Mechanical engineering

Subterms

    More stories

    • 188 Shares139 Views

      in Energy

      MIT spinout Gradiant reduces companies’ water use and waste by billions of gallons each day

      by

      When it comes to water use, most of us think of the water we drink. But industrial uses for things like manufacturing account for billions of gallons of water each day. For instance, making a single iPhone, by one estimate, requires more than 3,000 gallons.Gradiant is working to reduce the world’s industrial water footprint. Founded by a team from MIT, Gradiant offers water recycling, treatment, and purification solutions to some of the largest companies on Earth, including Coca Cola, Tesla, and the Taiwan Semiconductor Manufacturing Company. By serving as an end-to-end water company, Gradiant says it helps companies reuse 2 billion gallons of water each day and saves another 2 billion gallons of fresh water from being withdrawn.The company’s mission is to preserve water for generations to come in the face of rising global demand.“We work on both ends of the water spectrum,” Gradiant co-founder and CEO Anurag Bajpayee SM ’08, PhD ’12 says. “We work with ultracontaminated water, and we can also provide ultrapure water for use in areas like chip fabrication. Our specialty is in the extreme water challenges that can’t be solved with traditional technologies.”For each customer, Gradiant builds tailored water treatment solutions that combine chemical treatments with membrane filtration and biological process technologies, leveraging a portfolio of patents to drastically cut water usage and waste.“Before Gradiant, 40 million liters of water would be used in the chip-making process. It would all be contaminated and treated, and maybe 30 percent would be reused,” explains Gradiant co-founder and COO Prakash Govindan PhD ’12. “We have the technology to recycle, in some cases, 99 percent of the water. Now, instead of consuming 40 million liters, chipmakers only need to consume 400,000 liters, which is a huge shift in the water footprint of that industry. And this is not just with semiconductors. We’ve done this in food and beverage, we’ve done this in renewable energy, we’ve done this in pharmaceutical drug production, and several other areas.”Learning the value of waterGovindan grew up in a part of India that experienced a years-long drought beginning when he was 10. Without tap water, one of Govindan’s chores was to haul water up the stairs of his apartment complex each time a truck delivered it.“However much water my brother and I could carry was how much we had for the week,” Govindan recalls. “I learned the value of water the hard way.”Govindan attended the Indian Institute of Technology as an undergraduate, and when he came to MIT for his PhD, he sought out the groups working on water challenges. He began working on a water treatment method called carrier gas extraction for his PhD under Gradiant co-founder and MIT Professor John Lienhard.Bajpayee also worked on water treatment methods at MIT, and after brief stints as postdocs at MIT, he and Govindan licensed their work and founded Gradiant.Carrier gas extraction became Gradiant’s first proprietary technology when the company launched in 2013. The founders began by treating wastewater created by oil and gas wells, landing their first partner in a Texas company. But Gradiant gradually expanded to solving water challenges in power generation, mining, textiles, and refineries. Then the founders noticed opportunities in industries like electronics, semiconductors, food and beverage, and pharmaceuticals. Today, oil and gas wastewater treatment makes up a small percentage of Gradiant’s work.As the company expanded, it added technologies to its portfolio, patenting new water treatment methods around reverse osmosis, selective contaminant extraction, and free radical oxidation. Gradiant has also created a digital system that uses AI to measure, predict, and control water treatment facilities.“The advantage Gradiant has over every other water company is that R&D is in our DNA,” Govindan says, noting Gradiant has a world-class research lab at its headquarters in Boston. “At MIT, we learned how to do cutting-edge technology development, and we never let go of that.”The founders compare their suite of technologies to LEGO bricks they can mix and match depending on a customer’s water needs. Gradiant has built more than 2,500 of these end-to-end systems for customers around the world.“Our customers aren’t water companies; they are industrial clients like semiconductor manufacturers, drug companies, and food and beverage companies,” Bajpayee says. “They aren’t about to start operating a water treatment plant. They look at us as their water partner who can take care of the whole water problem.”Continuing innovationThe founders say Gradiant has been roughly doubling its revenue each year over the last five years, and it’s continuing to add technologies to its platform. For instance, Gradiant recently developed a critical minerals recovery solution to extract materials like lithium and nickel from customers’ wastewater, which could expand access to critical materials essential to the production of batteries and other products.“If we can extract lithium from brine water in an environmentally and economically feasible way, the U.S. can meet all of its lithium needs from within the U.S.,” Bajpayee says. “What’s preventing large-scale extraction of lithium from brine is technology, and we believe what we have now deployed will open the floodgates for direct lithium extraction and completely revolutionized the industry.”The company has also validated a method for eliminating PFAS — so-called toxic “forever chemicals” — in a pilot project with a leading U.S. semiconductor manufacturer. In the near future, it hopes to bring that solution to municipal water treatment plants to protect cities.At the heart of Gradiant’s innovation is the founders’ belief that industrial activity doesn’t have to deplete one of the world’s most vital resources.“Ever since the industrial revolution, we’ve been taking from nature,” Bajpayee says. “By treating and recycling water, by reducing water consumption and making industry highly water efficient, we have this unique opportunity to turn the clock back and give nature water back. If that’s your driver, you can’t choose not to innovate.” More

    • 150 Shares109 Views

      in Environment

      Surface-based sonar system could rapidly map the ocean floor at high resolution

      by

      On June 18, 2023, the Titan submersible was about an hour-and-a-half into its two-hour descent to the Titanic wreckage at the bottom of the Atlantic Ocean when it lost contact with its support ship. This cease in communication set off a frantic search for the tourist submersible and five passengers onboard, located about two miles below the ocean’s surface.Deep-ocean search and recovery is one of the many missions of military services like the U.S. Coast Guard Office of Search and Rescue and the U.S. Navy Supervisor of Salvage and Diving. For this mission, the longest delays come from transporting search-and-rescue equipment via ship to the area of interest and comprehensively surveying that area. A search operation on the scale of that for Titan — which was conducted 420 nautical miles from the nearest port and covered 13,000 square kilometers, an area roughly twice the size of Connecticut — could take weeks to complete. The search area for Titan is considered relatively small, focused on the immediate vicinity of the Titanic. When the area is less known, operations could take months. (A remotely operated underwater vehicle deployed by a Canadian vessel ended up finding the debris field of Titan on the seafloor, four days after the submersible had gone missing.)A research team from MIT Lincoln Laboratory and the MIT Department of Mechanical Engineering’s Ocean Science and Engineering lab is developing a surface-based sonar system that could accelerate the timeline for small- and large-scale search operations to days. Called the Autonomous Sparse-Aperture Multibeam Echo Sounder, the system scans at surface-ship rates while providing sufficient resolution to find objects and features in the deep ocean, without the time and expense of deploying underwater vehicles. The echo sounder — which features a large sonar array using a small set of autonomous surface vehicles (ASVs) that can be deployed via aircraft into the ocean — holds the potential to map the seabed at 50 times the coverage rate of an underwater vehicle and 100 times the resolution of a surface vessel.

      Play video

      Autonomous Sparse-Aperture Multibeam Echo SounderVideo: MIT Lincoln Laboratory

      “Our array provides the best of both worlds: the high resolution of underwater vehicles and the high coverage rate of surface ships,” says co–principal investigator Andrew March, assistant leader of the laboratory’s Advanced Undersea Systems and Technology Group. “Though large surface-based sonar systems at low frequency have the potential to determine the materials and profiles of the seabed, they typically do so at the expense of resolution, particularly with increasing ocean depth. Our array can likely determine this information, too, but at significantly enhanced resolution in the deep ocean.”Underwater unknownOceans cover 71 percent of Earth’s surface, yet more than 80 percent of this underwater realm remains undiscovered and unexplored. Humans know more about the surface of other planets and the moon than the bottom of our oceans. High-resolution seabed maps would not only be useful to find missing objects like ships or aircraft, but also to support a host of other scientific applications: understanding Earth’s geology, improving forecasting of ocean currents and corresponding weather and climate impacts, uncovering archaeological sites, monitoring marine ecosystems and habitats, and identifying locations containing natural resources such as mineral and oil deposits.Scientists and governments worldwide recognize the importance of creating a high-resolution global map of the seafloor; the problem is that no existing technology can achieve meter-scale resolution from the ocean surface. The average depth of our oceans is approximately 3,700 meters. However, today’s technologies capable of finding human-made objects on the seabed or identifying person-sized natural features — these technologies include sonar, lidar, cameras, and gravitational field mapping — have a maximum range of less than 1,000 meters through water.Ships with large sonar arrays mounted on their hull map the deep ocean by emitting low-frequency sound waves that bounce off the seafloor and return as echoes to the surface. Operation at low frequencies is necessary because water readily absorbs high-frequency sound waves, especially with increasing depth; however, such operation yields low-resolution images, with each image pixel representing a football field in size. Resolution is also restricted because sonar arrays installed on large mapping ships are already using all of the available hull space, thereby capping the sonar beam’s aperture size. By contrast, sonars on autonomous underwater vehicles (AUVs) that operate at higher frequencies within a few hundred meters of the seafloor generate maps with each pixel representing one square meter or less, resulting in 10,000 times more pixels in that same football field–sized area. However, this higher resolution comes with trade-offs: AUVs are time-consuming and expensive to deploy in the deep ocean, limiting the amount of seafloor that can be mapped; they have a maximum range of about 1,000 meters before their high-frequency sound gets absorbed; and they move at slow speeds to conserve power. The area-coverage rate of AUVs performing high-resolution mapping is about 8 square kilometers per hour; surface vessels map the deep ocean at more than 50 times that rate.A solution surfacesThe Autonomous Sparse-Aperture Multibeam Echo Sounder could offer a cost-effective approach to high-resolution, rapid mapping of the deep seafloor from the ocean’s surface. A collaborative fleet of about 20 ASVs, each hosting a small sonar array, effectively forms a single sonar array 100 times the size of a large sonar array installed on a ship. The large aperture achieved by the array (hundreds of meters) produces a narrow beam, which enables sound to be precisely steered to generate high-resolution maps at low frequency. Because very few sonars are installed relative to the array’s overall size (i.e., a sparse aperture), the cost is tractable.However, this collaborative and sparse setup introduces some operational challenges. First, for coherent 3D imaging, the relative position of each ASV’s sonar subarray must be accurately tracked through dynamic ocean-induced motions. Second, because sonar elements are not placed directly next to each other without any gaps, the array suffers from a lower signal-to-noise ratio and is less able to reject noise coming from unintended or undesired directions. To mitigate these challenges, the team has been developing a low-cost precision-relative navigation system and leveraging acoustic signal processing tools and new ocean-field estimation algorithms. The MIT campus collaborators are developing algorithms for data processing and image formation, especially to estimate depth-integrated water-column parameters. These enabling technologies will help account for complex ocean physics, spanning physical properties like temperature, dynamic processes like currents and waves, and acoustic propagation factors like sound speed.Processing for all required control and calculations could be completed either remotely or onboard the ASVs. For example, ASVs deployed from a ship or flying boat could be controlled and guided remotely from land via a satellite link or from a nearby support ship (with direct communications or a satellite link), and left to map the seabed for weeks or months at a time until maintenance is needed. Sonar-return health checks and coarse seabed mapping would be conducted on board, while full, high-resolution reconstruction of the seabed would require a supercomputing infrastructure on land or on a support ship.”Deploying vehicles in an area and letting them map for extended periods of time without the need for a ship to return home to replenish supplies and rotate crews would significantly simplify logistics and operating costs,” says co–principal investigator Paul Ryu, a researcher in the Advanced Undersea Systems and Technology Group.Since beginning their research in 2018, the team has turned their concept into a prototype. Initially, the scientists built a scale model of a sparse-aperture sonar array and tested it in a water tank at the laboratory’s Autonomous Systems Development Facility. Then, they prototyped an ASV-sized sonar subarray and demonstrated its functionality in Gloucester, Massachusetts. In follow-on sea tests in Boston Harbor, they deployed an 8-meter array containing multiple subarrays equivalent to 25 ASVs locked together; with this array, they generated 3D reconstructions of the seafloor and a shipwreck. Most recently, the team fabricated, in collaboration with Woods Hole Oceanographic Institution, a first-generation, 12-foot-long, all-electric ASV prototype carrying a sonar array underneath. With this prototype, they conducted preliminary relative navigation testing in Woods Hole, Massachusetts and Newport, Rhode Island. Their full deep-ocean concept calls for approximately 20 such ASVs of a similar size, likely powered by wave or solar energy.This work was funded through Lincoln Laboratory’s internally administered R&D portfolio on autonomous systems. The team is now seeking external sponsorship to continue development of their ocean floor–mapping technology, which was recognized with a 2024 R&D 100 Award.  More

    • 113 Shares99 Views

      in Security

      An inflatable gastric balloon could help people lose weight

      by

      Gastric balloons — silicone balloons filled with air or saline and placed in the stomach — can help people lose weight by making them feel too full to overeat. However, this effect eventually can wear off as the stomach becomes used to the sensation of fullness.To overcome that limitation, MIT engineers have designed a new type of gastric balloon that can be inflated and deflated as needed. In an animal study, they showed that inflating the balloon before a meal caused the animals to reduce their food intake by 60 percent.This type of intervention could offer an alternative for people who don’t want to undergo more invasive treatments such as gastric bypass surgery, or people who don’t respond well to weight-loss drugs, the researchers say.“The basic concept is we can have this balloon that is dynamic, so it would be inflated right before a meal and then you wouldn’t feel hungry. Then it would be deflated in between meals,” says Giovanni Traverso, an associate professor of mechanical engineering at MIT, a gastroenterologist at Brigham and Women’s Hospital, and the senior author of the study.Neil Zixun Jia, who received a PhD from MIT in 2023, is the lead author of the paper, which appears today in the journal Device.An inflatable balloonGastric balloons filled with saline are currently approved for use in the United States. These balloons stimulate a sense of fullness in the stomach, and studies have shown that they work well, but the benefits are often temporary.“Gastric balloons do work initially. Historically, what has been seen is that the balloon is associated with weight loss. But then in general, the weight gain resumes the same trajectory,” Traverso says. “What we reasoned was perhaps if we had a system that simulates that fullness in a transient way, meaning right before a meal, that could be a way of inducing weight loss.”To achieve a longer-lasting effect in patients, the researchers set out to design a device that could expand and contract on demand. They created two prototypes: One is a traditional balloon that inflates and deflates, and the other is a mechanical device with four arms that expand outward, pushing out an elastic polymer shell that presses on the stomach wall.In animal tests, the researchers found that the mechanical-arm device could effectively expand to fill the stomach, but they ended up deciding to pursue the balloon option instead.“Our sense was that the balloon probably distributed the force better, and down the line, if you have balloon that is applying the pressure, that is probably a safer approach in the long run,” Traverso says.The researchers’ new balloon is similar to a traditional gastric balloon, but it is inserted into the stomach through an incision in the abdominal wall. The balloon is connected to an external controller that can be attached to the skin and contains a pump that inflates and deflates the balloon when needed. Inserting this device would be similar to the procedure used to place a feeding tube into a patient’s stomach, which is commonly done for people who are unable to eat or drink.“If people, for example, are unable to swallow, they receive food through a tube like this. We know that we can keep tubes in for years, so there is already precedent for other systems that can stay in the body for a very long time. That gives us some confidence in the longer-term compatibility of this system,” Traverso says.Reduced food intakeIn tests in animals, the researchers found that inflating the balloon before meals led to a 60 percent reduction in the amount of food consumed. These studies were done over the course of a month, but the researchers now plan to do longer-term studies to see if this reduction leads to weight loss.“The deployment for traditional gastric balloons is usually six months, if not more, and only then you will see good amount of weight loss. We will have to evaluate our device in a similar or longer time span to prove it really works better,” Jia says.If developed for use in humans, the new gastric balloon could offer an alternative to existing obesity treatments. Other treatments for obesity include gastric bypass surgery, “stomach stapling” (a surgical procedure in which the stomach capacity is reduced), and drugs including GLP-1 receptor agonists such as semaglutide.The gastric balloon could be an option for patients who are not good candidates for surgery or don’t respond well to weight-loss drugs, Traverso says.“For certain patients who are higher-risk, who cannot undergo surgery, or did not tolerate the medication or had some other contraindication, there are limited options,” he says. “Traditional gastric balloons are still being used, but they come with a caveat that eventually the weight loss can plateau, so this is a way of trying to address that fundamental limitation.”The research was funded by MIT’s Department of Mechanical Engineering, the Karl van Tassel Career Development Professorship, the Whitaker Health Sciences Fund Fellowship, the T.S. Lin Fellowship, the MIT Undergraduate Research Opportunities Program, and the Boston University Yawkey Funded Internship Program.  More

    • 138 Shares149 Views

      in Security

      To design better water filters, MIT engineers look to manta rays

      by

      Filter feeders are everywhere in the animal world, from tiny crustaceans and certain types of coral and krill, to various molluscs, barnacles, and even massive basking sharks and baleen whales. Now, MIT engineers have found that one filter feeder has evolved to sift food in ways that could improve the design of industrial water filters.In a paper appearing this week in the Proceedings of the National Academy of Sciences, the team characterizes the filter-feeding mechanism of the mobula ray — a family of aquatic rays that includes two manta species and seven devil rays. Mobula rays feed by swimming open-mouthed through plankton-rich regions of the ocean and filtering plankton particles into their gullet as water streams into their mouths and out through their gills.The floor of the mobula ray’s mouth is lined on either side with parallel, comb-like structures, called plates, that siphon water into the ray’s gills. The MIT team has shown that the dimensions of these plates may allow for incoming plankton to bounce all the way across the plates and further into the ray’s cavity, rather than out through the gills. What’s more, the ray’s gills absorb oxygen from the outflowing water, helping the ray to simultaneously breathe while feeding.“We show that the mobula ray has evolved the geometry of these plates to be the perfect size to balance feeding and breathing,” says study author Anette “Peko” Hosoi, the Pappalardo Professor of Mechanical Engineering at MIT.The engineers fabricated a simple water filter modeled after the mobula ray’s plankton-filtering features. They studied how water flowed through the filter when it was fitted with 3D-printed plate-like structures. The team took the results of these experiments and drew up a blueprint, which they say designers can use to optimize industrial cross-flow filters, which are broadly similar in configuration to that of the mobula ray.“We want to expand the design space of traditional cross-flow filtration with new knowledge from the manta ray,” says lead author and MIT postdoc Xinyu Mao PhD ’24. “People can choose a parameter regime of the mobula ray so they could potentially improve overall filter performance.”Hosoi and Mao co-authored the new study with Irmgard Bischofberger, associate professor of mechanical engineering at MIT.A better trade-offThe new study grew out of the group’s focus on filtration during the height of the Covid pandemic, when the researchers were designing face masks to filter out the virus. Since then, Mao has shifted focus to study filtration in animals and how certain filter-feeding mechanisms might improve filters used in industry, such as in water treatment plants.Mao observed that any industrial filter must strike a balance between permeability (how easily fluid can flow through a filter), and selectivity (how successful a filter is at keeping out particles of a target size). For instance, a membrane that is studded with large holes might be highly permeable, meaning a lot of water can be pumped through using very little energy. However, the membrane’s large holes would let many particles through, making it very low in selectivity. Likewise, a membrane with much smaller pores would be more selective yet also require more energy to pump the water through the smaller openings.“We asked ourselves, how do we do better with this tradeoff between permeability and selectivity?” Hosoi says.As Mao looked into filter-feeding animals, he found that the mobula ray has struck an ideal balance between permeability and selectivity: The ray is highly permeable, in that it can let water into its mouth and out through its gills quickly enough to capture oxygen to breathe. At the same time, it is highly selective, filtering and feeding on plankton rather than letting the particles stream out through the gills.The researchers realized that the ray’s filtering features are broadly similar to that of industrial cross-flow filters. These filters are designed such that fluid flows across a permeable membrane that lets through most of the fluid, while any polluting particles continue flowing across the membrane and eventually out into a reservoir of waste.The team wondered whether the mobula ray might inspire design improvements to industrial cross-flow filters. For that, they took a deeper dive into the dynamics of mobula ray filtration.A vortex keyAs part of their new study, the team fabricated a simple filter inspired by the mobula ray. The filter’s design is what engineers refer to as a “leaky channel” — effectively, a pipe with holes along its sides. In this case, the team’s “channel” consists of two flat, transparent acrylic plates that are glued together at the edges, with a slight opening between the plates through which fluid can be pumped. At one end of the channel, the researchers inserted 3D-printed structures resembling the grooved plates that run along the floor of the mobula ray’s mouth.The team then pumped water through the channel at various rates, along with colored dye to visualize the flow. They took images across the channel and observed an interesting transition: At slow pumping rates, the flow was “very peaceful,” and fluid easily slipped through the grooves in the printed plates and out into a reservoir. When the researchers increased the pumping rate, the faster-flowing fluid did not slip through, but appeared to swirl at the mouth of each groove, creating a vortex, similar to a small knot of hair between the tips of a comb’s teeth.“This vortex is not blocking water, but it is blocking particles,” Hosoi explains. “Whereas in a slower flow, particles go through the filter with the water, at higher flow rates, particles try to get through the filter but are blocked by this vortex and are shot down the channel instead. The vortex is helpful because it prevents particles from flowing out.”The team surmised that vortices are the key to mobula rays’ filter-feeding ability. The ray is able to swim at just the right speed that water, streaming into its mouth, can form vortices between the grooved plates. These vortices effectively block any plankton particles — even those that are smaller than the space between plates. The particles then bounce across the plates and head further into the ray’s cavity, while the rest of the water can still flow between the plates and out through the gills.The researchers used the results of their experiments, along with dimensions of the filtering features of mobula rays, to develop a blueprint for cross-flow filtration.“We have provided practical guidance on how to actually filter as the mobula ray does,” Mao offers.“You want to design a filter such that you’re in the regime where you generate vortices,” Hosoi says. “Our guidelines tell you: If you want your plant to pump at a certain rate, then your filter has to have a particular pore diameter and spacing to generate vortices that will filter out particles of this size. The mobula ray is giving us a really nice rule of thumb for rational design.”This work was supported, in part, by the U.S. National Institutes of Health, and the Harvey P. Greenspan Fellowship Fund.  More

    • 113 Shares179 Views

      in Energy

      A nonflammable battery to power a safer, decarbonized future

      by

      Lithium-ion batteries are the workhorses of home electronics and are powering an electric revolution in transportation. But they are not suitable for every application.A key drawback is their flammability and toxicity, which make large-scale lithium-ion energy storage a bad fit in densely populated city centers and near metal processing or chemical manufacturing plants.Now Alsym Energy has developed a nonflammable, nontoxic alternative to lithium-ion batteries to help renewables like wind and solar bridge the gap in a broader range of sectors. The company’s electrodes use relatively stable, abundant materials, and its electrolyte is primarily water with some nontoxic add-ons.“Renewables are intermittent, so you need storage, and to really solve the decarbonization problem, we need to be able to make these batteries anywhere at low cost,” says Alsym co-founder and MIT Professor Kripa Varanasi.The company believes its batteries, which are currently being tested by potential customers around the world, hold enormous potential to decarbonize the high-emissions industrial manufacturing sector, and they see other applications ranging from mining to powering data centers, homes, and utilities.“We are enabling a decarbonization of markets that was not possible before,” Alsym co-founder and CEO Mukesh Chatter says. “No chemical or steel plant would dare put a lithium battery close to their premises because of the flammability, and industrial emissions are a much bigger problem than passenger cars. With this approach, we’re able to offer a new path.”Helping 1 billion peopleChatter started a telecommunications company with serial entrepreneurs and longtime members of the MIT community Ray Stata ’57, SM ’58 and Alec Dingee ’52 in 1997. Since the company was acquired in 1999, Chatter and his wife have started other ventures and invested in some startups, but after losing his mother to cancer in 2012, Chatter decided he wanted to maximize his impact by only working on technologies that could reach 1 billion people or more.The problem Chatter decided to focus on was electricity access.“The intent was to light up the homes of at least 1 billion people around the world who either did not have electricity, or only got it part of the time, condemning them basically to a life of poverty in the 19th century,” Chatter says. “When you don’t have access to electricity, you also don’t have the internet, cell phones, education, etc.”To solve the problem, Chatter decided to fund research into a new kind of battery. The battery had to be cheap enough to be adopted in low-resource settings, safe enough to be deployed in crowded areas, and work well enough to support two light bulbs, a fan, a refrigerator, and an internet modem.At first, Chatter was surprised how few takers he had to start the research, even from researchers at the top universities in the world.“It’s a burning problem, but the risk of failure was so high that nobody wanted to take the chance,” Chatter recalls.He finally found his partners in Varanasi, Rensselaer Polytechnic Institute Professor Nikhil Koratkar and Rensselaer researcher Rahul Mukherjee. Varanasi, who notes he’s been at MIT for 22 years, says the Institute’s culture gave him the confidence to tackle big problems.“My students, postdocs, and colleagues are inspirational to me,” he says. “The MIT ecosystem infuses us with this resolve to go after problems that look insurmountable.”Varanasi leads an interdisciplinary lab at MIT dedicated to understanding physicochemical and biological phenomena. His research has spurred the creation of materials, devices, products, and processes to tackle challenges in energy, agriculture, and other sectors, as well as startup companies to commercialize this work.“Working at the interfaces of matter has unlocked numerous new research pathways across various fields, and MIT has provided me the creative freedom to explore, discover, and learn, and apply that knowledge to solve critical challenges,” he says. “I was able to draw significantly from my learnings as we set out to develop the new battery technology.”Alsym’s founding team began by trying to design a battery from scratch based on new materials that could fit the parameters defined by Chatter. To make it nonflammable and nontoxic, the founders wanted to avoid lithium and cobalt.After evaluating many different chemistries, the founders settled on Alsym’s current approach, which was finalized in 2020.Although the full makeup of Alsym’s battery is still under wraps as the company waits to be granted patents, one of Alsym’s electrodes is made mostly of manganese oxide while the other is primarily made of a metal oxide. The electrolyte is primarily water.There are several advantages to Alsym’s new battery chemistry. Because the battery is inherently safer and more sustainable than lithium-ion, the company doesn’t need the same safety protections or cooling equipment, and it can pack its batteries close to each other without fear of fires or explosions. Varanasi also says the battery can be manufactured in any of today’s lithium-ion plants with minimal changes and at significantly lower operating cost.“We are very excited right now,” Chatter says. “We started out wanting to light up 1 billion people’s homes, and now in addition to the original goal we have a chance to impact the entire globe if we are successful at cutting back industrial emissions.”A new platform for energy storageAlthough the batteries don’t quite reach the energy density of lithium-ion batteries, Varanasi says Alsym is first among alternative chemistries at the system-level. He says 20-foot containers of Alsym’s batteries can provide 1.7 megawatt hours of electricity. The batteries can also fast-charge over four hours and can be configured to discharge over anywhere from two to 110 hours.“We’re highly configurable, and that’s important because depending on where you are, you can sometimes run on two cycles a day with solar, and in combination with wind, you could truly get 24/7 electricity,” Chatter says. “The need to do multiday or long duration storage is a small part of the market, but we support that too.”Alsym has been manufacturing prototypes at a small facility in Woburn, Massachusetts, for the last two years, and early this year it expanded its capacity and began to send samples to customers for field testing.In addition to large utilities, the company is working with municipalities, generator manufacturers, and providers of behind-the-meter power for residential and commercial buildings. The company is also in discussion with a large chemical manufacturers and metal processing plants to provide energy storage system to reduce their carbon footprint, something they say was not feasible with lithium-ion batteries, due to their flammability, or with nonlithium batteries, due to their large space requirements.Another critical area is data centers. With the growth of AI, the demand for data centers — and their energy consumption — is set to surge.“We must power the AI and digitization revolution without compromising our planet,” says Varanasi, adding that lithium batteries are unsuitable for co-location with data centers due to flammability risks. “Alsym batteries are well-positioned to offer a safer, more sustainable alternative. Intermittency is also a key issue for electrolyzers used in green hydrogen production and other markets.”Varanasi sees Alsym as a platform company, and Chatter says Alsym is already working on other battery chemistries that have higher densities and maintain performance at even more extreme temperatures.“When you use a single material in any battery, and the whole world starts to use it, you run out of that material,” Varanasi says. “What we have is a platform that has enabled us to not just to come up with just one chemistry, but at least three or four chemistries targeted at different applications so no one particular set of materials will be stressed in terms of supply.” More

    • 138 Shares169 Views

      in Energy

      Turning automotive engines into modular chemical plants to make green fuels

      by

      Reducing methane emissions is a top priority in the fight against climate change because of its propensity to trap heat in the atmosphere: Methane’s warming effects are 84 times more potent than CO2 over a 20-year timescale.And yet, as the main component of natural gas, methane is also a valuable fuel and a precursor to several important chemicals. The main barrier to using methane emissions to create carbon-negative materials is that human sources of methane gas — landfills, farms, and oil and gas wells — are relatively small and spread out across large areas, while traditional chemical processing facilities are huge and centralized. That makes it prohibitively expensive to capture, transport, and convert methane gas into anything useful. As a result, most companies burn or “flare” their methane at the site where it’s emitted, seeing it as a sunk cost and an environmental liability.The MIT spinout Emvolon is taking a new approach to processing methane by repurposing automotive engines to serve as modular, cost-effective chemical plants. The company’s systems can take methane gas and produce liquid fuels like methanol and ammonia on-site; these fuels can then be used or transported in standard truck containers.”We see this as a new way of chemical manufacturing,” Emvolon co-founder and CEO Emmanuel Kasseris SM ’07, PhD ’11 says. “We’re starting with methane because methane is an abundant emission that we can use as a resource. With methane, we can solve two problems at the same time: About 15 percent of global greenhouse gas emissions come from hard-to-abate sectors that need green fuel, like shipping, aviation, heavy heavy-duty trucks, and rail. Then another 15 percent of emissions come from distributed methane emissions like landfills and oil wells.”By using mass-produced engines and eliminating the need to invest in infrastructure like pipelines, the company says it’s making methane conversion economically attractive enough to be adopted at scale. The system can also take green hydrogen produced by intermittent renewables and turn it into ammonia, another fuel that can also be used to decarbonize fertilizers.“In the future, we’re going to need green fuels because you can’t electrify a large ship or plane — you have to use a high-energy-density, low-carbon-footprint, low-cost liquid fuel,” Kasseris says. “The energy resources to produce those green fuels are either distributed, as is the case with methane, or variable, like wind. So, you cannot have a massive plant [producing green fuels] that has its own zip code. You either have to be distributed or variable, and both of those approaches lend themselves to this modular design.”From a “crazy idea” to a companyKasseris first came to MIT to study mechanical engineering as a graduate student in 2004, when he worked in the Sloan Automotive Lab on a report on the future of transportation. For his PhD, he developed a novel technology for improving internal combustion engine fuel efficiency for a consortium of automotive and energy companies, which he then went to work for after graduation.Around 2014, he was approached by Leslie Bromberg ’73, PhD ’77, a serial inventor with more than 100 patents, who has been a principal research engineer in MIT’s Plasma Science and Fusion Center for nearly 50 years.“Leslie had this crazy idea of repurposing an internal combustion engine as a reactor,” Kasseris recalls. “I had looked at that while working in industry, and I liked it, but my company at the time thought the work needed more validation.”Bromberg had done that validation through a U.S. Department of Energy-funded project in which he used a diesel engine to “reform” methane — a high-pressure chemical reaction in which methane is combined with steam and oxygen to produce hydrogen. The work impressed Kasseris enough to bring him back to MIT as a research scientist in 2016.“We worked on that idea in addition to some other projects, and eventually it had reached the point where we decided to license the work from MIT and go full throttle,” Kasseris recalls. “It’s very easy to work with MIT’s Technology Licensing Office when you are an MIT inventor. You can get a low-cost licensing option, and you can do a lot with that, which is important for a new company. Then, once you are ready, you can finalize the license, so MIT was instrumental.”Emvolon continued working with MIT’s research community, sponsoring projects with Professor Emeritus John Heywood and participating in the MIT Venture Mentoring Service and the MIT Industrial Liaison Program.An engine-powered chemical plantAt the core of Emvolon’s system is an off-the-shelf automotive engine that runs “fuel rich” — with a higher ratio of fuel to air than what is needed for complete combustion.“That’s easy to say, but it takes a lot of [intellectual property], and that’s what was developed at MIT,” Kasseris says. “Instead of burning the methane in the gas to carbon dioxide and water, you partially burn it, or partially oxidize it, to carbon monoxide and hydrogen, which are the building blocks to synthesize a variety of chemicals.”The hydrogen and carbon monoxide are intermediate products used to synthesize different chemicals through further reactions. Those processing steps take place right next to the engine, which makes its own power. Each of Emvolon’s standalone systems fits within a 40-foot shipping container and can produce about 8 tons of methanol per day from 300,000 standard cubic feet of methane gas.The company is starting with green methanol because it’s an ideal fuel for hard-to-abate sectors such as shipping and heavy-duty transport, as well as an excellent feedstock for other high-value chemicals, such as sustainable aviation fuel. Many shipping vessels have already converted to run on green methanol in an effort to meet decarbonization goals.This summer, the company also received a grant from the Department of Energy to adapt its process to produce clean liquid fuels from power sources like solar and wind.“We’d like to expand to other chemicals like ammonia, but also other feedstocks, such as biomass and hydrogen from renewable electricity, and we already have promising results in that direction” Kasseris says. “We think we have a good solution for the energy transition and, in the later stages of the transition, for e-manufacturing.”A scalable approachEmvolon has already built a system capable of producing up to six barrels of green methanol a day in its 5,000 square-foot headquarters in Woburn, Massachusetts.“For chemical technologies, people talk about scale up risk, but with an engine, if it works in a single cylinder, we know it will work in a multicylinder engine,” Kasseris says. “It’s just engineering.”Last month, Emvolon announced an agreement with Montauk Renewables to build a commercial-scale demonstration unit next to a Texas landfill that will initially produce up to 15,000 gallons of green methanol a year and later scale up to 2.5 million gallons. That project could be expanded tenfold by scaling across Montauk’s other sites.“Our whole process was designed to be a very realistic approach to the energy transition,” Kasseris says. “Our solution is designed to produce green fuels and chemicals at prices that the markets are willing to pay today, without the need for subsidies. Using the engines as chemical plants, we can get the capital expenditure per unit output close to that of a large plant, but at a modular scale that enables us to be next to low-cost feedstock. Furthermore, our modular systems require small investments — of $1 to 10 million — that are quickly deployed, one at a time, within weeks, as opposed to massive chemical plants that require multiyear capital construction projects and cost hundreds of millions.” More

    • 125 Shares189 Views

      in Environment

      MIT engineers make converting CO2 into useful products more practical

      by

      As the world struggles to reduce greenhouse gas emissions, researchers are seeking practical, economical ways to capture carbon dioxide and convert it into useful products, such as transportation fuels, chemical feedstocks, or even building materials. But so far, such attempts have struggled to reach economic viability.New research by engineers at MIT could lead to rapid improvements in a variety of electrochemical systems that are under development to convert carbon dioxide into a valuable commodity. The team developed a new design for the electrodes used in these systems, which increases the efficiency of the conversion process.The findings are reported today in the journal Nature Communications, in a paper by MIT doctoral student Simon Rufer, professor of mechanical engineering Kripa Varanasi, and three others.“The CO2 problem is a big challenge for our times, and we are using all kinds of levers to solve and address this problem,” Varanasi says. It will be essential to find practical ways of removing the gas, he says, either from sources such as power plant emissions, or straight out of the air or the oceans. But then, once the CO2 has been removed, it has to go somewhere.A wide variety of systems have been developed for converting that captured gas into a useful chemical product, Varanasi says. “It’s not that we can’t do it — we can do it. But the question is how can we make this efficient? How can we make this cost-effective?”In the new study, the team focused on the electrochemical conversion of CO2 to ethylene, a widely used chemical that can be made into a variety of plastics as well as fuels, and which today is made from petroleum. But the approach they developed could also be applied to producing other high-value chemical products as well, including methane, methanol, carbon monoxide, and others, the researchers say.Currently, ethylene sells for about $1,000 per ton, so the goal is to be able to meet or beat that price. The electrochemical process that converts CO2 into ethylene involves a water-based solution and a catalyst material, which come into contact along with an electric current in a device called a gas diffusion electrode.There are two competing characteristics of the gas diffusion electrode materials that affect their performance: They must be good electrical conductors so that the current that drives the process doesn’t get wasted through resistance heating, but they must also be “hydrophobic,” or water repelling, so the water-based electrolyte solution doesn’t leak through and interfere with the reactions taking place at the electrode surface.Unfortunately, it’s a tradeoff. Improving the conductivity reduces the hydrophobicity, and vice versa. Varanasi and his team set out to see if they could find a way around that conflict, and after many months of trying, they did just that.The solution, devised by Rufer and Varanasi, is elegant in its simplicity. They used a plastic material, PTFE (essentially Teflon), that has been known to have good hydrophobic properties. However, PTFE’s lack of conductivity means that electrons must travel through a very thin catalyst layer, leading to significant voltage drop with distance. To overcome this limitation, the researchers wove a series of conductive copper wires through the very thin sheet of the PTFE.“This work really addressed this challenge, as we can now get both conductivity and hydrophobicity,” Varanasi says.Research on potential carbon conversion systems tends to be done on very small, lab-scale samples, typically less than 1-inch (2.5-centimeter) squares. To demonstrate the potential for scaling up, Varanasi’s team produced a sheet 10 times larger in area and demonstrated its effective performance.To get to that point, they had to do some basic tests that had apparently never been done before, running tests under identical conditions but using electrodes of different sizes to analyze the relationship between conductivity and electrode size. They found that conductivity dropped off dramatically with size, which would mean much more energy, and thus cost, would be needed to drive the reaction.“That’s exactly what we would expect, but it was something that nobody had really dedicatedly investigated before,” Rufer says. In addition, the larger sizes produced more unwanted chemical byproducts besides the intended ethylene.Real-world industrial applications would require electrodes that are perhaps 100 times larger than the lab versions, so adding the conductive wires will be necessary for making such systems practical, the researchers say. They also developed a model which captures the spatial variability in voltage and product distribution on electrodes due to ohmic losses. The model along with the experimental data they collected enabled them to calculate the optimal spacing for conductive wires to counteract the drop off in conductivity.In effect, by weaving the wire through the material, the material is divided into smaller subsections determined by the spacing of the wires. “We split it into a bunch of little subsegments, each of which is effectively a smaller electrode,” Rufer says. “And as we’ve seen, small electrodes can work really well.”Because the copper wire is so much more conductive than the PTFE material, it acts as a kind of superhighway for electrons passing through, bridging the areas where they are confined to the substrate and face greater resistance.To demonstrate that their system is robust, the researchers ran a test electrode for 75 hours continuously, with little change in performance. Overall, Rufer says, their system “is the first PTFE-based electrode which has gone beyond the lab scale on the order of 5 centimeters or smaller. It’s the first work that has progressed into a much larger scale and has done so without sacrificing efficiency.”The weaving process for incorporating the wire can be easily integrated into existing manufacturing processes, even in a large-scale roll-to-roll process, he adds.“Our approach is very powerful because it doesn’t have anything to do with the actual catalyst being used,” Rufer says. “You can sew this micrometric copper wire into any gas diffusion electrode you want, independent of catalyst morphology or chemistry. So, this approach can be used to scale anybody’s electrode.”“Given that we will need to process gigatons of CO2 annually to combat the CO2 challenge, we really need to think about solutions that can scale,” Varanasi says. “Starting with this mindset enables us to identify critical bottlenecks and develop innovative approaches that can make a meaningful impact in solving the problem. Our hierarchically conductive electrode is a result of such thinking.”The research team included MIT graduate students Michael Nitzsche and Sanjay Garimella,  as well as Jack Lake PhD ’23. The work was supported by Shell, through the MIT Energy Initiative. More

    • 113 Shares129 Views

      in Environment

      Tackling the energy revolution, one sector at a time

      by

      As a major contributor to global carbon dioxide (CO2) emissions, the transportation sector has immense potential to advance decarbonization. However, a zero-emissions global supply chain requires re-imagining reliance on a heavy-duty trucking industry that emits 810,000 tons of CO2, or 6 percent of the United States’ greenhouse gas emissions, and consumes 29 billion gallons of diesel annually in the U.S. alone.A new study by MIT researchers, presented at the recent American Society of Mechanical Engineers 2024 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference, quantifies the impact of a zero-emission truck’s design range on its energy storage requirements and operational revenue. The multivariable model outlined in the paper allows fleet owners and operators to better understand the design choices that impact the economic feasibility of battery-electric and hydrogen fuel cell heavy-duty trucks for commercial application, equipping stakeholders to make informed fleet transition decisions.“The whole issue [of decarbonizing trucking] is like a very big, messy pie. One of the things we can do, from an academic standpoint, is quantify some of those pieces of pie with modeling, based on information and experience we’ve learned from industry stakeholders,” says ZhiYi Liang, PhD student on the renewable hydrogen team at the MIT K. Lisa Yang Global Engineering and Research Center (GEAR) and lead author of the study. Co-authored by Bryony Dupont, visiting scholar at GEAR, and Amos Winter, the Germeshausen Professor in the MIT Department of Mechanical Engineering, the paper elucidates operational and socioeconomic factors that need to be considered in efforts to decarbonize heavy-duty vehicles (HDVs).Operational and infrastructure challengesThe team’s model shows that a technical challenge lies in the amount of energy that needs to be stored on the truck to meet the range and towing performance needs of commercial trucking applications. Due to the high energy density and low cost of diesel, existing diesel drivetrains remain more competitive than alternative lithium battery-electric vehicle (Li-BEV) and hydrogen fuel-cell-electric vehicle (H2 FCEV) drivetrains. Although Li-BEV drivetrains have the highest energy efficiency of all three, they are limited to short-to-medium range routes (under 500 miles) with low freight capacity, due to the weight and volume of the onboard energy storage needed. In addition, the authors note that existing electric grid infrastructure will need significant upgrades to support large-scale deployment of Li-BEV HDVs.While the hydrogen-powered drivetrain has a significant weight advantage that enables higher cargo capacity and routes over 750 miles, the current state of hydrogen fuel networks limits economic viability, especially once operational cost and projected revenue are taken into account. Deployment will most likely require government intervention in the form of incentives and subsidies to reduce the price of hydrogen by more than half, as well as continued investment by corporations to ensure a stable supply. Also, as H2-FCEVs are still a relatively new technology, the ongoing design of conformal onboard hydrogen storage systems — one of which is the subject of Liang’s PhD — is crucial to successful adoption into the HDV market.The current efficiency of diesel systems is a result of technological developments and manufacturing processes established over many decades, a precedent that suggests similar strides can be made with alternative drivetrains. However, interactions with fleet owners, automotive manufacturers, and refueling network providers reveal another major hurdle in the way that each “slice of the pie” is interrelated — issues must be addressed simultaneously because of how they affect each other, from renewable fuel infrastructure to technological readiness and capital cost of new fleets, among other considerations. And first steps into an uncertain future, where no one sector is fully in control of potential outcomes, is inherently risky. “Besides infrastructure limitations, we only have prototypes [of alternative HDVs] for fleet operator use, so the cost of procuring them is high, which means there isn’t demand for automakers to build manufacturing lines up to a scale that would make them economical to produce,” says Liang, describing just one step of a vicious cycle that is difficult to disrupt, especially for industry stakeholders trying to be competitive in a free market. Quantifying a path to feasibility“Folks in the industry know that some kind of energy transition needs to happen, but they may not necessarily know for certain what the most viable path forward is,” says Liang. Although there is no singular avenue to zero emissions, the new model provides a way to further quantify and assess at least one slice of pie to aid decision-making.Other MIT-led efforts aimed at helping industry stakeholders navigate decarbonization include an interactive mapping tool developed by Danika MacDonell, Impact Fellow at the MIT Climate and Sustainability Consortium (MCSC); alongside Florian Allroggen, executive director of MITs Zero Impact Aviation Alliance; and undergraduate researchers Micah Borrero, Helena De Figueiredo Valente, and Brooke Bao. The MCSC’s Geospatial Decision Support Tool supports strategic decision-making for fleet operators by allowing them to visualize regional freight flow densities, costs, emissions, planned and available infrastructure, and relevant regulations and incentives by region.While current limitations reveal the need for joint problem-solving across sectors, the authors believe that stakeholders are motivated and ready to tackle climate problems together. Once-competing businesses already appear to be embracing a culture shift toward collaboration, with the recent agreement between General Motors and Hyundai to explore “future collaboration across key strategic areas,” including clean energy. Liang believes that transitioning the transportation sector to zero emissions is just one part of an “energy revolution” that will require all sectors to work together, because “everything is connected. In order for the whole thing to make sense, we need to consider ourselves part of that pie, and the entire system needs to change,” says Liang. “You can’t make a revolution succeed by yourself.” The authors acknowledge the MIT Climate and Sustainability Consortium for connecting them with industry members in the HDV ecosystem; and the MIT K. Lisa Yang Global Engineering and Research Center and MIT Morningside Academy for Design for financial support. More