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      Power when the sun doesn’t shine

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      In 2016, at the huge Houston energy conference CERAWeek, MIT materials scientist Yet-Ming Chiang found himself talking to a Tesla executive about a thorny problem: how to store the output of solar panels and wind turbines for long durations.        

      Chiang, the Kyocera Professor of Materials Science and Engineering, and Mateo Jaramillo, a vice president at Tesla, knew that utilities lacked a cost-effective way to store renewable energy to cover peak levels of demand and to bridge the gaps during windless and cloudy days. They also knew that the scarcity of raw materials used in conventional energy storage devices needed to be addressed if renewables were ever going to displace fossil fuels on the grid at scale.

      Energy storage technologies can facilitate access to renewable energy sources, boost the stability and reliability of power grids, and ultimately accelerate grid decarbonization. The global market for these systems — essentially large batteries — is expected to grow tremendously in the coming years. A study by the nonprofit LDES (Long Duration Energy Storage) Council pegs the long-duration energy storage market at between 80 and 140 terawatt-hours by 2040. “That’s a really big number,” Chiang notes. “Every 10 people on the planet will need access to the equivalent of one EV [electric vehicle] battery to support their energy needs.”

      In 2017, one year after they met in Houston, Chiang and Jaramillo joined forces to co-found Form Energy in Somerville, Massachusetts, with MIT graduates Marco Ferrara SM ’06, PhD ’08 and William Woodford PhD ’13, and energy storage veteran Ted Wiley.

      “There is a burgeoning market for electrical energy storage because we want to achieve decarbonization as fast and as cost-effectively as possible,” says Ferrara, Form’s senior vice president in charge of software and analytics.

      Investors agreed. Over the next six years, Form Energy would raise more than $800 million in venture capital.

      Bridging gaps

      The simplest battery consists of an anode, a cathode, and an electrolyte. During discharge, with the help of the electrolyte, electrons flow from the negative anode to the positive cathode. During charge, external voltage reverses the process. The anode becomes the positive terminal, the cathode becomes the negative terminal, and electrons move back to where they started. Materials used for the anode, cathode, and electrolyte determine the battery’s weight, power, and cost “entitlement,” which is the total cost at the component level.

      During the 1980s and 1990s, the use of lithium revolutionized batteries, making them smaller, lighter, and able to hold a charge for longer. The storage devices Form Energy has devised are rechargeable batteries based on iron, which has several advantages over lithium. A big one is cost.

      Chiang once declared to the MIT Club of Northern California, “I love lithium-ion.” Two of the four MIT spinoffs Chiang founded center on innovative lithium-ion batteries. But at hundreds of dollars a kilowatt-hour (kWh) and with a storage capacity typically measured in hours, lithium-ion was ill-suited for the use he now had in mind.

      The approach Chiang envisioned had to be cost-effective enough to boost the attractiveness of renewables. Making solar and wind energy reliable enough for millions of customers meant storing it long enough to fill the gaps created by extreme weather conditions, grid outages, and when there is a lull in the wind or a few days of clouds.

      To be competitive with legacy power plants, Chiang’s method had to come in at around $20 per kilowatt-hour of stored energy — one-tenth the cost of lithium-ion battery storage.

      But how to transition from expensive batteries that store and discharge over a couple of hours to some as-yet-undefined, cheap, longer-duration technology?

      “One big ball of iron”

      That’s where Ferrara comes in. Ferrara has a PhD in nuclear engineering from MIT and a PhD in electrical engineering and computer science from the University of L’Aquila in his native Italy. In 2017, as a research affiliate at the MIT Department of Materials Science and Engineering, he worked with Chiang to model the grid’s need to manage renewables’ intermittency.

      How intermittent depends on where you are. In the United States, for instance, there’s the windy Great Plains; the sun-drenched, relatively low-wind deserts of Arizona, New Mexico, and Nevada; and the often-cloudy Pacific Northwest.

      Ferrara, in collaboration with Professor Jessika Trancik of MIT’s Institute for Data, Systems, and Society and her MIT team, modeled four representative locations in the United States and concluded that energy storage with capacity costs below roughly $20/kWh and discharge durations of multiple days would allow a wind-solar mix to provide cost-competitive, firm electricity in resource-abundant locations.

      Now that they had a time frame, they turned their attention to materials. At the price point Form Energy was aiming for, lithium was out of the question. Chiang looked at plentiful and cheap sulfur. But a sulfur, sodium, water, and air battery had technical challenges.

      Thomas Edison once used iron as an electrode, and iron-air batteries were first studied in the 1960s. They were too heavy to make good transportation batteries. But this time, Chiang and team were looking at a battery that sat on the ground, so weight didn’t matter. Their priorities were cost and availability.

      “Iron is produced, mined, and processed on every continent,” Chiang says. “The Earth is one big ball of iron. We wouldn’t ever have to worry about even the most ambitious projections of how much storage that the world might use by mid-century.” If Form ever moves into the residential market, “it’ll be the safest battery you’ve ever parked at your house,” Chiang laughs. “Just iron, air, and water.”

      Scientists call it reversible rusting. While discharging, the battery takes in oxygen and converts iron to rust. Applying an electrical current converts the rusty pellets back to iron, and the battery “breathes out” oxygen as it charges. “In chemical terms, you have iron, and it becomes iron hydroxide,” Chiang says. “That means electrons were extracted. You get those electrons to go through the external circuit, and now you have a battery.”

      Form Energy’s battery modules are approximately the size of a washer-and-dryer unit. They are stacked in 40-foot containers, and several containers are electrically connected with power conversion systems to build storage plants that can cover several acres.

      The right place at the right time

      The modules don’t look or act like anything utilities have contracted for before.

      That’s one of Form’s key challenges. “There is not widespread knowledge of needing these new tools for decarbonized grids,” Ferrara says. “That’s not the way utilities have typically planned. They’re looking at all the tools in the toolkit that exist today, which may not contemplate a multi-day energy storage asset.”

      Form Energy’s customers are largely traditional power companies seeking to expand their portfolios of renewable electricity. Some are in the process of decommissioning coal plants and shifting to renewables.

      Ferrara’s research pinpointing the need for very low-cost multi-day storage provides key data for power suppliers seeking to determine the most cost-effective way to integrate more renewable energy.

      Using the same modeling techniques, Ferrara and team show potential customers how the technology fits in with their existing system, how it competes with other technologies, and how, in some cases, it can operate synergistically with other storage technologies.

      “They may need a portfolio of storage technologies to fully balance renewables on different timescales of intermittency,” he says. But other than the technology developed at Form, “there isn’t much out there, certainly not within the cost entitlement of what we’re bringing to market.”  Thanks to Chiang and Jaramillo’s chance encounter in Houston, Form has a several-year lead on other companies working to address this challenge. 

      In June 2023, Form Energy closed its biggest deal to date for a single project: Georgia Power’s order for a 15-megawatt/1,500-megawatt-hour system. That order brings Form’s total amount of energy storage under contracts with utility customers to 40 megawatts/4 gigawatt-hours. To meet the demand, Form is building a new commercial-scale battery manufacturing facility in West Virginia.

      The fact that Form Energy is creating jobs in an area that lost more than 10,000 steel jobs over the past decade is not lost on Chiang. “And these new jobs are in clean tech. It’s super exciting to me personally to be doing something that benefits communities outside of our traditional technology centers.

      “This is the right time for so many reasons,” Chiang says. He says he and his Form Energy co-founders feel “tremendous urgency to get these batteries out into the world.”

      This article appears in the Winter 2024 issue of Energy Futures, the magazine of the MIT Energy Initiative. More

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      MADMEC winner creates “temporary tattoos” for T-shirts

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      Have you ever gotten a free T-shirt at an event that you never wear? What about a music or sports-themed shirt you wear to one event and then lose interest in entirely? Such one-off T-shirts — and the waste and pollution associated with them — are an unfortunately common part of our society.

      But what if you could change the designs on shirts after each use? The winners of this year’s MADMEC competition developed biodegradable “temporary tattoos” for T-shirts to make one-wear clothing more sustainable.

      Members of the winning team, called Me-Shirts, got their inspiration from the MADMEC event itself, which ordinarily makes a different T-shirt each year.

      “If you think about all the textile waste that’s produced for all these shirts, it’s insane,” team member and PhD candidate Isabella Caruso said in the winning presentation. “The main markets we are trying to address are for one-time T-shirts and custom T-shirts.”

      The problem is a big one. According to the team, the custom T-shirt market is a $4.3 billion industry. That doesn’t include trends like fast fashion that contribute to the 17 million tons of textile waste produced each year.

      “Our proposed solution is a temporary shirt tattoo made from biodegradable, nontoxic materials,” Caruso explained. “We wanted designs that are fully removable through washing, so that you can wear your T-shirt for your one-time event and then get a nice white T-shirt back afterward.”

      The team’s scalable design process mixes three simple ingredients: potato starch, glycerin, and water. The design can be imprinted on the shirt temporarily through ironing.

      The Me-Shirt team, which earned $10,000 with the win, plans to continue exploring material combinations to make the design more flexible and easier for people to apply at home. Future iterations could allow users to decide if they want the design to stay on the shirt during washes based on the settings of the washing machine.

      Hosted by MIT’s Department of Materials Science and Engineering (DMSE), the competition was the culmination of team projects that began in the fall and included a series of design challenges throughout the semester. Each team received guidance, access to equipment and labs, and up to $1,000 in funding to build and test their prototypes.

      “The main goal is that they gained some confidence in their ability to design and build devices and platforms that are different from their normal experiences,” Mike Tarkanian, a senior lecturer in DMSE and coordinator of MADMEC, said at the event. “If it’s a departure from their normal research and coursework activities that’s a win, I think, to make them better engineers.”

      The second-place, $6,000 prize went to Alkalyne, which is creating a carbon-neutral polymer for petrochemical production. The company is developing approaches for using electricity and inorganic carbon to generate a high-energy hydrocarbon precursor. If developed using renewable energy, the approach could be used to achieve carbon negative petrochemical production.

      “A lot of our research, and a lot of the research around MIT in general, has to do with sustainability, so we wanted to try an angle that we think looks promising but doesn’t seem to be investigated enough,” PhD candidate Christopher Mallia explained.

      The third-place prize went to Microbeco, which is exploring the use of microbial fuel cells for continuous water quality monitoring. Microbes have been proposed as a way to detect and measure contaminants in water for decades, but the team believes the varying responses of microbes to different contaminants has limited the effectiveness of the approach.

      To overcome that problem, the team is working to isolate microbial strains that respond more regularly to specific contaminants.

      Overall, Tarkanian believes this year’s program was a success not only because of the final results presented at the competition, but because of the experience the students got along the way using equipment like laser cutters, 3D printers, and soldering irons. Many participants said they had never used that type of equipment before. They also said by working to build physical prototypes, the program helped make their coursework come to life.

      “It was a chance to try something new by applying my skills to a different environment,” PhD candidate Zachary Adams said. “I can see a lot of the concepts I learn in my classes through this work.” More

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      Angela Belcher delivers 2023 Dresselhaus Lecture on evolving organisms for new nanomaterials

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      “How do we get to making nanomaterials that haven’t been evolved before?” asked Angela Belcher at the 2023 Mildred S. Dresselhaus Lecture at MIT on Nov. 20. “We can use elements that biology has already given us.”

      The combined in-person and virtual audience of over 300 was treated to a light-up, 3D model of M13 bacteriophage, a virus that only infects bacteria, complete with a pull-out strand of DNA. Belcher used the feather-boa-like model to show how her research group modifies the M13’s genes to add new DNA and peptide sequences to template inorganic materials.

      “I love controlling materials at the nanoscale using biology,” said Belcher, the James Mason Crafts Professor of Biological Engineering, materials science professor, and of the Koch Institute of Integrative Cancer Research at MIT. “We all know if you control materials at the nanoscale and you can start to tune them, then you can have all kinds of different applications.” And the opportunities are indeed vast — from building batteries, fuel cells, and solar cells to carbon sequestration and storage, environmental remediation, catalysis, and medical diagnostics and imaging.

      Belcher sprinkled her talk with models and props, lined up on a table at the front of the 10-250 lecture hall, to demonstrate a wide variety of concepts and projects made possible by the intersection of biology and nanotechnology.

      Play video

      2023 Mildred S. Dresselhaus Lecture: Angela BelcherVideo: MIT.nano

      Energy storage and environment

      “How do you go from a DNA sequence to a functioning battery?” posed Belcher. Grabbing a model of a large carbon nanotube, she explained how her group engineered a phage to pick up carbon nanotubes that would wind all the way around the virus and then fill in with different cathode or anode materials to make nanowires for battery electrodes.

      How about using the M13 bacteriophage to improve the environment? Belcher referred to a project by former student Geran Zhang PhD ’19 that proved the virus can be modified for this context, too. He used the phage to template high-surface-area, carbon-based materials that can grab small molecules and break them down, Belcher said, opening a realm of possibilities from cleaning up rivers to developing chemical warfare agents to combating smog.

      Belcher’s lab worked with the U.S. Army to produce protective clothing and masks made of these carbon-based virus nanofibers. “We went from five liters in our lab to a thousand liters, then 10,000 liters in the army labs where we’re able to make kilograms of the material,” Belcher said, stressing the importance of being able to test and prototype at scale.

      Imaging tools and therapeutics in cancer

      In the area of biomedical imaging, Belcher explained, a lot less is known in near-infrared imaging — imaging in wavelengths above 1,000 nanometers — than other imaging techniques, yet with near-infrared scientists can see much deeper inside the body. Belcher’s lab built their own systems to image at these wavelengths. The third generation of this system provides real-time, sub-millimeter optical imaging for guided surgery.

      Working with Sangeeta Bhatia, the John J. and Dorothy Wilson Professor of Engineering, Belcher used carbon nanotubes to build imaging tools that find tiny tumors during surgery that doctors otherwise would not be able to see. The tool is actually a virus engineered to carry with it a fluorescent, single-walled carbon nanotube as it seeks out the tumors.

      Nearing the end of her talk, Belcher presented a goal: to develop an accessible detection and diagnostic technology for ovarian cancer in five to 10 years.

      “We think that we can do it,” Belcher said. She described her students’ work developing a way to scan an entire fallopian tube, as opposed to just one small portion, to find pre-cancer lesions, and talked about the team of MIT faculty, doctors, and researchers working collectively toward this goal.

      “Part of the secret of life and the meaning of life is helping other people enjoy the passage of time,” said Belcher in her closing remarks. “I think that we can all do that by working to solve some of the biggest issues on the planet, including helping to diagnose and treat ovarian cancer early so people have more time to spend with their family.”

      Honoring Mildred S. Dresselhaus

      Belcher was the fifth speaker to deliver the Dresselhaus Lecture, an annual event organized by MIT.nano to honor the late MIT physics and electrical engineering Institute Professor Mildred Dresselhaus. The lecture features a speaker from anywhere in the world whose leadership and impact echo Dresselhaus’s life, accomplishments, and values.

      “Millie was and is a huge hero of mine,” said Belcher. “Giving a lecture in Millie’s name is just the greatest honor.”

      Belcher dedicated the talk to Dresselhaus, whom she described with an array of accolades — a trailblazer, a genius, an amazing mentor, teacher, and inventor. “Just knowing her was such a privilege,” she said.

      Belcher also dedicated her talk to her own grandmother and mother, both of whom passed away from cancer, as well as late MIT professors Susan Lindquist and Angelika Amon, who both died of ovarian cancer.

      “I’ve been so fortunate to work with just the most talented and dedicated graduate students, undergraduate students, postdocs, and researchers,” concluded Belcher. “It has been a pure joy to be in partnership with all of you to solve these very daunting problems.” More

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      Celebrating five years of MIT.nano

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      There is vast opportunity for nanoscale innovation to transform the world in positive ways — expressed MIT.nano Director Vladimir Bulović as he posed two questions to attendees at the start of the inaugural Nano Summit: “Where are we heading? And what is the next big thing we can develop?”

      “The answer to that puts into perspective our main purpose — and that is to change the world,” Bulović, the Fariborz Maseeh Professor of Emerging Technologies, told an audience of more than 325 in-person and 150 virtual participants gathered for an exploration of nano-related research at MIT and a celebration of MIT.nano’s fifth anniversary.

      Over a decade ago, MIT embarked on a massive project for the ultra-small — building an advanced facility to support research at the nanoscale. Construction of MIT.nano in the heart of MIT’s campus, a process compared to assembling a ship in a bottle, began in 2015, and the facility launched in October 2018.

      Fast forward five years: MIT.nano now contains nearly 170 tools and instruments serving more than 1,200 trained researchers. These individuals come from over 300 principal investigator labs, representing more than 50 MIT departments, labs, and centers. The facility also serves external users from industry, other academic institutions, and over 130 startup and multinational companies.

      A cross section of these faculty and researchers joined industry partners and MIT community members to kick off the first Nano Summit, which is expected to become an annual flagship event for MIT.nano and its industry consortium. Held on Oct. 24, the inaugural conference was co-hosted by the MIT Industrial Liaison Program.

      Six topical sessions highlighted recent developments in quantum science and engineering, materials, advanced electronics, energy, biology, and immersive data technology. The Nano Summit also featured startup ventures and an art exhibition.

      Watch the videos here.

      Seeing and manipulating at the nanoscale — and beyond

      “We need to develop new ways of building the next generation of materials,” said Frances Ross, the TDK Professor in Materials Science and Engineering (DMSE). “We need to use electron microscopy to help us understand not only what the structure is after it’s built, but how it came to be. I think the next few years in this piece of the nano realm are going to be really amazing.”

      Speakers in the session “The Next Materials Revolution,” chaired by MIT.nano co-director for Characterization.nano and associate professor in DMSE James LeBeau, highlighted areas in which cutting-edge microscopy provides insights into the behavior of functional materials at the nanoscale, from anti-ferroelectrics to thin-film photovoltaics and 2D materials. They shared images and videos collected using the instruments in MIT.nano’s characterization suites, which were specifically designed and constructed to minimize mechanical-vibrational and electro-magnetic interference.

      Later, in the “Biology and Human Health” session chaired by Boris Magasanik Professor of Biology Thomas Schwartz, biologists echoed the materials scientists, stressing the importance of the ultra-quiet, low-vibration environment in Characterization.nano to obtain high-resolution images of biological structures.

      “Why is MIT.nano important for us?” asked Schwartz. “An important element of biology is to understand the structure of biology macromolecules. We want to get to an atomic resolution of these structures. CryoEM (cryo-electron microscopy) is an excellent method for this. In order to enable the resolution revolution, we had to get these instruments to MIT. For that, MIT.nano was fantastic.”

      Seychelle Vos, the Robert A. Swanson (1969) Career Development Professor of Life Sciences, shared CryoEM images from her lab’s work, followed by biology Associate Professor Joey Davis who spoke about image processing. When asked about the next stage for CryoEM, Davis said he’s most excited about in-situ tomography, noting that there are new instruments being designed that will improve the current labor-intensive process.

      To chart the future of energy, chemistry associate professor Yogi Surendranath is also using MIT.nano to see what is happening at the nanoscale in his research to use renewable electricity to change carbon dioxide into fuel.

      “MIT.nano has played an immense role, not only in facilitating our ability to make nanostructures, but also to understand nanostructures through advanced imaging capabilities,” said Surendranath. “I see a lot of the future of MIT.nano around the question of how nanostructures evolve and change under the conditions that are relevant to their function. The tools at MIT.nano can help us sort that out.”

      Tech transfer and quantum computing

      The “Advanced Electronics” session chaired by Jesús del Alamo, the Donner Professor of Science in the Department of Electrical Engineering and Computer Science (EECS), brought together industry partners and MIT faculty for a panel discussion on the future of semiconductors and microelectronics. “Excellence in innovation is not enough, we also need to be excellent in transferring these to the marketplace,” said del Alamo. On this point, panelists spoke about strengthening the industry-university connection, as well as the importance of collaborative research environments and of access to advanced facilities, such as MIT.nano, for these environments to thrive.

      The session came on the heels of a startup exhibit in which eleven START.nano companies presented their technologies in health, energy, climate, and virtual reality, among other topics. START.nano, MIT.nano’s hard-tech accelerator, provides participants use of MIT.nano’s facilities at a discounted rate and access to MIT’s startup ecosystem. The program aims to ease hard-tech startups’ transition from the lab to the marketplace, surviving common “valleys of death” as they move from idea to prototype to scaling up.

      When asked about the state of quantum computing in the “Quantum Science and Engineering” session, physics professor Aram Harrow related his response to these startup challenges. “There are quite a few valleys to cross — there are the technical valleys, and then also the commercial valleys.” He spoke about scaling superconducting qubits and qubits made of suspended trapped ions, and the need for more scalable architectures, which we have the ingredients for, he said, but putting everything together is quite challenging.

      Throughout the session, William Oliver, professor of physics and the Henry Ellis Warren (1894) Professor of Electrical Engineering and Computer Science, asked the panelists how MIT.nano can address challenges in assembly and scalability in quantum science.

      “To harness the power of students to innovate, you really need to allow them to get their hands dirty, try new things, try all their crazy ideas, before this goes into a foundry-level process,” responded Kevin O’Brien, associate professor in EECS. “That’s what my group has been working on at MIT.nano, building these superconducting quantum processors using the state-of-the art fabrication techniques in MIT.nano.”

      Connecting the digital to the physical

      In his reflections on the semiconductor industry, Douglas Carlson, senior vice president for technology at MACOM, stressed connecting the digital world to real-world application. Later, in the “Immersive Data Technology” session, MIT.nano associate director Brian Anthony explained how, at the MIT.nano Immersion Lab, researchers are doing just that.

      “We think about and facilitate work that has the human immersed between hardware, data, and experience,” said Anthony, principal research scientist in mechanical engineering. He spoke about using the capabilities of the Immersion Lab to apply immersive technologies to different areas — health, sports, performance, manufacturing, and education, among others. Speakers in this session gave specific examples in hardware, pediatric health, and opera.

      Anthony connected this third pillar of MIT.nano to the fab and characterization facilities, highlighting how the Immersion Lab supports work conducted in other parts of the building. The Immersion Lab’s strength, he said, is taking novel work being developed inside MIT.nano and bringing it up to the human scale to think about applications and uses.

      Artworks that are scientifically inspired

      The Nano Summit closed with a reception at MIT.nano where guests could explore the facility and gaze through the cleanroom windows, where users were actively conducting research. Attendees were encouraged to visit an exhibition on MIT.nano’s first- and second-floor galleries featuring work by students from the MIT Program in Art, Culture, and Technology (ACT) who were invited to utilize MIT.nano’s tool sets and environments as inspiration for art.

      In his closing remarks, Bulović reflected on the community of people who keep MIT.nano running and who are using the tools to advance their research. “Today we are celebrating the facility and all the work that has been done over the last five years to bring it to where it is today. It is there to function not just as a space, but as an essential part of MIT’s mission in research, innovation, and education. I hope that all of us here today take away a deep appreciation and admiration for those who are leading the journey into the nano age.” More

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      Team engineers nanoparticles using ion irradiation to advance clean energy and fuel conversion

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      MIT researchers and colleagues have demonstrated a way to precisely control the size, composition, and other properties of nanoparticles key to the reactions involved in a variety of clean energy and environmental technologies. They did so by leveraging ion irradiation, a technique in which beams of charged particles bombard a material.

      They went on to show that nanoparticles created this way have superior performance over their conventionally made counterparts.

      “The materials we have worked on could advance several technologies, from fuel cells to generate CO2-free electricity to the production of clean hydrogen feedstocks for the chemical industry [through electrolysis cells],” says Bilge Yildiz, leader of the work and a professor in MIT’s departments of Nuclear Science and Engineering and Materials Science and Engineering.

      Critical catalyst

      Fuel and electrolysis cells both involve electrochemical reactions through three principal parts: two electrodes (a cathode and anode) separated by an electrolyte. The difference between the two cells is that the reactions involved run in reverse.

      The electrodes are coated with catalysts, or materials that make the reactions involved go faster. But a critical catalyst made of metal-oxide materials has been limited by challenges including low durability. “The metal catalyst particles coarsen at high temperatures, and you lose surface area and activity as a result,” says Yildiz, who is also affiliated with the Materials Research Laboratory and is an author of an open-access paper on the work published in the journal Energy & Environmental Science.

      Enter metal exsolution, which involves precipitating metal nanoparticles out of a host oxide onto the surface of the electrode. The particles embed themselves into the electrode, “and that anchoring makes them more stable,” says Yildiz. As a result, exsolution has “led to remarkable progress in clean energy conversion and energy-efficient computing devices,” the researchers write in their paper.

      However, controlling the precise properties of the resulting nanoparticles has been difficult. “We know that exsolution can give us stable and active nanoparticles, but the challenging part is really to control it. The novelty of this work is that we’ve found a tool — ion irradiation — that can give us that control,” says Jiayue Wang PhD ’22, first author of the paper. Wang, who conducted the work while earning his PhD in the MIT Department of Nuclear Science and Engineering, is now a postdoc at Stanford University.

      Sossina Haile ’86, PhD ’92, the Walter P. Murphy Professor of Materials Science and Engineering at Northwestern University, who was not involved in the current work, says:

      “Metallic nanoparticles serve as catalysts in a whole host of reactions, including the important reaction of splitting water to generate hydrogen for energy storage. In this work, Yildiz and colleagues have created an ingenious method for controlling the way that nanoparticles form.”

      Haile continues, “the community has shown that exsolution results in structurally stable nanoparticles, but the process is not easy to control, so one doesn’t necessarily get the optimal number and size of particles. Using ion irradiation, this group was able to precisely control the features of the nanoparticles, resulting in excellent catalytic activity for water splitting.”

      What they did

      The researchers found that aiming a beam of ions at the electrode while simultaneously exsolving metal nanoparticles onto the electrode’s surface allowed them to control several properties of the resulting nanoparticles.

      “Through ion-matter interactions, we have successfully engineered the size, composition, density, and location of the exsolved nanoparticles,” the team writes in Energy & Environmental Science.

      For example, they could make the particles much smaller — down to 2 billionths of a meter in diameter — than those made using conventional thermal exsolution methods alone. Further, they were able to change the composition of the nanoparticles by irradiating with specific elements. They demonstrated this with a beam of nickel ions that implanted nickel into the exsolved metal nanoparticle. As a result, they demonstrated a direct and convenient way to engineer the composition of exsolved nanoparticles.

      “We want to have multi-element nanoparticles, or alloys, because they usually have higher catalytic activity,” Yildiz says. “With our approach, the exsolution target does not have to be dependent on the substrate oxide itself.” Irradiation opens the door to many more compositions. “We can pretty much choose any oxide and any ion that we can irradiate with and exsolve that,” says Yildiz.

      The team also found that ion irradiation forms defects in the electrode itself. And these defects provide additional nucleation sites, or places for the exsolved nanoparticles to grow from, increasing the density of the resulting nanoparticles.

      Irradiation could also allow extreme spatial control over the nanoparticles. “Because you can focus the ion beam, you can imagine that you could ‘write’ with it to form specific nanostructures,” says Wang. “We did a preliminary demonstration [of that], but we believe it has potential to realize well-controlled micro- and nano-structures.”

      The team also showed that the nanoparticles they created with ion irradiation had superior catalytic activity over those created by conventional thermal exsolution alone.

      Additional MIT authors of the paper are Kevin B. Woller, a principal research scientist at the Plasma Science and Fusion Center (PSFC), home to the equipment used for ion irradiation; Abinash Kumar PhD ’22, who received his PhD from the Department of Materials Science and Engineering (DMSE) and is now at Oak Ridge National Laboratory; and James M. LeBeau, an associate professor in DMSE. Other authors are Zhan Zhang and Hua Zhou of Argonne National Laboratory, and Iradwikanari Waluyo and Adrian Hunt of Brookhaven National Laboratory.

      This work was funded by the OxEon Corp. and MIT’s PSFC. The research also used resources supported by the U.S. Department of Energy Office of Science, MIT’s Materials Research Laboratory, and MIT.nano. The work was performed, in part, at Harvard University through a network funded by the National Science Foundation. More

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      A green hydrogen innovation for clean energy

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      Renewable energy today — mainly derived from the sun or wind — depends on batteries for storage. While costs have dropped in recent years, the pursuit of more efficient means of storing renewable power continues.

      “All of these technologies, unfortunately, have a long way to go,” said Sossina Haile SB ’86, PhD ’92, the Walter P. Murphy Professor of Materials Science and Engineering at Northwestern University, at recent talk at MIT. She was the speaker of the fall 2023 Wulff Lecture, an event hosted by the Department of Materials Science and Engineering (DMSE) to ignite enthusiasm for the discipline.

      To add to the renewable energy mix — and help quicken the pace to a sustainable future — Haile is working on an approach based on hydrogen in fuel cells, particularly for eco-friendly fuel in cars. Fuel cells, like batteries, produce electricity from chemical reactions but don’t lose their charge so long as fuel is supplied.

      To generate power, the hydrogen must be pure — not attached to another molecule. Most methods of producing hydrogen today require burning fossil fuel, which generates planet-heating carbon emissions. Haile proposes a “green” process using renewable electricity to extract the hydrogen from steam.

      When hydrogen is used in a fuel cell, “you have water as the product, and that’s the beautiful zero emissions,” Haile said, referring to the renewable energy production cycle that is set in motion.

      Ammonia fuels hydrogen’s potential

      Hydrogen is not yet widely used as a fuel because it’s difficult to transport. For one, it has low energy density, meaning a large volume of hydrogen gas is needed to store a large amount of energy. And storing it is challenging because hydrogen’s tiny molecules can infiltrate metal tanks or pipes, causing cracks and gas leakage.

      Haile’s solution for transporting hydrogen is using ammonia to “carry” it. Ammonia is three parts hydrogen and one part nitrogen, so the hydrogen needs to be separated from the nitrogen before it can be used in the kind of fuel cells that can power cars.

      Ammonia has some advantages, including using existing pipelines and a high transmission capacity, Haile said — so more power can be transmitted at any given time.

      To extract the hydrogen from ammonia, Haile has built devices that look a lot like fuel cells, with cesium dihydrogen phosphate as an electrolyte. The “superprotonic” material displays high proton conductivity — it allows protons, or positively charged particles, to move through it. This is important for hydrogen, which has just a proton and an electron. By letting only protons through the electrolyte, the device strips hydrogen from the ammonia, leaving behind the nitrogen.

      The material has other benefits, too, Haile said: “It’s inexpensive, nontoxic, earth-abundant — all these good things that you want to have when you think about a sustainable energy technology.”

      Play video

      2023 Fall Wulff LectureVideo: Department of Materials Science and Engineering

      Sparking interest — and hope

      Haile’s talk piqued interest in the audience, which nearly filled the 6-120 auditorium at MIT, which seats about 150 people.

      Materials science and engineering major Nikhita Law heard hope in Haile’s talk for a more sustainable future.

      “A major problem in making our energy system sustainable is finding ways to store energy from renewables,” Law says. Even if hydrogen-powered cars are not as wide-scale as lithium-battery-powered electric cars, “a permanent energy storage station where we convert electricity into hydrogen and convert it back seems like it makes more sense than mining more lithium.”

      Another DMSE student, senior Daniel Tong, learned about the challenges involved in transporting hydrogen at another seminar and was curious to learn more. “This was something I hadn’t thought of: Can you carry hydrogen more effectively in a different form? That’s really cool.”

      He adds that talks like the Wulff Lecture are helpful in keeping people up to date in a wide-ranging, interdisciplinary field such as materials science and engineering, which spans chemistry, physics, engineering, and other disciplines. “This is a really good way to get exposed to different parts of materials science. There are so many more facets than you know of.”

      In her talk, Haile encouraged audience members to get involved in sustainability research.

      “There’s lots of room for further insight and materials discovery,” she said.

      Haile concluded by underscoring the challenges faced by developing countries in dealing with climate change impacts, particularly those near the equator where there isn’t adequate infrastructure to deal with big swings in precipitation and temperature. For the people who aren’t driven to solve problems that affect people on the other side of the world, Haile offered some extra motivation.

      “I’m sure many of you enjoy coffee. This is going to put the coffee crops in jeopardy as well,” she said. More

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      in Environment

      Merging science and systems thinking to make materials more sustainable

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      For Professor Elsa Olivetti, tackling a problem as large and complex as climate change requires not only lab research but also understanding the systems of production that power the global economy.

      Her career path reflects a quest to investigate materials at scales ranging from the microscopic to the mass-manufactured.

      “I’ve always known what questions I wanted to ask, and then set out to build the tools to help me ask those questions,” says Olivetti, the Jerry McAfee Professor in Engineering.

      Olivetti, who earned tenure in 2022 and was recently appointed associate dean of engineering, has sought to equip students with similar skills, whether in the classroom, in her lab group, or through the interdisciplinary programs she leads at MIT. Those efforts have earned her accolades including the Bose Award for Excellence in Teaching, a MacVicar Faculty Fellowship in 2021, and the McDonald Award for Excellence in Mentoring and Advising in 2023.

      “I think to make real progress in sustainability, materials scientists need to think in interdisciplinary, systems-level ways, but at a deep technical level,” Olivetti says. “Supporting my students so that’s something that a lot more people can do is very rewarding for me.”

      Her mission to make materials more sustainable also makes Olivetti grateful [EAO1] she’s at MIT, which has a long tradition of both interdisciplinary collaboration and technical know-how.

      “MIT’s core competencies are well-positioned for bold achievements in climate and sustainability — the deep expertise on the economics side, the frontier knowledge in science, the computational creativity,” Olivetti says. “It’s a really exciting time and place where the key ingredients for progress are simmering in transformative ways.”

      Answering the call

      The moment that set Olivetti on her life’s journey began when she was 8, with a knock at her door. Her parents were in the other room, so Olivetti opened the door and met an organizer for Greenpeace, a nonprofit that works to raise awareness of environmental issues.

      “I had a chat with that guy and got hooked on environmental concerns,” Olivetti says. “I still remember that conversation.”

      The interaction changed the way Olivetti thought about her place in the world, and her new perspective manifested itself in some unique ways. Her elementary school science fair projects became elaborate pursuits of environmental solutions involving burying various items in the backyard to test for biodegradability. There was also an awkward attempt at natural pesticide development, which lead to a worm hatching in her bedroom.

      As an undergraduate at the University of Virginia, Olivetti gravitated toward classes in environmentalism and materials science.

      “There was a link between materials science and a broader, systems way of framing design for environment, and that just clicked for me in terms of the way I wanted to think about environmental problems — from the atom to the system,” Olivetti recalls.

      That interest led Olivetti to MIT for a PhD in 2001, where she studied the feasibility of new materials for lithium-ion batteries.

      “I really wanted to be thinking of things at a systems level, but I wanted to ground that in lab-based research,” Olivetti says. “I wanted an experiential experience in grad school, and that’s why I chose MIT’s program.”

      Whether it was her undergraduate studies, her PhD, or her ensuing postdoc work at MIT, Olivetti sought to learn new skills to continue bridging the gap between materials science and environmental systems thinking.

      “I think of it as, ‘Here’s how I can build up the ways I ask questions,’” Olivetti explains. “How do we design these materials while thinking about their implications as early as possible?”

      Since joining MIT’s faculty in 2014, Olivetti has developed computational models to measure the cost and environmental impact of new materials, explored ways to adopt more sustainable and circular supply chains, and evaluated potential materials limitations as lithium-ion battery production is scaled. That work helps companies increase their use of greener, recyclable materials and more sustainably dispose of waste.

      Olivetti believes the wide scope of her research gives the students in her lab a more holistic understanding of the life cycle of materials.

      “When the group started, each student was working on a different aspect of the problem — like on the natural language processing pipeline, or on recycling technology assessment, or beneficial use of waste — and now each student can link each of those pieces in their research,” Olivetti explains.

      Beyond her research, Olivetti also co-directs the MIT Climate and Sustainability Consortium, which has established a set of eight areas of sustainability that it organizes coalitions around. Each coalition involves technical leaders at companies and researchers at MIT that work together to accelerate the impact of MIT’s research by helping companies adopt innovative and more sustainable technologies.

      “Climate change mitigation and resilience is such a complex problem, and at MIT we have practice in working together across disciplines on many challenges,” Olivetti says. “It’s been exciting to lean on that culture and unlock ways to move forward more effectively.”

      Bridging divides

      Today, Olivetti tries to maximize the impact of her and her students’ research in materials industrial ecology by maintaining close ties to applications. In her research, this means working directly with aluminum companies to design alloys that could incorporate more scrap material or with nongovernmental organizations to incorporate agricultural residues in building products. In the classroom, that means bringing in people from companies to explain how they think about concepts like heat exchange or fluid flow in their products.

      “I enjoy trying to ground what students are learning in the classroom with what’s happening in the world,” Olivetti explains.

      Exposing students to industry is also a great way to help them think about their own careers. In her research lab, she’s started using the last 30 minutes of meetings to host talks from people working in national labs, startups, and larger companies to show students what they can do after their PhDs. The talks are similar to the Industry Seminar series Olivetti started that pairs undergraduate students with people working in areas like 3D printing, environmental consulting, and manufacturing.

      “It’s about helping students learn what they’re excited about,” Olivetti says.

      Whether in the classroom, lab, or at events held by organizations like MCSC, Olivetti believes collaboration is humanity’s most potent tool to combat climate change.

      “I just really enjoy building links between people,” Olivetti says. “Learning about people and meeting them where they are is a way that one can create effective links. It’s about creating the right playgrounds for people to think and learn.” More

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      in Energy

      Engineers develop an efficient process to make fuel from carbon dioxide

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      The search is on worldwide to find ways to extract carbon dioxide from the air or from power plant exhaust and then make it into something useful. One of the more promising ideas is to make it into a stable fuel that can replace fossil fuels in some applications. But most such conversion processes have had problems with low carbon efficiency, or they produce fuels that can be hard to handle, toxic, or flammable.

      Now, researchers at MIT and Harvard University have developed an efficient process that can convert carbon dioxide into formate, a liquid or solid material that can be used like hydrogen or methanol to power a fuel cell and generate electricity. Potassium or sodium formate, already produced at industrial scales and commonly used as a de-icer for roads and sidewalks, is nontoxic, nonflammable, easy to store and transport, and can remain stable in ordinary steel tanks to be used months, or even years, after its production.

      The new process, developed by MIT doctoral students Zhen Zhang, Zhichu Ren, and Alexander H. Quinn; Harvard University doctoral student Dawei Xi; and MIT Professor Ju Li, is described this week in an open-access paper in Cell Reports Physical Science. The whole process — including capture and electrochemical conversion of the gas to a solid formate powder, which is then used in a fuel cell to produce electricity — was demonstrated at a small, laboratory scale. However, the researchers expect it to be scalable so that it could provide emissions-free heat and power to individual homes and even be used in industrial or grid-scale applications.

      Other approaches to converting carbon dioxide into fuel, Li explains, usually involve a two-stage process: First the gas is chemically captured and turned into a solid form as calcium carbonate, then later that material is heated to drive off the carbon dioxide and convert it to a fuel feedstock such as carbon monoxide. That second step has very low efficiency, typically converting less than 20 percent of the gaseous carbon dioxide into the desired product, Li says.

      By contrast, the new process achieves a conversion of well over 90 percent and eliminates the need for the inefficient heating step by first converting the carbon dioxide into an intermediate form, liquid metal bicarbonate. That liquid is then electrochemically converted into liquid potassium or sodium formate in an electrolyzer that uses low-carbon electricity, e.g. nuclear, wind, or solar power. The highly concentrated liquid potassium or sodium formate solution produced can then be dried, for example by solar evaporation, to produce a solid powder that is highly stable and can be stored in ordinary steel tanks for up to years or even decades, Li says.

      Several steps of optimization developed by the team made all the difference in changing an inefficient chemical-conversion process into a practical solution, says Li, who holds joint appointments in the departments of Nuclear Science and Engineering and of Materials Science and Engineering.

      The process of carbon capture and conversion involves first an alkaline solution-based capture that concentrates carbon dioxide, either from concentrated streams such as from power plant emissions or from very low-concentration sources, even open air, into the form of a liquid metal-bicarbonate solution. Then, through the use of a cation-exchange membrane electrolyzer, this bicarbonate is electrochemically converted into solid formate crystals with a carbon efficiency of greater than 96 percent, as confirmed in the team’s lab-scale experiments.

      These crystals have an indefinite shelf life, remaining so stable that they could be stored for years, or even decades, with little or no loss. By comparison, even the best available practical hydrogen storage tanks allow the gas to leak out at a rate of about 1 percent per day, precluding any uses that would require year-long storage, Li says. Methanol, another widely explored alternative for converting carbon dioxide into a fuel usable in fuel cells, is a toxic substance that cannot easily be adapted to use in situations where leakage could pose a health hazard. Formate, on the other hand, is widely used and considered benign, according to national safety standards.

      Several improvements account for the greatly improved efficiency of this process. First, a careful design of the membrane materials and their configuration overcomes a problem that previous attempts at such a system have encountered, where a buildup of certain chemical byproducts changes the pH, causing the system to steadily lose efficiency over time. “Traditionally, it is difficult to achieve long-term, stable, continuous conversion of the feedstocks,” Zhang says. “The key to our system is to achieve a pH balance for steady-state conversion.”

      To achieve that, the researchers carried out thermodynamic modeling to design the new process so that it is chemically balanced and the pH remains at a steady state with no shift in acidity over time. It can therefore continue operating efficiently over long periods. In their tests, the system ran for over 200 hours with no significant decrease in output. The whole process can be done at ambient temperatures and relatively low pressures (about five times atmospheric pressure).

      Another issue was that unwanted side reactions produced other chemical products that were not useful, but the team figured out a way to prevent these side reactions by the introduction of an extra “buffer” layer of bicarbonate-enriched fiberglass wool that blocked these reactions.

      The team also built a fuel cell specifically optimized for the use of this formate fuel to produce electricity. The stored formate particles are simply dissolved in water and pumped into the fuel cell as needed. Although the solid fuel is much heavier than pure hydrogen, when the weight and volume of the high-pressure gas tanks needed to store hydrogen is considered, the end result is an electricity output near parity for a given storage volume, Li says.

      The formate fuel can potentially be adapted for anything from home-sized units to large scale industrial uses or grid-scale storage systems, the researchers say. Initial household applications might involve an electrolyzer unit about the size of a refrigerator to capture and convert the carbon dioxide into formate, which could be stored in an underground or rooftop tank. Then, when needed, the powdered solid would be mixed with water and fed into a fuel cell to provide power and heat. “This is for community or household demonstrations,” Zhang says, “but we believe that also in the future it may be good for factories or the grid.”

      “The formate economy is an intriguing concept because metal formate salts are very benign and stable, and a compelling energy carrier,” says Ted Sargent, a professor of chemistry and of electrical and computer engineering at Northwestern University, who was not associated with this work. “The authors have demonstrated enhanced efficiency in liquid-to-liquid conversion from bicarbonate feedstock to formate, and have demonstrated these fuels can be used later to produce electricity,” he says.

      The work was supported by the U.S. Department of Energy Office of Science. More