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    Cleaning up critical minerals and materials production, using microwave plasma

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    The push to bring manufacturing back to the U.S. is running up against an unfortunate truth: The processes for making many critical materials today create toxic byproducts and other environmental hazards. That’s true for commonly used industrial metals like nickel and titanium, as well as specialty minerals, materials, and coatings that go into batteries, advanced electronics, and defense applications.Now 6K, founded by former MIT research scientist Kamal Hadidi, is using a new production process to bring critical materials production back to America without the toxic byproducts.The company is actively scaling its microwave plasma technology, which it calls UniMelt, to transform the way critical minerals are processed, creating new domestic supply chains in the process. UniMelt uses beams of tightly controlled thermal plasma to melt or vaporize precursor materials into particles with precise sizes and crystalline phases.The technology converts metals, such as titanium, nickel, and refractory alloys, into particles optimized for additive manufacturing for a range of industrial applications. It is also being used to create battery materials for electric vehicles, grid infrastructure, and data centers.“The markets and critical materials we are focused on are important for not just economic reasons but also U.S. national security, because the bulk of these materials are manufactured today in nonfriendly countries,” 6K CEO Saurabh Ullal says. “Now, the [U.S. government] and our growing customer base can leverage this technology invented at MIT to make the U.S. less dependent on these nonfriendly countries, ensuring supply chain independence now and in the future.”Named after the 6,000-degree temperature of its plasma, 6K is currently selling its high-performance metal powders to parts manufacturers as well as defense, automotive, medical, and oil and gas companies for use in applications from engine components and medical implants to rockets. To scale its battery materials business, 6K is also building a 100,000-square-foot production facility in Jackson, Tennessee, which will begin construction later this year.A weekend projectBetween 1994 and 2007, Hadidi worked at the Plasma Science and Fusion Center (PFSC), where he developed plasma technologies for a range of applications, including hydrogen production, fuel reforming, and detecting environmental toxins. His first company was founded in 2000 out of the PFSC to detect mercury in coal-fired power plants’ smokestacks.“I loved working at MIT,” Hadidi says. “It’s an amazing place that really challenges you. Just being there is so stimulating because everyone’s trying to come up with new solutions and connect dots between different fields.”Hadidi also began using high-frequency microwave plasmas to create nanomaterials for use in optical applications. He wasn’t a materials expert, so he collaborated with Professor Eric Jordan, a materials synthesis expert from the University of Connecticut, and the researchers started working on nights and weekends in the PSFC to develop the idea further, eventually patenting the technology.Hadidi officially founded the company as Amastan in 2007, exploring the use of his microwave plasma technology, later named UniMelt for “uniform melt state process,” to make a host of different materials as part of a government grant he and Jordan received.The researchers soon realized the microwave plasma technology had several advantages over traditional production techniques for certain materials. For one, it could eliminate several high-energy steps of conventional processes, reducing production times from days to hours in some cases. For batteries and certain critical minerals, the process also works with recycled feedstocks. Amastan was renamed 6K in 2019.Early on, Hadidi produced metal powders used in additive manufacturing through a process called spheroidization, which results in dense, spherical powders that flow well and make high-performance 3D-printed parts.Following another grant, Hadidi explored methods for producing a type of battery cathode made from lithium, nickel, manganese, and cobalt (NMC). The standard process for making NMCs involved chemical synthesis, precipitation, heat treatment, and a lot of water. 6K is able to reduce many of those steps, speeding up production and lowering costs while also being more sustainable.“Our technology completely eliminates toxic waste and recycles all of the byproducts back through the process to utilize everything, including water,” Ullal says.Scaling domestic productionToday, 6K’s additive manufacturing arm operates out of a factory in Pennsylvania. The company’s critical minerals processing, refining, and recycling systems can produce about 400 tons of material per year and can be used to make more than a dozen types of metal powders. The company also has 33,000-square-foot battery center in North Andover, Massachusetts, where it produces battery cathode materials for its energy storage and mobility customers.The Tennessee facility will be used to produce battery cathode materials and represents a massive step up in throughput. The company says it will be able to produce 13,000 tons of material annually when construction is complete next year.“I’m happy if what I started brings something positive to society, and I’m extremely thankful to all the people that helped me,” says Hadidi, who left the company in 2019. “I’m an entrepreneur at heart. I like to make things. But that doesn’t mean I always succeed. It’s personally very satisfying to see this make an impact.”The 6K team says its technology can also create a variety of specialty ceramics, advanced coatings, and nanoengineered materials. They say it may also be used to eliminate PFAS, or “forever chemicals,” though that work is at an early stage.The company recently received a grant to demonstrate a process for recycling critical materials from military depots to produce aerospace and defense products, creating a new value stream for these materials that would otherwise deteriorate or go to landfill. That work is consistent with the company’s motto, “We take nothing from the ground and put nothing into the ground.”The company’s additive division recently received a $23.4 Defense Production Act grant “that will enable us to double processing capacity in the next three years,” Ullal says. “The next step is to scale battery materials production to the tens of thousands of tons per year. At this point, it’s a scale-up of known processes, and we just need to execute. The idea of creating a circular economy is near and dear to us because that’s how we’ve built this company and that’s how we generate value: addressing our U.S. national security concerns and protecting the planet as well.” More

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      in Environment

      Startup turns mining waste into critical metals for the U.S.

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      At the heart of the energy transition is a metal transition. Wind farms, solar panels, and electric cars require many times more copper, zinc, and nickel than their gas-powered alternatives. They also require more exotic metals with unique properties, known as rare earth elements, which are essential for the magnets that go into things like wind turbines and EV motors.Today, China dominates the processing of rare earth elements, refining around 60 percent of those materials for the world. With demand for such materials forecasted to skyrocket, the Biden administration has said the situation poses national and economic security threats.Substantial quantities of rare earth metals are sitting unused in the United States and many other parts of the world today. The catch is they’re mixed with vast quantities of toxic mining waste.Phoenix Tailings is scaling up a process for harvesting materials, including rare earth metals and nickel, from mining waste. The company uses water and recyclable solvents to collect oxidized metal, then puts the metal into a heated molten salt mixture and applies electricity.The company, co-founded by MIT alumni, says its pilot production facility in Woburn, Massachusetts, is the only site in the world producing rare earth metals without toxic byproducts or carbon emissions. The process does use electricity, but Phoenix Tailings currently offsets that with renewable energy contracts.The company expects to produce more than 3,000 tons of the metals by 2026, which would have represented about 7 percent of total U.S. production last year.Now, with support from the Department of Energy, Phoenix Tailings is expanding the list of metals it can produce and accelerating plans to build a second production facility.For the founding team, including MIT graduates Tomás Villalón ’14 and Michelle Chao ’14 along with Nick Myers and Anthony Balladon, the work has implications for geopolitics and the planet.“Being able to make your own materials domestically means that you’re not at the behest of a foreign monopoly,” Villalón says. “We’re focused on creating critical materials for the next generation of technologies. More broadly, we want to get these materials in ways that are sustainable in the long term.”Tackling a global problemVillalón got interested in chemistry and materials science after taking Course 3.091 (Introduction to Solid-State Chemistry) during his first year at MIT. In his senior year, he got a chance to work at Boston Metal, another MIT spinoff that uses an electrochemical process to decarbonize steelmaking at scale. The experience got Villalón, who majored in materials science and engineering, thinking about creating more sustainable metallurgical processes.But it took a chance meeting with Myers at a 2018 Bible study for Villalón to act on the idea.“We were discussing some of the major problems in the world when we came to the topic of electrification,” Villalón recalls. “It became a discussion about how the U.S. gets its materials and how we should think about electrifying their production. I was finally like, ‘I’ve been working in the space for a decade, let’s go do something about it.’ Nick agreed, but I thought he just wanted to feel good about himself. Then in July, he randomly called me and said, ‘I’ve got [$7,000]. When do we start?’”Villalón brought in Chao, his former MIT classmate and fellow materials science and engineering major, and Myers brought Balladon, a former co-worker, and the founders started experimenting with new processes for producing rare earth metals.“We went back to the base principles, the thermodynamics I learned with MIT professors Antoine Allanore and Donald Sadoway, and understanding the kinetics of reactions,” Villalón says. “Classes like Course 3.022 (Microstructural Evolution in Materials) and 3.07 (Introduction to Ceramics) were also really useful. I touched on every aspect I studied at MIT.”The founders also received guidance from MIT’s Venture Mentoring Service (VMS) and went through the U.S. National Science Foundation’s I-Corps program. Sadoway served as an advisor for the company.After drafting one version of their system design, the founders bought an experimental quantity of mining waste, known as red sludge, and set up a prototype reactor in Villalón’s backyard. The founders ended up with a small amount of product, but they had to scramble to borrow the scientific equipment needed to determine what exactly it was. It turned out to be a small amount of rare earth concentrate along with pure iron.Today, at the company’s refinery in Woburn, Phoenix Tailings puts mining waste rich in rare earth metals into its mixture and heats it to around 1,300 degrees Fahrenheit. When it applies an electric current to the mixture, pure metal collects on an electrode. The process leaves minimal waste behind.“The key for all of this isn’t just the chemistry, but how everything is linked together, because with rare earths, you have to hit really high purities compared to a conventionally produced metal,” Villalón explains. “As a result, you have to be thinking about the purity of your material the entire way through.”From rare earths to nickel, magnesium, and moreVillalón says the process is economical compared to conventional production methods, produces no toxic byproducts, and is completely carbon free when renewable energy sources are used for electricity.The Woburn facility is currently producing several rare earth elements for customers, including neodymium and dysprosium, which are important in magnets. Customers are using the materials for things likewind turbines, electric cars, and defense applications.The company has also received two grants with the U.S. Department of Energy’s ARPA-E program totaling more than $2 million. Its 2023 grant supports the development of a system to extract nickel and magnesium from mining waste through a process that uses carbonization and recycled carbon dioxide. Both nickel and magnesium are critical materials for clean energy applications like batteries.The most recent grant will help the company adapt its process to produce iron from mining waste without emissions or toxic byproducts. Phoenix Tailings says its process is compatible with a wide array of ore types and waste materials, and the company has plenty of material to work with: Mining and processing mineral ores generates about 1.8 billion tons of waste in the U.S. each year.“We want to take our knowledge from processing the rare earth metals and slowly move it into other segments,” Villalón explains. “We simply have to refine some of these materials here. There’s no way we can’t. So, what does that look like from a regulatory perspective? How do we create approaches that are economical and environmentally compliant not just now, but 30 years from now?” More

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      in Environment

      China-based emissions of three potent climate-warming greenhouse gases spiked in past decade

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      When it comes to heating up the planet, not all greenhouse gases are created equal. They vary widely in their global warming potential (GWP), a measure of how much infrared thermal radiation a greenhouse gas would absorb over a given time frame once it enters the atmosphere. For example, measured over a 100-year period, the GWP of methane is about 28 times that of carbon dioxide (CO2), and the GWPs of a class of greenhouse gases known as perfluorocarbons (PFCs) are thousands of times that of CO2. The lifespans in the atmosphere of different greenhouse gases also vary widely. Methane persists in the atmosphere for around 10 years; CO2 for over 100 years, and PFCs for up to tens of thousands of years.Given the high GWPs and lifespans of PFCs, their emissions could pose a major roadblock to achieving the aspirational goal of the Paris Agreement on climate change — to limit the increase in global average surface temperature to 1.5 degrees Celsius above preindustrial levels. Now, two new studies based on atmospheric observations inside China and high-resolution atmospheric models show a rapid rise in Chinese emissions over the last decade (2011 to 2020 or 2021) of three PFCs: tetrafluoromethane (PFC-14) and hexafluoroethane (PFC-116) (results in PNAS), and perfluorocyclobutane (PFC-318) (results in Environmental Science & Technology).Both studies find that Chinese emissions have played a dominant role in driving up global emission levels for all three PFCs.The PNAS study identifies substantial PFC-14 and PFC-116 emission sources in the less-populated western regions of China from 2011 to 2021, likely due to the large amount of aluminum industry in these regions. The semiconductor industry also contributes to some of the emissions detected in the more economically developed eastern regions. These emissions are byproducts from aluminum smelting, or occur during the use of the two PFCs in the production of semiconductors and flat panel displays. During the observation period, emissions of both gases in China rose by 78 percent, accounting for most of the increase in global emissions of these gases.The ES&T study finds that during 2011-20, a 70 percent increase in Chinese PFC-318 emissions (contributing more than half of the global emissions increase of this gas) — originated primarily in eastern China. The regions with high emissions of PFC-318 in China overlap with geographical areas densely populated with factories that produce polytetrafluoroethylene (PTFE, commonly used for nonstick cookware coatings), implying that PTFE factories are major sources of PFC-318 emissions in China. In these factories, PFC-318 is formed as a byproduct.“Using atmospheric observations from multiple monitoring sites, we not only determined the magnitudes of PFC emissions, but also pinpointed the possible locations of their sources,” says Minde An, a postdoc at the MIT Center for Global Change Science (CGCS), and corresponding author of both studies. “Identifying the actual source industries contributing to these PFC emissions, and understanding the reasons for these largely byproduct emissions, can provide guidance for developing region- or industry-specific mitigation strategies.”“These three PFCs are largely produced as unwanted byproducts during the manufacture of otherwise widely used industrial products,” says MIT professor of atmospheric sciences Ronald Prinn, director of both the MIT Joint Program on the Science and Policy of Global Change and CGCS, and a co-author of both studies. “Phasing out emissions of PFCs as early as possible is highly beneficial for achieving global climate mitigation targets and is likely achievable by recycling programs and targeted technological improvements in these industries.”Findings in both studies were obtained, in part, from atmospheric observations collected from nine stations within a Chinese network, including one station from the Advanced Global Atmospheric Gases Experiment (AGAGE) network. For comparison, global total emissions were determined from five globally distributed, relatively unpolluted “background” AGAGE stations, as reported in the latest United Nations Environment Program and World Meteorological Organization Ozone Assessment report. More

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      in Energy

      Embracing life’s surprises

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      Experiments often yield unexpected results. In research and in life, MIT Associate Professor Cem Tasan has learned to embrace that uncertainty.

      “Very often we start with an idea or a hypothesis, and to test that idea we design experiments, and when we run the experiments, we see something totally different,” says Tasan, the newly tenured Thomas B. King Associate Professor of Metallurgy.

      Tasan has used those surprises to explore the boundaries of metallurgy and solid mechanics, gleaning new insights into how metals break and deform, and designing new kinds of damage-resistant alloys.

      “As they say, science is like taking a walk in the hills,” Tasan says. “You see the mountain far away, and that’s where you want to go, but as you head toward it, you see a beautiful flower on a different pathway, so you check that out. That happens so often to [my group]. It’s exciting.”

      Tasan has extended that approach to his career, leading him to take a faculty position at MIT despite not seeing the campus until his first job interview.

      “Being at MIT, or even in the USA, was never on my radar,” Tasan says. “It just wasn’t part of a plan.”

      That mindset has also helped him mentor students, whom he’s learned never to judge based on initial impressions.

      “I had a really bright student reach out and say ‘Everything is great, we have funding, we are productive, but I’m not sure I like what I’m doing,’” Tasan recalls. “We talked and identified another direction closer to the student’s interests, but that would mean we might not have secure funding or the necessary know-how, so there were all these disadvantages.

      “But we went down that road and it was amazing, because now this student was doing the research they really liked, and that successful student became an amazing student. Mentoring is complicated because on the outside things can seem fine, but the key idea is to pay attention to small details and keep communicating with these young people, who are on their own journeys. There’s no easy way other than communicating and observing.”

      A winding path

      Tasan grew up in Turkey and studied metallurgical and materials engineering at the country’s top college in the field, the Middle East Technical University.

      “What intrigued me about metallurgy is that it’s an engineering field, but it’s also strongly related with basic sciences,” Tasan says. “That connection exists in other engineering fields as well, but not as strongly. In materials science, it’s fair to say one leg is almost always in the fundamental side of things.”

      Tasan also travelled a lot as a young adult, backpacking with friends across Europe on a shoestring budget.

      “Early on, my personal goal in life was to move to Spain and eat tapas all the time and have fun,” Tasan jokes.

      During one such trip, Tasan packed a suit in the bottom of his backpack just in case he landed an interview with a graduate program. The preparation paid off in the Netherlands, where he met with members of the mechanical engineering department at the Eindhoven University of Technology. Tasan would go on to earn his PhD at the school, studying how damage and cracking takes place in metals.

      After earning his PhD in 2010, Tasan joined the Max Planck Institute for Iron Research in Germany, where he eventually led a research group that continued studying metal behavior and worked on creating new metal alloys that were more damage-resistant and had other unique properties.

      By 2015, Tasan was settled into a comfortable life in Germany. Then a position at MIT opened up.

      “At MIT, I could suddenly do much more on these topics that excited me, so my research could create a bigger impact,” Tasan says.

      After traveling to MIT for interviews, the talent and atmosphere also convinced Tasan to make the move.

      “I think it’s important to be surrounded by people who are very ambitious and who want to have a big impact,” Tasan says. “You walk in the Infinite Corridor, or any other MIT corridor, and every board you pass has stuff about people changing the world in a different way. Being in that environment inspires you.”

      Once in Cambridge, Tasan immediately loved what he describes as its “small-town feel,” comparing it to some European towns. He’s also embraced the Boston culture, becoming a fan of baseball and the Red Sox.

      Since arriving at MIT, Tasan’s group has studied metal samples’ response to stress and other stimuli in real time using a technique called in situ electron microscopy.

      “We do in situ tests, which means you take an electron microscope and basically build machines inside that allows you to take any metal and put it under different conditions, as you watch its structure evolve,” Tasan explains. “Because these experiments are so unique and complex, when a student designs an experiment and eventually brings the results back to me, it’s often the first-ever observation of some phenomena.”

      In 2020 Tasan’s group developed new in-situ methods for studying the effects of hydrogen in metals, leading to insights that could help with the transition to clean hydrogen energy. The approach has been adopted by other labs for further study.

      Tasan’s group also created a more damage resistant, high temperature alloy that’s part of a class of metals known as high entropy alloys. That work was published in the journal Nature Materials.

      “Doing physical metallurgy research allows us to connect basic understanding of metals and industrial applications,” Tasan says. “I’m dealing with atoms and how they interact — and at the same time I’m talking weekly with companies that produce thousands of tons of metals, and we’re using the same language. I can talk to a company producing steels for auto bodies or titanium for airplane engines, and the stuff I study in my lab is still valuable to them.”

      In one much-publicized Science paper, Tasan’s group uncovered the reasons why even the sharpest knives and razors dull after everyday processes like shaving.

      “We like to demonstrate the importance of materials science and metallurgy to a broader audience,” Tasan says. “The paper on why hair deforms steel was great because it was picked up in all kinds of news channels around the world, and it showed that even in very conventional areas, like making knives or blades, there’s a lot of new insights and paths to find.”

      Solving the ultimate puzzles

      Tasan brings the same careful diligence he uses to study metals to support students. He says he’s found that like metals, people also typically have more complex stories that you can only see if you look closely enough.

      “It’s interesting because everybody is so different,” Tasan says. “Once you start working with people and trying to help them, you see so many different dimensions that were not visible before. You have the opportunity to sit down with them and look them in the eye and try to understand what they really want. And it’s interesting because often they also don’t know what they want, and sometimes they even don’t know that they don’t know that!”

      Fortunately, Tasan enjoys those challenges most of all.

      “In a way, the researchers are puzzles waiting to be solved, like the research itself,” Tasan says. “And if you put in enough effort and you really care, you get this enormously gratifying feeling of helping someone succeed in life. It’s really a unique part of the job, and it’s what I love more than anything.” More

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      in Energy

      Team creates map for production of eco-friendly metals

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      In work that could usher in more efficient, eco-friendly processes for producing important metals like lithium, iron, and cobalt, researchers from MIT and the SLAC National Accelerator Laboratory have mapped what is happening at the atomic level behind a particularly promising approach called metal electrolysis.

      By creating maps for a wide range of metals, they not only determined which metals should be easiest to produce using this approach, but also identified fundamental barriers behind the efficient production of others. As a result, the researchers’ map could become an important design tool for optimizing the production of all these metals.

      The work could also aid the development of metal-air batteries, cousins of the lithium-ion batteries used in today’s electric vehicles.

      Most of the metals key to society today are produced using fossil fuels. These fuels generate the high temperatures necessary to convert the original ore into its purified metal. But that process is a significant source of greenhouse gases — steel alone accounts for some 7 percent of carbon dioxide emissions globally. As a result, researchers from around the world are working to identify more eco-friendly ways for the production of metals.

      One promising approach is metal electrolysis, in which a metal oxide, the ore, is zapped with electricity to create pure metal with oxygen as the byproduct. That is the reaction explored at the atomic level in new research reported in the April 8 issue of the journal Chemistry of Materials.

      Donald Siegel is department chair and professor of mechanical engineering at the University of Texas at Austin. Says Siegel, who was not involved in the Chemistry of Materials study: “This work is an important contribution to improving the efficiency of metal production from metal oxides. It clarifies our understanding of low-carbon electrolysis processes by tracing the underlying thermodynamics back to elementary metal-oxygen interactions. I expect that this work will aid in the creation of design rules that will make these industrially important processes less reliant on fossil fuels.”

      Yang Shao-Horn, the JR East Professor of Engineering in MIT’s Department of Materials Science and Engineering (DMSE) and Department of Mechanical Engineering, is a leader of the current work, with Michal Bajdich of SLAC.

      “Here we aim to establish some basic understanding to predict the efficiency of electrochemical metal production and metal-air batteries from examining computed thermodynamic barriers for the conversion between metal and metal oxides,” says Shao-Horn, who is on the research team for MIT’s new Center for Electrification and Decarbonization of Industry, a winner of the Institute’s first-ever Climate Grand Challenges competition. Shao-Horn is also affiliated with MIT’s Materials Research Laboratory and Research Laboratory of Electronics.

      In addition to Shao-Horn and Bajdich, other authors of the Chemistry of Materials paper are Jaclyn R. Lunger, first author and a DMSE graduate student; mechanical engineering senior Naomi Lutz; and DMSE graduate student Jiayu Peng.

      Other applications

      The work could also aid in developing metal-air batteries such as lithium-air, aluminum-air, and zinc-air batteries. These cousins of the lithium-ion batteries used in today’s electric vehicles have the potential to electrify aviation because their energy densities are much higher. However, they are not yet on the market due to a variety of problems including inefficiency.

      Charging metal-air batteries also involves electrolysis. As a result, the new atomic-level understanding of these reactions could not only help engineers develop efficient electrochemical routes for metal production, but also design more efficient metal-air batteries.

      Learning from water splitting

      Electrolysis is also used to split water into oxygen and hydrogen, which stores the resulting energy. That hydrogen, in turn, could become an eco-friendly alternative to fossil fuels. Since much more is known about water electrolysis, the focus of Bajdich’s work at SLAC, than the electrolysis of metal oxides, the team compared the two processes for the first time.

      The result: “Slowly, we uncovered the elementary steps involved in metal electrolysis,” says Bajdich. The work was challenging, says Lunger, because “it was unclear to us what those steps are. We had to figure out how to get from A to B,” or from a metal oxide to metal and oxygen.

      All of the work was conducted with supercomputer simulations. “It’s like a sandbox of atoms, and then we play with them. It’s a little like Legos,” says Bajdich. More specifically, the team explored different scenarios for the electrolysis of several metals. Each involved different catalysts, molecules that boost the speed of a reaction.

      Says Lunger, “To optimize the reaction, you want to find the catalyst that makes it most efficient.” The team’s map is essentially a guide for designing the best catalysts for each different metal.

      What’s next? Lunger noted that the current work focused on the electrolysis of pure metals. “I’m interested in seeing what happens in more complex systems involving multiple metals. Can you make the reaction more efficient if there’s sodium and lithium present, or cadmium and cesium?”

      This work was supported by a U.S. Department of Energy Office of Science Graduate Student Research award. It was also supported by an MIT Energy Initiative fellowship, the Toyota Research Institute through the Accelerated Materials Design and Discovery Program, the Catalysis Science Program of Department of Energy, Office of Basic Energy Sciences, and by the Differentiate Program through the U.S. Advanced Research Projects Agency — Energy.  More