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    Pioneering the future of materials extraction

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    The next time you cook pasta, imagine that you are cooking spaghetti, rigatoni, and seven other varieties all together, and they need to be separated onto 10 different plates before serving. A colander can remove the water — but you still have a mound of unsorted noodles. Now imagine that this had to be done for thousands of tons of pasta a day. That gives you an idea of the scale of the problem facing Brendan Smith PhD ’18, co-founder and CEO of SiTration, a startup formed out of MIT’s Department of Materials Science and Engineering (DMSE) in 2020. SiTration, which raised $11.8 million in seed capital led by venture capital firm 2150 earlier this month, is revolutionizing the extraction and refining of copper, cobalt, nickel, lithium, precious metals, and other materials critical to manufacturing clean-energy technologies such as electric motors, wind turbines, and batteries. Its initial target applications are recovering the materials from complex mining feed streams, spent lithium-ion batteries from electric vehicles, and various metals refining processes. The company’s breakthrough lies in a new silicon membrane technology that can be adjusted to efficiently recover disparate materials, providing a more sustainable and economically viable alternative to conventional, chemically intensive processes. Think of a colander with adjustable pores to strain different types of pasta. SiTration’s technology has garnered interest from industry players, including mining giant Rio Tinto. Some observers may question whether targeting such different industries could cause the company to lose focus. “But when you dig into these markets, you discover there is actually a significant overlap in how all of these materials are recovered, making it possible for a single solution to have impact across verticals,” Smith says.Powering up materials recoveryConventional methods of extracting critical materials in mining, refining, and recycling lithium-ion batteries involve heavy use of chemicals and heat, which harm the environment. Typically, raw ore from mines or spent batteries are ground into fine particles before being dissolved in acid or incinerated in a furnace. Afterward, they undergo intensive chemical processing to separate and purify the valuable materials. “It requires as much as 10 tons of chemical input to produce one ton of critical material recovered from the mining or battery recycling feedstock,” says Smith. Operators can then sell the recaptured materials back into the supply chain, but suffer from wide swings in profitability due to uncertain market prices. Lithium prices have been the most volatile, having surged more than 400 percent before tumbling back to near-original levels in the past two years. Despite their poor economics and negative environmental impact, these processes remain the state of the art today. By contrast, SiTration is electrifying the critical-materials recovery process, improving efficiency, producing less chemical waste, and reducing the use of chemicals and heat. What’s more, the company’s processing technology is built to be highly adaptable, so it can handle all kinds of materials. The core technology is based on work done at MIT to develop a novel type of membrane made from silicon, which is durable enough to withstand harsh chemicals and high temperatures while conducting electricity. It’s also highly tunable, meaning it can be modified or adjusted to suit different conditions or target specific materials. SiTration’s technology also incorporates electro-extraction, a technique that uses electrochemistry to further isolate and extract specific target materials. This powerful combination of methods in a single system makes it more efficient and effective at isolating and recovering valuable materials, Smith says. So depending on what needs to be separated or extracted, the filtration and electro-extraction processes are adjusted accordingly. “We can produce membranes with pore sizes from the molecular scale up to the size of a human hair in diameter, and everything in between. Combined with the ability to electrify the membrane and separate based on a material’s electrochemical properties, this tunability allows us to target a vast array of different operations and separation applications across industrial fields,” says Smith. Efficient access to materials like lithium, cobalt, and copper — and precious metals like platinum, gold, silver, palladium, and rare-earth elements — is key to unlocking innovation in business and sustainability as the world moves toward electrification and away from fossil fuels.“This is an era when new materials are critical,” says Professor Jeffrey Grossman, co-founder and chief scientist of SiTration and the Morton and Claire Goulder and Family Professor in Environmental Systems at DMSE. “For so many technologies, they’re both the bottleneck and the opportunity, offering tremendous potential for non-incremental advances. And the role they’re having in commercialization and in entrepreneurship cannot be overstated.”SiTration’s commercial frontierSmith became interested in separation technology in 2013 as a PhD student in Grossman’s DMSE research group, which has focused on the design of new membrane materials for a range of applications. The two shared a curiosity about separation of critical materials and a hunger to advance the technology. After years of study under Grossman’s mentorship, and with support from several MIT incubators and foundations including the Abdul Latif Jameel Water and Food Systems Lab’s Solutions Program, the Deshpande Center for Technological Innovation, the Kavanaugh Fellowship, MIT Sandbox, and Venture Mentoring Service, Smith was ready to officially form SiTration in 2020. Grossman has a seat on the board and plays an active role as a strategic and technical advisor. Grossman is involved in several MIT spinoffs and embraces the different imperatives of research versus commercialization. “At SiTration, we’re driving this technology to work at scale. There’s something super exciting about that goal,” he says. “The challenges that come with scaling are very different than the challenges that come in a university lab.” At the same time, although not every research breakthrough becomes a commercial product, open-ended, curiosity-driven knowledge pursuit holds its own crucial value, he adds.It has been rewarding for Grossman to see his technically gifted student and colleague develop a host of other skills the role of CEO demands. Getting out to the market and talking about the technology with potential partners, putting together a dynamic team, discovering the challenges facing industry, drumming up support, early on — those became the most pressing activities on Smith’s agenda. “What’s most fun to me about being a CEO of an early-stage startup is that there are 100 different factors, most people-oriented, that you have to navigate every day. Each stakeholder has different motivations and objectives. And you basically try to fit that all together, to create value for our partners and customers, the company, and for society,” says Smith. “You start with just an idea, and you have to keep leveraging that to form a more and more tangible product, to multiply and progress commercial relationships, and do it all at an ever-expanding scale.” MIT DNA runs deep in the nine-person company, with DMSE grad and former Grossman student Jatin Patil as director of product; Ahmed Helal, from MIT’s Department of Mechanical Engineering, as vice president of research and development; Daniel Bregante, from the Department of Chemistry, as VP of technology; and Sarah Melvin, from the departments of Physics and Political Science, as VP of strategy and operations. Melvin is the first hire devoted to business development. Smith plans to continue expanding the team following the closing of the company’s seed round.  Strategic alliancesBeing a good communicator was important when it came to securing funding, Smith says. SiTration received $2.35 million in pre-seed funding in 2022 led by Azolla Ventures, which reserves its $239 million in investment capital for startups that would not otherwise easily obtain funding. “We invest only in solution areas that can achieve gigaton-scale climate impact by 2050,” says Matthew Nordan, a general partner at Azolla and now SiTration board member. The MIT-affiliated E14 Fund also contributed to the pre-seed round; Azolla and E14 both participated in the recent seed funding round. “Brendan demonstrated an extraordinary ability to go from being a thoughtful scientist to a business leader and thinker who has punched way above his weight in engaging with customers and recruiting a well-balanced team and navigating tricky markets,” says Nordan. One of SiTration’s first partnerships is with Rio Tinto, one of the largest mining companies in the world. As SiTration evaluated various uses cases in its early days, identifying critical materials as its target market, Rio Tinto was looking for partners to recover valuable metals such as cobalt and copper from the wastewater generated at mines. These metals were typically trapped in the water, creating harmful waste and resulting in lost revenue. “We thought this was a great innovation challenge and posted it on our website to scout for companies to partner with who can help us solve this water challenge,” said Nick Gurieff, principal advisor for mine closure, in an interview with MIT’s Industrial Liaison Program in 2023. At SiTration, mining was not yet a market focus, but Smith couldn’t help noticing that Rio Tinto’s needs were in alignment with what his young company offered. SiTration submitted its proposal in August 2022. Gurieff said SiTration’s tunable membrane set it apart. The companies formed a business partnership in June 2023, with SiTration adjusting its membrane to handle mine wastewater and incorporating Rio Tinto feedback to refine the technology. After running tests with water from mine sites, SiTration will begin building a small-scale critical-materials recovery unit, followed by larger-scale systems processing up to 100 cubic meters of water an hour.SiTration’s focused technology development with Rio Tinto puts it in a good position for future market growth, Smith says. “Every ounce of effort and resource we put into developing our product is geared towards creating real-world value. Having an industry-leading partner constantly validating our progress is a tremendous advantage.”It’s a long time from the days when Smith began tinkering with tiny holes in silicon in Grossman’s DMSE lab. Now, they work together as business partners who are scaling up technology to meet a global need. Their joint passion for applying materials innovation to tough problems has served them well. “Materials science and engineering is an engine for a lot of the innovation that is happening today,” Grossman says. “When you look at all of the challenges we face to make the transition to a more sustainable planet, you realize how many of these are materials challenges.” More

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      Building communities, founding a startup with people in mind

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

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

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

      The MIT community

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

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

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

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

      Membrane technology

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

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

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

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

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

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

      FAIL!

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

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

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

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

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      Cleaning up industrial filtration

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

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

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

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

      Play video

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

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

      MITEI Seed Grant

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

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

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

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

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

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

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

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

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

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

      Scaling up

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

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

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

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

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

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

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