gallium and indium I put in and use it again” — a valuable feature as gallium and (especially) indium are costly and in relatively short supply.

      Impacts of alloying elements on hydrogen generation

      The researchers next investigated how the presence of alloying elements affects hydrogen generation. They tested samples that had been treated with the eutectic for 96 hours; by then, the hydrogen yield and flow rates had leveled off in all the samples.

      The presence of 0.6 percent silicon increased the hydrogen yield for a given weight of aluminum by 20 percent compared to pure aluminum — even though the silicon-containing sample had less aluminum than the pure aluminum sample. In contrast, the presence of 1 percent magnesium produced far less hydrogen, while adding both silicon and magnesium pushed the yield up, but not to the level of pure aluminum.

      The presence of silicon also greatly accelerated the reaction rate, producing a far higher peak in the flow rate but cutting short the duration of hydrogen output. The presence of magnesium produced a lower flow rate but allowed the hydrogen output to remain fairly steady over time. And once again, aluminum with both alloying elements produced a flow rate between that of magnesium-doped and pure aluminum.

      Those results provide practical guidance on how to adjust the hydrogen output to match the operating needs of a hydrogen-consuming device. If the starting material is commercially pure aluminum, adding small amounts of carefully selected alloying elements can tailor the hydrogen yield and flow rate. If the starting material is scrap aluminum, careful choice of the source can be key. For high, brief bursts of hydrogen, pieces of silicon-containing aluminum from an auto junkyard could work well. For lower but longer flows, magnesium-containing scraps from the frame of a demolished building might be better. For results somewhere in between, aluminum containing both silicon and magnesium should work well; such material is abundantly available from scrapped cars and motorcycles, yachts, bicycle frames, and even smartphone cases.

      It should also be possible to combine scraps of different aluminum alloys to tune the outcome, notes Meroueh. “If I have a sample of activated aluminum that contains just silicon and another sample that contains just magnesium, I can put them both into a container of water and let them react,” she says. “So I get the fast ramp-up in hydrogen production from the silicon and then the magnesium takes over and has that steady output.”

      Another opportunity for tuning: Reducing grain size

      Another practical way to affect hydrogen production could be to reduce the size of the aluminum grains — a change that should increase the total surface area available for reactions to occur.

      To investigate that approach, the researchers requested specially customized samples from their supplier. Using standard industrial procedures, the Novelis experts first fed each sample through two rollers, squeezing it from the top and bottom so that the internal grains were flattened. They then heated each sample until the long, flat grains had reorganized and shrunk to a targeted size.

      In a series of carefully designed experiments, the MIT team found that reducing the grain size increased the efficiency and decreased the duration of the reaction to varying degrees in the different samples. Again, the presence of particular alloying elements had a major effect on the outcome.

      Needed: A revised theory that explains observations

      Throughout their experiments, the researchers encountered some unexpected results. For example, standard corrosion theory predicts that pure aluminum will generate more hydrogen than silicon-doped aluminum will — the opposite of what they observed in their experiments.

      To shed light on the underlying chemical reactions, Hart, Meroueh, and Eagar investigated hydrogen “flux,” that is, the volume of hydrogen generated over time on each square centimeter of aluminum surface, including the interior grains. They examined three grain sizes for each of their four compositions and collected thousands of data points measuring hydrogen flux.

      Their results show that reducing grain size has significant effects. It increases the peak hydrogen flux from silicon-doped aluminum as much as 100 times and from the other three compositions by 10 times. With both pure aluminum and silicon-containing aluminum, reducing grain size also decreases the delay before the peak flux and increases the rate of decline afterward. With magnesium-containing aluminum, reducing the grain size brings about an increase in peak hydrogen flux and results in a slightly faster decline in the rate of hydrogen output. With both silicon and magnesium present, the hydrogen flux over time resembles that of magnesium-containing aluminum when the grain size is not manipulated. When the grain size is reduced, the hydrogen output characteristics begin to resemble behavior observed in silicon-containing aluminum. That outcome was unexpected because when silicon and magnesium are both present, they react to form magnesium silicide, resulting in a new type of aluminum alloy with its own properties.

      The researchers stress the benefits of developing a better fundamental understanding of the underlying chemical reactions involved. In addition to guiding the design of practical systems, it might help them find a replacement for the expensive indium in their pre-treatment mixture. Other work has shown that gallium will naturally permeate through the grain boundaries of aluminum. “At this point, we know that the indium in our eutectic is important, but we don’t really understand what it does, so we don’t know how to replace it,” says Hart.

      But already Hart, Meroueh, and Eagar have demonstrated two practical ways of tuning the hydrogen reaction rate: by adding certain elements to the aluminum and by manipulating the size of the interior aluminum grains. In combination, those approaches can deliver significant results. “If you go from magnesium-containing aluminum with the largest grain size to silicon-containing aluminum with the smallest grain size, you get a hydrogen reaction rate that differs by two orders of magnitude,” says Meroueh. “That’s huge if you’re trying to design a real system that would use this reaction.”

      This research was supported through the MIT Energy Initiative by ExxonMobil-MIT Energy Fellowships awarded to Laureen Meroueh PhD ’20 from 2018 to 2020.

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

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      Electrifying cars and light trucks to meet Paris climate goals

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      On Aug. 5, the White House announced that it seeks to ensure that 50 percent of all new passenger vehicles sold in the United States by 2030 are powered by electricity. The purpose of this target is to enable the U.S to remain competitive with China in the growing electric vehicle (EV) market and meet its international climate commitments. Setting ambitious EV sales targets and transitioning to zero-carbon power sources in the United States and other nations could lead to significant reductions in carbon dioxide and other greenhouse gas emissions in the transportation sector and move the world closer to achieving the Paris Agreement’s long-term goal of keeping global warming well below 2 degrees Celsius relative to preindustrial levels.

      At this time, electrification of the transportation sector is occurring primarily in private light-duty vehicles (LDVs). In 2020, the global EV fleet exceeded 10 million, but that’s a tiny fraction of the cars and light trucks on the road. How much of the LDV fleet will need to go electric to keep the Paris climate goal in play? 

      To help answer that question, researchers at the MIT Joint Program on the Science and Policy of Global Change and MIT Energy Initiative have assessed the potential impacts of global efforts to reduce carbon dioxide emissions on the evolution of LDV fleets over the next three decades.

      Using an enhanced version of the multi-region, multi-sector MIT Economic Projection and Policy Analysis (EPPA) model that includes a representation of the household transportation sector, they projected changes for the 2020-50 period in LDV fleet composition, carbon dioxide emissions, and related impacts for 18 different regions. Projections were generated under four increasingly ambitious climate mitigation scenarios: a “Reference” scenario based on current market trends and fuel efficiency policies, a “Paris Forever” scenario in which current Paris Agreement commitments (Nationally Determined Contributions, or NDCs) are maintained but not strengthened after 2030, a “Paris to 2 C” scenario in which decarbonization actions are enhanced to be consistent with capping global warming at 2 C, and an “Accelerated Actions” scenario the caps global warming at 1.5 C through much more aggressive emissions targets than the current NDCs.

      Based on projections spanning the first three scenarios, the researchers found that the global EV fleet will likely grow to about 95-105 million EVs by 2030, and 585-823 million EVs by 2050. In the Accelerated Actions scenario, global EV stock reaches more than 200 million vehicles in 2030, and more than 1 billion in 2050, accounting for two-thirds of the global LDV fleet. The research team also determined that EV uptake will likely grow but vary across regions over the 30-year study time frame, with China, the United States, and Europe remaining the largest markets. Finally, the researchers found that while EVs play a role in reducing oil use, a more substantial reduction in oil consumption comes from economy-wide carbon pricing. The results appear in a study in the journal Economics of Energy & Environmental Policy.

      “Our study shows that EVs can contribute significantly to reducing global carbon emissions at a manageable cost,” says MIT Joint Program Deputy Director and MIT Energy Initiative Senior Research Scientist Sergey Paltsev, the lead author. “We hope that our findings will help decision-makers to design efficient pathways to reduce emissions.”  

      To boost the EV share of the global LDV fleet, the study’s co-authors recommend more ambitious policies to mitigate climate change and decarbonize the electric grid. They also envision an “integrated system approach” to transportation that emphasizes making internal combustion engine vehicles more efficient, a long-term shift to low- and net-zero carbon fuels, and systemic efficiency improvements through digitalization, smart pricing, and multi-modal integration. While the study focuses on EV deployment, the authors also stress for the need for investment in all possible decarbonization options related to transportation, including enhancing public transportation, avoiding urban sprawl through strategic land-use planning, and reducing the use of private motorized transport by mode switching to walking, biking, and mass transit.

      This research is an extension of the authors’ contribution to the MIT Mobility of the Future study. 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

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      Vapor-collection technology saves water while clearing the air

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      About two-fifths of all the water that gets withdrawn from lakes, rivers, and wells in the U.S. is used not for agriculture, drinking, or sanitation, but to cool the power plants that provide electricity from fossil fuels or nuclear power. Over 65 percent of these plants use evaporative cooling, leading to huge white plumes that billow from their cooling towers, which can be a nuisance and, in some cases, even contribute to dangerous driving conditions.

      Now, a small company based on technology recently developed at MIT by the Varanasi Research Group is hoping to reduce both the water needs at these plants and the resultant plumes — and to potentially help alleviate water shortages in areas where power plants put pressure on local water systems.

      The technology is surprisingly simple in principle, but developing it to the point where it can now be tested at full scale on industrial plants was a more complex proposition. That required the real-world experience that the company’s founders gained from installing prototype systems, first on MIT’s natural-gas-powered cogeneration plant and then on MIT’s nuclear research reactor.

      In these demanding tests, which involved exposure to not only the heat and vibrations of a working industrial plant but also the rigors of New England winters, the system proved its effectiveness at both eliminating the vapor plume and recapturing water. And, it purified the water in the process, so that it was 100 times cleaner than the incoming cooling water. The system is now being prepared for full-scale tests in a commercial power plant and in a chemical processing plant.

      “Campus as a living laboratory”

      The technology was originally envisioned by professor of mechanical engineering Kripa Varanasi to develop efficient water-recovery systems by capturing water droplets from both natural fog and plumes from power plant cooling towers. The project began as part of doctoral thesis research of Maher Damak PhD ’18, with funding from the MIT Tata Center for Technology and Design, to improve the efficiency of fog-harvesting systems like the ones used in some arid coastal regions as a source of potable water. Those systems, which generally consist of plastic or metal mesh hung vertically in the path of fogbanks, are extremely inefficient, capturing only about 1 to 3 percent of the water droplets that pass through them.

      Varanasi and Damak found that vapor collection could be made much more efficient by first zapping the tiny droplets of water with a beam of electrically charged particles, or ions, to give each droplet a slight electric charge. Then, the stream of droplets passes through a wire mesh, like a window screen, that has an opposite electrical charge. This causes the droplets to be strongly attracted to the mesh, where they fall away due to gravity and can be collected in trays placed below the mesh.

      Lab tests showed the concept worked, and the researchers, joined by Karim Khalil PhD ’18, won the MIT $100K Entrepreneurship Competition in 2018 for the basic concept. The nascent company, which they called Infinite Cooling, with Damak as CEO, Khalil as CTO, and Varanasi as chairperson, immediately went to work setting up a test installation on one of the cooling towers of MIT’s natural-gas-powered Central Utility Plant, with funding from the MIT Office of Sustainability. After experimenting with various configurations, they were able to show that the system could indeed eliminate the plume and produce water of high purity.

      Professor Jacopo Buongiorno in the Department of Nuclear Science and Engineering immediately spotted a good opportunity for collaboration, offering the use of MIT’s Nuclear Reactor Laboratory research facility for further testing of the system with the help of NRL engineer Ed Block. With its 24/7 operation and its higher-temperature vapor emissions, the plant would provide a more stringent real-world test of the system, as well as proving its effectiveness in an actual operating reactor licensed by the Nuclear Regulatory Commission, an important step in “de-risking” the technology so that electric utilities could feel confident in adopting the system.

      After the system was installed above one of the plant’s four cooling towers, testing showed that the water being collected was more than 100 times cleaner than the feedwater coming into the cooling system. It also proved that the installation — which, unlike the earlier version, had its mesh screens mounted vertically, parallel to the vapor stream — had no effect at all on the operation of the plant. Video of the tests dramatically illustrates how as soon as the power is switched on to the collecting mesh, the white plume of vapor immediately disappears completely.

      The high temperature and volume of the vapor plume from the reactor’s cooling towers represented “kind of a worst-case scenario in terms of plumes,” Damak says, “so if we can capture that, we can basically capture anything.”

      Working with MIT’s Nuclear Reactor Laboratory, Varanasi says, “has been quite an important step because it helped us to test it at scale. … It really both validated the water quality and the performance of the system.” The process, he says, “shows the importance of using the campus as a living laboratory. It allows us to do these kinds of experiments at scale, and also showed the ability to sustainably reduce the water footprint of the campus.”

      Far-reaching benefits

      Power plant plumes are often considered an eyesore and can lead to local opposition to new power plants because of the potential for obscured views, and even potential traffic hazards when the obscuring plumes blow across roadways. “The ability to eliminate the plumes could be an important benefit, allowing plants to be sited in locations that might otherwise be restricted,” Buongiorno says. At the same time, the system could eliminate a significant amount of water used by the plants and then lost to the sky, potentially alleviating pressure on local water systems, which could be especially helpful in arid regions.

      The system is essentially a distillation process, and the pure water it produces could go into power plant boilers — which are separate from the cooling system — that require high-purity water. That might reduce the need for both fresh water and purification systems for the boilers.

      What’s more, in many arid coastal areas power plants are cooled directly with seawater. This system would essentially add a water desalination capability to the plant, at a fraction of the cost of building a new standalone desalination plant, and at an even smaller fraction of its operating costs since the heat would essentially be provided for free.

      Contamination of water is typically measured by testing its electrical conductivity, which increases with the amount of salts and other contaminants it contains. Water used in power plant cooling systems typically measures 3,000 microsiemens per centimeter, Khalil explains, while the water supply in the City of Cambridge is typically around 500 or 600 microsiemens per centimeter. The water captured by this system, he says, typically measures below 50 microsiemens per centimeter.

      Thanks to the validation provided by the testing on MIT’s plants, the company has now been able to secure arrangements for its first two installations on operating commercial plants, which should begin later this year. One is a 900-megawatt power plant where the system’s clean water production will be a major advantage, and the other is at a chemical manufacturing plant in the Midwest.

      In many locations power plants have to pay for the water they use for cooling, Varanasi says, and the new system is expected to reduce the need for water by up to 20 percent. For a typical power plant, that alone could account for about a million dollars saved in water costs per year, he says.

      “Innovation has been a hallmark of the U.S. commercial industry for more than six decades,” says Maria G. Korsnick, president and CEO of the Nuclear Energy Institute, who was not involved in the research. “As the changing climate impacts every aspect of life, including global water supplies, companies across the supply chain are innovating for solutions. The testing of this innovative technology at MIT provides a valuable basis for its consideration in commercial applications.” More

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      Cleaning up industrial filtration

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      If you wanted to get pasta out of a pot of water, would you boil off the water, or use a strainer? While home cooks would choose the strainer, many industries continue to use energy-intensive thermal methods of separating out liquids. In some cases, that’s because it’s difficult to make a filtration system for chemical separation, which requires pores small enough to separate atoms.

      In other cases, membranes exist to separate liquids, but they are made of fragile polymers, which can break down or gum up in industrial use.

      Via Separations, a startup that emerged from MIT in 2017, has set out to address these challenges with a membrane that is cost-effective and robust. Made of graphene oxide (a “cousin” of pencil lead), the membrane can reduce the amount of energy used in industrial separations by 90 percent, according to Shreya Dave PhD ’16, company co-founder and CEO.

      This is valuable because separation processes account for about 22 percent of all in-plant energy use in the United States, according to Oak Ridge National Laboratory. By making such processes significantly more efficient, Via Separations plans to both save energy and address the significant emissions produced by thermal processes. “Our goal is eliminating 500 megatons of carbon dioxide emissions by 2050,” Dave says.

      Play video

      What do our passions for pasta and decarbonizing the Earth have in common? MIT alumna Shreya Dave PhD ’16 explains how she and her team at Via Separations are building the equivalent of a pasta strainer to separate chemical compounds for industry.

      Via Separations began piloting its technology this year at a U.S. paper company and expects to deploy a full commercial system there in the spring of 2022. “Our vision is to help manufacturers slow carbon dioxide emissions next year,” Dave says.

      MITEI Seed Grant

      The story of Via Separations begins in 2012, when the MIT Energy Initiative (MITEI) awarded a Seed Fund grant to Professor Jeffrey Grossman, who is now the Morton and Claire Goulder and Family Professor in Environmental Systems and head of MIT’s Department of Materials Science and Engineering. Grossman was pursuing research into nanoporous membranes for water desalination. “We thought we could bring down the cost of desalination and improve access to clean water,” says Dave, who worked on the project as a graduate student in Grossman’s lab.

      There, she teamed up with Brent Keller PhD ’16, another Grossman graduate student and a 2016-17 ExxonMobil-MIT Energy Fellow, who was developing lab experiments to fabricate and test new materials. “We were early comrades in figuring out how to debug experiments or fix equipment,” says Keller, Via Separations’ co-founder and chief technology officer. “We were fast friends who spent a lot of time talking about science over burritos.”

      Dave went on to write her doctoral thesis on using graphene oxide for water desalination, but that turned out to be the wrong application of the technology from a business perspective, she says. “The cost of desalination doesn’t lie in the membrane materials,” she explains.

      So, after Dave and Keller graduated from MIT in 2016, they spent a lot of time talking to customers to learn more about the needs and opportunities for their new separation technology. This research led them to target the paper industry, because the environmental benefits of improving paper processing are enormous, Dave says. “The paper industry is particularly exciting because separation processes just in that industry account for more than 2 percent of U.S. energy consumption,” she says. “It’s a very concentrated, high-energy-use industry.”

      Most paper today is made by breaking down the chemical bonds in wood to create wood pulp, the primary ingredient of paper. This process generates a byproduct called black liquor, a toxic solution that was once simply dumped into waterways. To clean up this process, paper mills turned to boiling off the water from black liquor and recovering both water and chemicals for reuse in the pulping process. (Today, the most valuable way to use the liquor is as biomass feedstock to generate energy.) Via Separations plans to accomplish this same separation work by filtering black liquor through its graphene oxide membrane.

      “The advantage of graphene oxide is that it’s very robust,” Dave says. “It’s got carbon double bonds that hold together in a lot of environments, including at different pH levels and temperatures that are typically unfriendly to materials.”

      Such properties should also make the company’s membranes attractive to other industries that use membrane separation, Keller says, because today’s polymer membranes have drawbacks. “For most of the things we make — from plastics to paper and gasoline — those polymers will swell or react or degrade,” he says.

      Graphene oxide is significantly more durable, and Via Separations can customize the pores in the material to suit each industry’s application. “That’s our secret sauce,” Dave says, “modulating pore size while retaining robustness to operate in challenging environments.”

      “We’re building a catalog of products to serve different applications,” Keller says, noting that the next target market could be the food and beverage industry. “In that industry, instead of separating different corrosive paper chemicals from water, we’re trying to separate particular sugars and food ingredients from other things.”

      Future target customers include pharmaceutical companies, oil refineries, and semiconductor manufacturers, or even carbon capture businesses.

      Scaling up

      Dave, Keller, and Grossman launched Via Separations in 2017 — with a lot of help from MIT. After the seed grant, in 2015, the founders received a year of funding and support from the J-WAFS Solutions program to explore markets and to develop their business plans. The company’s first capital investment came from The Engine, a venture firm founded by MIT to support “tough tech” companies (tech businesses with transformative potential but long and challenging paths to success). They also received advice and support from MIT’s Deshpande Center for Technological Innovation, Venture Mentoring Service, and Technology Licensing Office. In addition, Grossman continues to serve the company as chief scientist.

      “We were incredibly fortunate to be starting a company in the MIT entrepreneurial ecosystem,” Keller says, noting that The Engine support alone “probably shaved years off our progress.”

      Already, Via Separations has grown to employ 17 people, while significantly scaling up its product. “Our customers are producing thousands of gallons per minute,” Keller explains. “To process that much liquid, we need huge areas of membrane.”

      Via Separations’ manufacturing process, which is now capable of making more than 10,000 square feet of membrane in one production run, is a key competitive advantage, Dave says. The company rolls 300-400 square feet of membrane into a module, and modules can be combined as needed to increase filtration capacity.

      The goal, Dave says, is to contribute to a more sustainable world by making an environmentally beneficial product that makes good business sense. “What we do is make manufacturing things more energy-efficient,” she says. “We allow a paper mill or chemical facility to make more product using less energy and with lower costs. So, there is a bottom-line benefit that’s significant on an industrial scale.”

      Keller says he shares Dave’s goal of building a more sustainable future. “Climate change and energy are central challenges of our time,” he says. “Working on something that has a chance to make a meaningful impact on something so important to everyone is really fulfilling.”

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

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      Amy Watterson: Model engineer

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      “I love that we are doing something that no one else is doing.”

      Amy Watterson is excited when she talks about SPARC, the pilot fusion plant being developed by MIT spinoff Commonwealth Fusion Systems (CSF). Since being hired as a mechanical engineer at the Plasma Science and Fusion Center (PSFC) two years ago, Watterson has found her skills stretching to accommodate the multiple needs of the project.

      Fusion, which fuels the sun and stars, has long been sought as a carbon-free energy source for the world. For decades researchers have pursued the “tokamak,” a doughnut-shaped vacuum chamber where hot plasma can be contained by magnetic fields and heated to the point where fusion occurs. Sustaining the fusion reactions long enough to draw energy from them has been a challenge.

      Watterson is intimately aware of this difficulty. Much of her life she has heard the quip, “Fusion is 50 years away and always will be.” The daughter of PSFC research scientist Catherine Fiore, who headed the PSFC’s Office of Environment, Safety and Health, and Reich Watterson, an optical engineer working at the center, she had watched her parents devote years to making fusion a reality. She determined before entering Rensselaer Polytechnic Institute that she could forgo any attempt to follow her parents into a field that might not produce results during her career.

      Working on SPARC has changed her mindset. Taking advantage of a novel high-temperature superconducting tape, SPARC’s magnets will be compact while generating magnetic fields stronger than would be possible from other mid-sized tokamaks, and producing more fusion power. It suggests a high-field device that produces net fusion gain is not 50 years away. SPARC is scheduled to be begin operation in 2025.

      An education in modeling

      Watterson’s current excitement, and focus, is due to an approaching milestone for SPARC: a test of the Toroidal Field Magnet Coil (TFMC), a scaled prototype for the HTS magnets that will surround SPARC’s toroidal vacuum chamber. Its design and manufacture have been shaped by computer models and simulations. As part of a large research team, Waterson has received an education in modeling over the past two years.

      Computer models move scientific experiments forward by allowing researchers to predict what will happen to an experiment — or its materials — if a parameter is changed. Modeling a component of the TFMC, for example, researchers can test how it is affected by varying amounts of current, different temperatures or different materials. With this information they can make choices that will improve the success of the experiment.

      In preparation for the magnet testing, Watterson has modeled aspects of the cryogenic system that will circulate helium gas around the TFMC to keep it cold enough to remain superconducting. Taking into consideration the amount of cooling entering the system, the flow rate of the helium, the resistance created by valves and transfer lines and other parameters, she can model how much helium flow will be necessary to guarantee the magnet stays cold enough. Adjusting a parameter can make the difference between a magnet remaining superconducting and becoming overheated or even damaged.

      Watterson and her teammates have also modeled pressures and stress on the inside of the TFMC. Pumping helium through the coil to cool it down will add 20 atmospheres of pressure, which could create a degree of flex in elements of the magnet that are welded down. Modeling can help determine how much pressure a weld can sustain.

      “How thick does a weld need to be, and where should you put the weld so that it doesn’t break — that’s something you don’t want to leave until you’re finally assembling it,” says Watterson.

      Modeling the behavior of helium is particularly challenging because its properties change significantly as the pressure and temperature change.

      “A few degrees or a little pressure will affect the fluid’s viscosity, density, thermal conductivity, and heat capacity,” says Watterson. “The flow has different pressures and temperatures at different places in the cryogenic loop. You end up with a set of equations that are very dependent on each other, which makes it a challenge to solve.”

      Role model

      Watterson notes that her modeling depends on the contributions of colleagues at the PSFC, and praises the collaborative spirit among researchers and engineers, a community that now feels like family. Her teammates have been her mentors. “I’ve learned so much more on the job in two years than I did in four years at school,” she says.

      She realizes that having her mother as a role model in her own family has always made it easier for her to imagine becoming a scientist or engineer. Tracing her early passion for engineering to a middle school Lego robotics tournament, her eyes widen as she talks about the need for more female engineers, and the importance of encouraging girls to believe they are equal to the challenge.

      “I want to be a role model and tell them ‘I’m a successful engineer, you can be too.’ Something I run into a lot is that little girls will say, ‘I can’t be an engineer, I’m not cut out for that.’ And I say, ‘Well that’s not true. Let me show you. If you can make this Lego robot, then you can be an engineer.’ And it turns out they usually can.”

      Then, as if making an adjustment to one of her computer models, she continues.

      “Actually, they always can.” More

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      Inaugural fund supports early-stage collaborations between MIT and Jordan

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      MIT International Science and Technology Initiatives (MISTI), together with the Abdul Hameed Shoman Foundation (AHSF), the cultural and social responsibility arm of the Arab Bank, recently created a new initiative to support collaboration with the Middle East. The MIT-Jordan Abdul Hameed Shoman Foundation Seed Fund is providing awardees with financial grants up to $30,000 to cover travel, meeting, and workshop expenses, including in-person visits to build cultural and scientific connections between MIT and Jordan. MISTI and AHSF recently celebrated the first round of awardees in a virtual ceremony held in Amman and the United States.

      The new grant is part of the Global Seed Funds (GSF), MISTI’s annual grant program that enables participating teams to collaborate with international peers, either at MIT or abroad, to develop and launch joint research projects. Many of the projects funded lead to additional grant awards and the development of valuable long-term relationships between international researchers and MIT faculty and students.

      Since MIT’s first major collaboration in the Middle East in the 1970s, the Institute has deepened its connection and commitment to the region, expanding to create the MIT-Arab World program. The MIT-Jordan Abdul Hameed Shoman Foundation Seed Fund enables the MIT-Arab World program to move forward on its key objectives: build critical cultural and scientific connections between MIT and the Arab world; develop a cadre of students who have a deep understanding of the Middle East; and bring tangible value to the partners in the region.

      Valentina Qussisiya, CEO of the foundation, shared the importance of collaboration between research institutes to improve and advance scientific research. She highlighted the role of AHSF in supporting science and researchers since 1982, emphasizing, “The partnership with MIT through the MISTI program is part of AHSF commitment toward this role in Jordan and hoped-for future collaborations and the impact of the fund on science in Jordan.”

      The new fund, open to both Jordanian and MIT faculty, is available to those pursuing research in the following fields: environmental engineering; water resource management; lean and modern technologies; automation; nanotechnology; entrepreneurship; nuclear engineering; materials engineering; energy and thermal engineering; biomedical engineering, prostheses, computational neuroscience, and technology; social and management sciences; urban studies and planning; science, technology, and society; innovation in education; Arabic language automation; and food security and sustainable agriculture.

      Philip S. Khoury, faculty director of MISTI’s MIT-Arab World program and Ford International Professor of History and associate provost at MIT, explained that the winning projects all deal with critical issues that will benefit both MIT and Jordan, both on- and off-campus. “Beyond the actual faculty collaboration, these projects will bring much value to the hands-on education of MIT and Jordanian students and their capacity to get to know one another as future leaders in science and technology,” he says.

      This year, the MIT-Jordan Abdul Hameed Shoman Foundation Seed Fund received numerous high-quality proposals. Applications were reviewed by MIT and Jordanian faculty and selected by a committee of MIT faculty. There were six winning projects in the inaugural round:

      Low-Cost Renewable-Powered Electrodialysis Desalination and Drip Irrigation: Amos Winter (MIT principal investigator) and Samer Talozi (international collaborator)

      iPSC and CRISPR Gene Editing to Study Rare Diseases: Ernest Fraenkel (MIT principal investigator) and Nidaa Ababneh (international collaborator)

      Use of Distributed Low-Cost Sensor Networks for Air Quality Monitoring in Amann: Jesse Kroll (MIT principal investigator) and Tareq Hussein (international collaborator)

      Radiation Effects on Medical Devices Made by 3D Printing: Ju Li (MIT principal investigator) and Belal Gharaibeh (international collaborator)

      Superprotonic Conductivity in Metal-Organic Frameworks for Proton-Exchange Membrane Fuel Cells: Mircea Dinca (MIT principal investigator) and Kyle Cordova (international collaborator)

      Mapping Urban Air Quality Using Mobile Low-cost Sensors and Geospatial Techniques: Sarah Williams (MIT principal investigator) and Khaled Hazaymeh (international collaborator)

      The goal of these funded projects is for researchers and their students to form meaningful professional partnerships across cultures and leave a lasting impact upon the scientific communities in Jordan and at MIT.

      “[The fund will] enhance the future career prospects of emerging scholars from both countries,” said awardee Professor Kyle Cordova, executive director for scientific research at Royal Scientific Society and assistant to Her Royal Highness Princess Sumaya bint El Hassan for scientific affairs. “Our young scholars will gain a unique perspective of the influence of different cultures on scientific investigation that will help them to function effectively in a multidisciplinary and multicultural environment.” More