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    For clean ammonia, MIT engineers propose going underground

    Ammonia is the most widely produced chemical in the world today, used primarily as a source for nitrogen fertilizer. Its production is also a major source of greenhouse gas emissions — the highest in the whole chemical industry.Now, a team of researchers at MIT has developed an innovative way of making ammonia without the usual fossil-fuel-powered chemical plants that require high heat and pressure. Instead, they have found a way to use the Earth itself as a geochemical reactor, producing ammonia underground. The processes uses Earth’s naturally occurring heat and pressure, provided free of charge and free of emissions, as well as the reactivity of minerals already present in the ground.The trick the team devised is to inject water underground, into an area of iron-rich subsurface rock. The water carries with it a source of nitrogen and particles of a metal catalyst, allowing the water to react with the iron to generate clean hydrogen, which in turn reacts with the nitrogen to make ammonia. A second well is then used to pump that ammonia up to the surface.The process, which has been demonstrated in the lab but not yet in a natural setting, is described today in the journal Joule. The paper’s co-authors are MIT professors of materials science and engineering Iwnetim Abate and Ju Li, graduate student Yifan Gao, and five others at MIT.“When I first produced ammonia from rock in the lab, I was so excited,” Gao recalls. “I realized this represented an entirely new and never-reported approach to ammonia synthesis.’”The standard method for making ammonia is called the Haber-Bosch process, which was developed in Germany in the early 20th century to replace natural sources of nitrogen fertilizer such as mined deposits of bat guano, which were becoming depleted. But the Haber-Bosch process is very energy intensive: It requires temperatures of 400 degrees Celsius and pressures of 200 atmospheres, and this means it needs huge installations in order to be efficient. Some areas of the world, such as sub-Saharan Africa and Southeast Asia, have few or no such plants in operation.  As a result, the shortage or extremely high cost of fertilizer in these regions has limited their agricultural production.The Haber-Bosch process “is good. It works,” Abate says. “Without it, we wouldn’t have been able to feed 2 out of the total 8 billion people in the world right now, he says, referring to the portion of the world’s population whose food is grown with ammonia-based fertilizers. But because of the emissions and energy demands, a better process is needed, he says.Burning fuel to generate heat is responsible for about 20 percent of the greenhouse gases emitted from plants using the Haber-Bosch process. Making hydrogen accounts for the remaining 80 percent.  But ammonia, the molecule NH3, is made up only of nitrogen and hydrogen. There’s no carbon in the formula, so where do the carbon emissions come from? The standard way of producing the needed hydrogen is by processing methane gas with steam, breaking down the gas into pure hydrogen, which gets used, and carbon dioxide gas that gets released into the air.Other processes exist for making low- or no-emissions hydrogen, such as by using solar or wind-generated electricity to split water into oxygen and hydrogen, but that process can be expensive. That’s why Abate and his team worked on developing a system to produce what they call geological hydrogen. Some places in the world, including some in Africa, have been found to naturally generate hydrogen underground through chemical reactions between water and iron-rich rocks. These pockets of naturally occurring hydrogen can be mined, just like natural methane reservoirs, but the extent and locations of such deposits are still relatively unexplored.Abate realized this process could be created or enhanced by pumping water, laced with copper and nickel catalyst particles to speed up the process, into the ground in places where such iron-rich rocks were already present. “We can use the Earth as a factory to produce clean flows of hydrogen,” he says.He recalls thinking about the problem of the emissions from hydrogen production for ammonia: “The ‘aha!’ moment for me was thinking, how about we link this process of geological hydrogen production with the process of making Haber-Bosch ammonia?”That would solve the biggest problem of the underground hydrogen production process, which is how to capture and store the gas once it’s produced. Hydrogen is a very tiny molecule — the smallest of them all — and hard to contain. But by implementing the entire Haber-Bosch process underground, the only material that would need to be sent to the surface would be the ammonia itself, which is easy to capture, store, and transport.The only extra ingredient needed to complete the process was the addition of a source of nitrogen, such as nitrate or nitrogen gas, into the water-catalyst mixture being injected into the ground. Then, as the hydrogen gets released from water molecules after interacting with the iron-rich rocks, it can immediately bond with the nitrogen atoms also carried in the water, with the deep underground environment providing the high temperatures and pressures required by the Haber-Bosch process. A second well near the injection well then pumps the ammonia out and into tanks on the surface.“We call this geological ammonia,” Abate says, “because we are using subsurface temperature, pressure, chemistry, and geologically existing rocks to produce ammonia directly.”Whereas transporting hydrogen requires expensive equipment to cool and liquefy it, and virtually no pipelines exist for its transport (except near oil refinery sites), transporting ammonia is easier and cheaper. It’s about one-sixth the cost of transporting hydrogen, and there are already more than 5,000 miles of ammonia pipelines and 10,000 terminals in place in the U.S. alone. What’s more, Abate explains, ammonia, unlike hydrogen, already has a substantial commercial market in place, with production volume projected to grow by two to three times by 2050, as it is used not only for fertilizer but also as feedstock for a wide variety of chemical processes.For example, ammonia can be burned directly in gas turbines, engines, and industrial furnaces, providing a carbon-free alternative to fossil fuels. It is being explored for maritime shipping and aviation as an alternative fuel, and as a possible space propellant.Another upside to geological ammonia is that untreated wastewater, including agricultural runoff, which tends to be rich in nitrogen already, could serve as the water source and be treated in the process. “We can tackle the problem of treating wastewater, while also making something of value out of this waste,” Abate says.Gao adds that this process “involves no direct carbon emissions, presenting a potential pathway to reduce global CO2 emissions by up to 1 percent.” To arrive at this point, he says, the team “overcame numerous challenges and learned from many failed attempts. For example, we tested a wide range of conditions and catalysts before identifying the most effective one.”The project was seed-funded under a flagship project of MIT’s Climate Grand Challenges program, the Center for the Electrification and Decarbonization of Industry. Professor Yet-Ming Chiang, co-director of the center, says “I don’t think there’s been any previous example of deliberately using the Earth as a chemical reactor. That’s one of the key novel points of this approach.”  Chiang emphasizes that even though it is a geological process, it happens very fast, not on geological timescales. “The reaction is fundamentally over in a matter of hours,” he says. “The reaction is so fast that this answers one of the key questions: Do you have to wait for geological times? And the answer is absolutely no.”Professor Elsa Olivetti, a mission director of the newly established Climate Project at MIT, says, “The creative thinking by this team is invaluable to MIT’s ability to have impact at scale. Coupling these exciting results with, for example, advanced understanding of the geology surrounding hydrogen accumulations represent the whole-of-Institute efforts the Climate Project aims to support.”“This is a significant breakthrough for the future of sustainable development,” says Geoffrey Ellis, a geologist at the U.S. Geological Survey, who was not associated with this work. He adds, “While there is clearly more work that needs to be done to validate this at the pilot stage and to get this to the commercial scale, the concept that has been demonstrated is truly transformative.  The approach of engineering a system to optimize the natural process of nitrate reduction by Fe2+ is ingenious and will likely lead to further innovations along these lines.”The initial work on the process has been done in the laboratory, so the next step will be to prove the process using a real underground site. “We think that kind of experiment can be done within the next one to two years,” Abate says. This could open doors to using a similar approach for other chemical production processes, he adds.The team has applied for a patent and aims to work towards bringing the process to market.“Moving forward,” Gao says, “our focus will be on optimizing the process conditions and scaling up tests, with the goal of enabling practical applications for geological ammonia in the near future.”The research team also included Ming Lei, Bachu Sravan Kumar, Hugh Smith, Seok Hee Han, and Lokesh Sangabattula, all at MIT. Additional funding was provided by the National Science Foundation and was carried out, in part, through the use of MIT.nano facilities. More

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    Unlocking the hidden power of boiling — for energy, space, and beyond

    Most people take boiling water for granted. For Associate Professor Matteo Bucci, uncovering the physics behind boiling has been a decade-long journey filled with unexpected challenges and new insights.The seemingly simple phenomenon is extremely hard to study in complex systems like nuclear reactors, and yet it sits at the core of a wide range of important industrial processes. Unlocking its secrets could thus enable advances in efficient energy production, electronics cooling, water desalination, medical diagnostics, and more.“Boiling is important for applications way beyond nuclear,” says Bucci, who earned tenure at MIT in July. “Boiling is used in 80 percent of the power plants that produce electricity. My research has implications for space propulsion, energy storage, electronics, and the increasingly important task of cooling computers.”Bucci’s lab has developed new experimental techniques to shed light on a wide range of boiling and heat transfer phenomena that have limited energy projects for decades. Chief among those is a problem caused by bubbles forming so quickly they create a band of vapor across a surface that prevents further heat transfer. In 2023, Bucci and collaborators developed a unifying principle governing the problem, known as the boiling crisis, which could enable more efficient nuclear reactors and prevent catastrophic failures.For Bucci, each bout of progress brings new possibilities — and new questions to answer.“What’s the best paper?” Bucci asks. “The best paper is the next one. I think Alfred Hitchcock used to say it doesn’t matter how good your last movie was. If your next one is poor, people won’t remember it. I always tell my students that our next paper should always be better than the last. It’s a continuous journey of improvement.”From engineering to bubblesThe Italian village where Bucci grew up had a population of about 1,000 during his childhood. He gained mechanical skills by working in his father’s machine shop and by taking apart and reassembling appliances like washing machines and air conditioners to see what was inside. He also gained a passion for cycling, competing in the sport until he attended the University of Pisa for undergraduate and graduate studies.In college, Bucci was fascinated with matter and the origins of life, but he also liked building things, so when it came time to pick between physics and engineering, he decided nuclear engineering was a good middle ground.“I have a passion for construction and for understanding how things are made,” Bucci says. “Nuclear engineering was a very unlikely but obvious choice. It was unlikely because in Italy, nuclear was already out of the energy landscape, so there were very few of us. At the same time, there were a combination of intellectual and practical challenges, which is what I like.”For his PhD, Bucci went to France, where he met his wife, and went on to work at a French national lab. One day his department head asked him to work on a problem in nuclear reactor safety known as transient boiling. To solve it, he wanted to use a method for making measurements pioneered by MIT Professor Jacopo Buongiorno, so he received grant money to become a visiting scientist at MIT in 2013. He’s been studying boiling at MIT ever since.Today Bucci’s lab is developing new diagnostic techniques to study boiling and heat transfer along with new materials and coatings that could make heat transfer more efficient. The work has given researchers an unprecedented view into the conditions inside a nuclear reactor.“The diagnostics we’ve developed can collect the equivalent of 20 years of experimental work in a one-day experiment,” Bucci says.That data, in turn, led Bucci to a remarkably simple model describing the boiling crisis.“The effectiveness of the boiling process on the surface of nuclear reactor cladding determines the efficiency and the safety of the reactor,” Bucci explains. “It’s like a car that you want to accelerate, but there is an upper limit. For a nuclear reactor, that upper limit is dictated by boiling heat transfer, so we are interested in understanding what that upper limit is and how we can overcome it to enhance the reactor performance.”Another particularly impactful area of research for Bucci is two-phase immersion cooling, a process wherein hot server parts bring liquid to boil, then the resulting vapor condenses on a heat exchanger above to create a constant, passive cycle of cooling.“It keeps chips cold with minimal waste of energy, significantly reducing the electricity consumption and carbon dioxide emissions of data centers,” Bucci explains. “Data centers emit as much CO2 as the entire aviation industry. By 2040, they will account for over 10 percent of emissions.”Supporting studentsBucci says working with students is the most rewarding part of his job. “They have such great passion and competence. It’s motivating to work with people who have the same passion as you.”“My students have no fear to explore new ideas,” Bucci adds. “They almost never stop in front of an obstacle — sometimes to the point where you have to slow them down and put them back on track.”In running the Red Lab in the Department of Nuclear Science and Engineering, Bucci tries to give students independence as well as support.“We’re not educating students, we’re educating future researchers,” Bucci says. “I think the most important part of our work is to not only provide the tools, but also to give the confidence and the self-starting attitude to fix problems. That can be business problems, problems with experiments, problems with your lab mates.”Some of the more unique experiments Bucci’s students do require them to gather measurements while free falling in an airplane to achieve zero gravity.“Space research is the big fantasy of all the kids,” says Bucci, who joins students in the experiments about twice a year. “It’s very fun and inspiring research for students. Zero g gives you a new perspective on life.”Applying AIBucci is also excited about incorporating artificial intelligence into his field. In 2023, he was a co-recipient of a multi-university research initiative (MURI) project in thermal science dedicated solely to machine learning. In a nod to the promise AI holds in his field, Bucci also recently founded a journal called AI Thermal Fluids to feature AI-driven research advances.“Our community doesn’t have a home for people that want to develop machine-learning techniques,” Bucci says. “We wanted to create an avenue for people in computer science and thermal science to work together to make progress. I think we really need to bring computer scientists into our community to speed this process up.”Bucci also believes AI can be used to process huge reams of data gathered using the new experimental techniques he’s developed as well as to model phenomena researchers can’t yet study.“It’s possible that AI will give us the opportunity to understand things that cannot be observed, or at least guide us in the dark as we try to find the root causes of many problems,” Bucci says. More

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    MIT spinout Commonwealth Fusion Systems unveils plans for the world’s first fusion power plant

    America is one step closer to tapping into a new and potentially limitless clean energy source today, with the announcement from MIT spinout Commonwealth Fusion Systems (CFS) that it plans to build the world’s first grid-scale fusion power plant in Chesterfield County, Virginia.The announcement is the latest milestone for the company, which has made groundbreaking progress toward harnessing fusion — the reaction that powers the sun — since its founders first conceived of their approach in an MIT classroom in 2012. CFS is now commercializing a suite of advanced technologies developed in MIT research labs.“This moment exemplifies the power of MIT’s mission, which is to create knowledge that serves the nation and the world, whether via the classroom, the lab, or out in communities,” MIT Vice President for Research Ian Waitz says. “From student coursework 12 years ago to today’s announcement of the siting in Virginia of the world’s first fusion power plant, progress has been amazingly rapid. At the same time, we owe this progress to over 65 years of sustained investment by the U.S. federal government in basic science and energy research.”The new fusion power plant, named ARC, is expected to come online in the early 2030s and generate about 400 megawatts of clean, carbon-free electricity — enough energy to power large industrial sites or about 150,000 homes.The plant will be built at the James River Industrial Park outside of Richmond through a nonfinancial collaboration with Dominion Energy Virginia, which will provide development and technical expertise along with leasing rights for the site. CFS will independently finance, build, own, and operate the power plant.The plant will support Virginia’s economic and clean energy goals by generating what is expected to be billions of dollars in economic development and hundreds of jobs during its construction and long-term operation.More broadly, ARC will position the U.S. to lead the world in harnessing a new form of safe and reliable energy that could prove critical for economic prosperity and national security, including for meeting increasing electricity demands driven by needs like artificial intelligence.“This will be a watershed moment for fusion,” says CFS co-founder Dennis Whyte, the Hitachi America Professor of Engineering at MIT. “It sets the pace in the race toward commercial fusion power plants. The ambition is to build thousands of these power plants and to change the world.”Fusion can generate energy from abundant fuels like hydrogen and lithium isotopes, which can be sourced from seawater, and leave behind no emissions or toxic waste. However, harnessing fusion in a way that produces more power than it takes in has proven difficult because of the high temperatures needed to create and maintain the fusion reaction. Over the course of decades, scientists and engineers have worked to make the dream of fusion power plants a reality.In 2012, teaching the MIT class 22.63 (Principles of Fusion Engineering), Whyte challenged a group of graduate students to design a fusion device that would use a new kind of superconducting magnet to confine the plasma used in the reaction. It turned out the magnets enabled a more compact and economic reactor design. When Whyte reviewed his students’ work, he realized that could mean a new development path for fusion.Since then, a huge amount of capital and expertise has rushed into the once fledgling fusion industry. Today there are dozens of private fusion companies around the world racing to develop the first net-energy fusion power plants, many utilizing the new superconducting magnets. CFS, which Whyte founded with several students from his class, has attracted more than $2 billion in funding.“It all started with that class, where our ideas kept evolving as we challenged the standard assumptions that came with fusion,” Whyte says. “We had this new superconducting technology, so much of the common wisdom was no longer valid. It was a perfect forum for students, who can challenge the status quo.”Since the company’s founding in 2017, it has collaborated with researchers in MIT’s Plasma Science and Fusion Center (PFSC) on a range of initiatives, from validating the underlying plasma physics for the first demonstration machine to breaking records with a new kind of magnet to be used in commercial fusion power plants. Each piece of progress moves the U.S. closer to harnessing a revolutionary new energy source.CFS is currently completing development of its fusion demonstration machine, SPARC, at its headquarters in Devens, Massachusetts. SPARC is expected to produce its first plasma in 2026 and net fusion energy shortly after, demonstrating for the first time a commercially relevant design that will produce more power than it consumes. SPARC will pave the way for ARC, which is expected to deliver power to the grid in the early 2030s.“There’s more challenging engineering and science to be done in this field, and we’re very enthusiastic about the progress that CFS and the researchers on our campus are making on those problems,” Waitz says. “We’re in a ‘hockey stick’ moment in fusion energy, where things are moving incredibly quickly now. On the other hand, we can’t forget about the much longer part of that hockey stick, the sustained support for very complex, fundamental research that underlies great innovations. If we’re going to continue to lead the world in these cutting-edge technologies, continued investment in those areas will be crucial.” More

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    Transforming fusion from a scientific curiosity into a powerful clean energy source

    If you’re looking for hard problems, building a nuclear fusion power plant is a pretty good place to start. Fusion — the process that powers the sun — has proven to be a difficult thing to recreate here on Earth despite decades of research.“There’s something very attractive to me about the magnitude of the fusion challenge,” Hartwig says. “It’s probably true of a lot of people at MIT. I’m driven to work on very hard problems. There’s something intrinsically satisfying about that battle. It’s part of the reason I’ve stayed in this field. We have to cross multiple frontiers of physics and engineering if we’re going to get fusion to work.”The problem got harder when, in Hartwig’s last year in graduate school, the Department of Energy announced plans to terminate funding for the Alcator C-Mod tokamak, a major fusion experiment in MIT’s Plasma Science and Fusion Center that Hartwig needed to do to graduate. Hartwig was able to finish his PhD, and the scare didn’t dissuade him from the field. In fact, he took an associate professor position at MIT in 2017 to keep working on fusion.“It was a pretty bleak time to take a faculty position in fusion energy, but I am a person who loves to find a vacuum,” says Hartwig, who is a newly tenured associate professor at MIT. “I adore a vacuum because there’s enormous opportunity in chaos.”Hartwig did have one very good reason for hope. In 2012, he had taken a class taught by Professor Dennis Whyte that challenged students to design and assess the economics of a nuclear fusion power plant that incorporated a new kind of high-temperature superconducting magnet. Hartwig says the magnets enable fusion reactors to be much smaller, cheaper, and faster.Whyte, Hartwig, and a few other members of the class started working nights and weekends to prove the reactors were feasible. In 2017, the group founded Commonwealth Fusion Systems (CFS) to build the world’s first commercial-scale fusion power plants.Over the next four years, Hartwig led a research project at MIT with CFS that further developed the magnet technology and scaled it to create a 20-Tesla superconducting magnet — a suitable size for a nuclear fusion power plant.The magnet and subsequent tests of its performance represented a turning point for the industry. Commonwealth Fusion Systems has since attracted more than $2 billion in investments to build its first reactors, while the fusion industry overall has exceeded $8 billion in private investment.The old joke in fusion is that the technology is always 30 years away. But fewer people are laughing these days.“The perspective in 2024 looks quite a bit different than it did in 2016, and a huge part of that is tied to the institutional capability of a place like MIT and the willingness of people here to accomplish big things,” Hartwig says.A path to the starsAs a child growing up in St. Louis, Hartwig was interested in sports and playing outside with friends but had little interest in physics. When he went to Boston University as an undergraduate, he studied biomedical engineering simply because his older brother had done it, so he thought he could get a job. But as he was introduced to tools for structural experiments and analysis, he found himself more interested in how the tools worked than what they could do.“That led me to physics, and physics ended up leading me to nuclear science, where I’m basically still doing applied physics,” Hartwig explains.Joining the field late in his undergraduate studies, Hartwig worked hard to get his physics degree on time. After graduation, he was burnt out, so he took two years off and raced his bicycle competitively while working in a bike shop.“There’s so much pressure on people in science and engineering to go straight through,” Hartwig says. “People say if you take time off, you won’t be able to get into graduate school, you won’t be able to get recommendation letters. I always tell my students, ‘It depends on the person.’ Everybody’s different, but it was a great period for me, and it really set me up to enter graduate school with a more mature mindset and to be more focused.”Hartwig returned to academia as a PhD student in MIT’s Department of Nuclear Science and Engineering in 2007. When his thesis advisor, Dennis Whyte, announced a course focused on designing nuclear fusion power plants, it caught Hartwig’s eye. The final projects showed a surprisingly promising path forward for a fusion field that had been stagnant for decades. The rest was history.“We started CFS with the idea that it would partner deeply with MIT and MIT’s Plasma Science and Fusion Center to leverage the infrastructure, expertise, people, and capabilities that we have MIT,” Hartwig says. “We had to start the company with the idea that it would be deeply partnered with MIT in an innovative way that hadn’t really been done before.”Guided by impactHartwig says the Department of Nuclear Science and Engineering, and the Plasma Science and Fusion Center in particular, have seen a huge influx in graduate student applications in recent years.“There’s so much demand, because people are excited again about the possibilities,” Hartwig says. “Instead of having fusion and a machine built in one or two generations, we’ll hopefully be learning how these things work in under a decade.”Hartwig’s research group is still testing CFS’ new magnets, but it is also partnering with other fusion companies in an effort to advance the field more broadly.Overall, when Hartwig looks back at his career, the thing he is most proud of is switching specialties every six years or so, from building equipment for his PhD to conducting fundamental experiments to designing reactors to building magnets.“It’s not that traditional in academia,” Hartwig says. “Where I’ve found success is coming into something new, bringing a naivety but also realism to a new field, and offering a different toolkit, a different approach, or a different idea about what can be done.”Now Hartwig is onto his next act, developing new ways to study materials for use in fusion and fission reactors.“I’m already interested in moving on to the next thing; the next field where I’m not a trained expert,” Hartwig says. “It’s about identifying where there’s stagnation in fusion and in technology, where innovation is not happening where we desperately need it, and bringing new ideas to that.” More

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    Decarbonizing heavy industry with thermal batteries

    Whether you’re manufacturing cement, steel, chemicals, or paper, you need a large amount of heat. Almost without exception, manufacturers around the world create that heat by burning fossil fuels.In an effort to clean up the industrial sector, some startups are changing manufacturing processes for specific materials. Some are even changing the materials themselves. Daniel Stack SM ’17, PhD ’21 is trying to address industrial emissions across the board by replacing the heat source.Since coming to MIT in 2014, Stack has worked to develop thermal batteries that use electricity to heat up a conductive version of ceramic firebricks, which have been used as heat stores and insulators for centuries. In 2021, Stack co-founded Electrified Thermal Solutions, which has since demonstrated that its firebricks can store heat efficiently for hours and discharge it by heating air or gas up to 3,272 degrees Fahrenheit — hot enough to power the most demanding industrial applications.Achieving temperatures north of 3,000 F represents a breakthrough for the electric heating industry, as it enables some of the world’s hardest-to-decarbonize sectors to utilize renewable energy for the first time. It also unlocks a new, low-cost model for using electricity when it’s at its cheapest and cleanest.“We have a global perspective at Electrified Thermal, but in the U.S. over the last five years, we’ve seen an incredible opportunity emerge in energy prices that favors flexible offtake of electricity,” Stack says. “Throughout the middle of the country, especially in the wind belt, electricity prices in many places are negative for more than 20 percent of the year, and the trend toward decreasing electricity pricing during off-peak hours is a nationwide phenomenon. Technologies like our Joule Hive Thermal Battery will enable us to access this inexpensive, clean electricity and compete head to head with fossil fuels on price for industrial heating needs, without even factoring in the positive climate impact.”A new approach to an old technologyStack’s research plans changed quickly when he joined MIT’s Department of Nuclear Science and Engineering as a master’s student in 2014.“I went to MIT excited to work on the next generation of nuclear reactors, but what I focused on almost from day one was how to heat up bricks,” Stack says. “It wasn’t what I expected, but when I talked to my advisor, [Principal Research Scientist] Charles Forsberg, about energy storage and why it was valuable to not just nuclear power but the entire energy transition, I realized there was no project I would rather work on.”Firebricks are ubiquitous, inexpensive clay bricks that have been used for millennia in fireplaces and ovens. In 2017, Forsberg and Stack co-authored a paper showing firebricks’ potential to store heat from renewable resources, but the system still used electric resistance heaters — like the metal coils in toasters and space heaters — which limited its temperature output.For his doctoral work, Stack worked with Forsberg to make firebricks that were electrically conductive, replacing the resistance heaters so the bricks produced the heat directly.“Electric heaters are your biggest limiter: They burn out too fast, they break down, they don’t get hot enough,” Stack explains. “The idea was to skip the heaters because firebricks themselves are really cheap, abundant materials that can go to flame-like temperatures and hang out there for days.”Forsberg and Stacks were able to create conductive firebricks by tweaking the chemical composition of traditional firebricks. Electrified Thermal’s bricks are 98 percent similar to existing firebricks and are produced using the same processes, allowing existing manufacturers to make them inexpensively.Toward the end of his PhD program, Stack realized the invention could be commercialized. He started taking classes at the MIT Sloan School of Management and spending time at the Martin Trust Center for MIT Entrepreneurship. He also entered the StartMIT program and the I-Corps program, and received support from the U.S. Department of Energy and MIT’s Venture Mentoring Service (VMS).“Through the Boston ecosystem, the MIT ecosystem, and with help from the Department of Energy, we were able to launch this from the lab at MIT,” Stack says. “What we spun out was an electrically conductive firebrick, or what we refer to as an e-Brick.”Electrified Thermal contains its firebrick arrays in insulated, off-the-shelf metal boxes. Although the system is highly configurable depending on the end use, the company’s standard system can collect and release about 5 megawatts of energy and store about 25 megawatt-hours.The company has demonstrated its system’s ability to produce high temperatures and has been cycling its system at its headquarters in Medford, Massachusetts. That work has collectively earned Electrified Thermal $40 million from various the Department of Energy offices to scale the technology and work with manufacturers.“Compared to other electric heating, we can run hotter and last longer than any other solution on the market,” Stack says. “That means replacing fossil fuels at a lot of industrial sites that couldn’t otherwise decarbonize.”Scaling to solve a global problemElectrified Thermal is engaging with hundreds of industrial companies, including manufacturers of cement, steel, glass, basic and specialty chemicals, food and beverage, and pulp and paper.“The industrial heating challenge affects everyone under the sun,” Stack says. “They all have fundamentally the same problem, which is getting their heat in a way that is affordable and zero carbon for the energy transition.”The company is currently building a megawatt-scale commercial version of its system, which it expects to be operational in the next seven months.“Next year will be a huge proof point to the industry,” Stack says. “We’ll be using the commercial system to showcase a variety of operating points that customers need to see, and we’re hoping to be running systems on customer sites by the end of the year. It’ll be a huge achievement and a first for electric heating because no other solution in the market can put out the kind of temperatures that we can put out.”By working with manufacturers to produce its firebricks and casings, Electrified Thermal hopes to be able to deploy its systems rapidly and at low cost across a massive industry.“From the very beginning, we engineered these e-bricks to be rapidly scalable and rapidly producible within existing supply chains and manufacturing processes,” Stack says. “If you want to decarbonize heavy industry, there will be no cheaper way than turning electricity into heat from zero-carbon electricity assets. We’re seeking to be the premier technology that unlocks those capabilities, with double digit percentages of global energy flowing through our system as we accomplish the energy transition.” More

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    Nanoscale transistors could enable more efficient electronics

    Silicon transistors, which are used to amplify and switch signals, are a critical component in most electronic devices, from smartphones to automobiles. But silicon semiconductor technology is held back by a fundamental physical limit that prevents transistors from operating below a certain voltage.This limit, known as “Boltzmann tyranny,” hinders the energy efficiency of computers and other electronics, especially with the rapid development of artificial intelligence technologies that demand faster computation.In an effort to overcome this fundamental limit of silicon, MIT researchers fabricated a different type of three-dimensional transistor using a unique set of ultrathin semiconductor materials.Their devices, featuring vertical nanowires only a few nanometers wide, can deliver performance comparable to state-of-the-art silicon transistors while operating efficiently at much lower voltages than conventional devices.“This is a technology with the potential to replace silicon, so you could use it with all the functions that silicon currently has, but with much better energy efficiency,” says Yanjie Shao, an MIT postdoc and lead author of a paper on the new transistors.The transistors leverage quantum mechanical properties to simultaneously achieve low-voltage operation and high performance within an area of just a few square nanometers. Their extremely small size would enable more of these 3D transistors to be packed onto a computer chip, resulting in fast, powerful electronics that are also more energy-efficient.“With conventional physics, there is only so far you can go. The work of Yanjie shows that we can do better than that, but we have to use different physics. There are many challenges yet to be overcome for this approach to be commercial in the future, but conceptually, it really is a breakthrough,” says senior author Jesús del Alamo, the Donner Professor of Engineering in the MIT Department of Electrical Engineering and Computer Science (EECS).They are joined on the paper by Ju Li, the Tokyo Electric Power Company Professor in Nuclear Engineering and professor of materials science and engineering at MIT; EECS graduate student Hao Tang; MIT postdoc Baoming Wang; and professors Marco Pala and David Esseni of the University of Udine in Italy. The research appears today in Nature Electronics.Surpassing siliconIn electronic devices, silicon transistors often operate as switches. Applying a voltage to the transistor causes electrons to move over an energy barrier from one side to the other, switching the transistor from “off” to “on.” By switching, transistors represent binary digits to perform computation.A transistor’s switching slope reflects the sharpness of the “off” to “on” transition. The steeper the slope, the less voltage is needed to turn on the transistor and the greater its energy efficiency.But because of how electrons move across an energy barrier, Boltzmann tyranny requires a certain minimum voltage to switch the transistor at room temperature.To overcome the physical limit of silicon, the MIT researchers used a different set of semiconductor materials — gallium antimonide and indium arsenide — and designed their devices to leverage a unique phenomenon in quantum mechanics called quantum tunneling.Quantum tunneling is the ability of electrons to penetrate barriers. The researchers fabricated tunneling transistors, which leverage this property to encourage electrons to push through the energy barrier rather than going over it.“Now, you can turn the device on and off very easily,” Shao says.But while tunneling transistors can enable sharp switching slopes, they typically operate with low current, which hampers the performance of an electronic device. Higher current is necessary to create powerful transistor switches for demanding applications.Fine-grained fabricationUsing tools at MIT.nano, MIT’s state-of-the-art facility for nanoscale research, the engineers were able to carefully control the 3D geometry of their transistors, creating vertical nanowire heterostructures with a diameter of only 6 nanometers. They believe these are the smallest 3D transistors reported to date.Such precise engineering enabled them to achieve a sharp switching slope and high current simultaneously. This is possible because of a phenomenon called quantum confinement.Quantum confinement occurs when an electron is confined to a space that is so small that it can’t move around. When this happens, the effective mass of the electron and the properties of the material change, enabling stronger tunneling of the electron through a barrier.Because the transistors are so small, the researchers can engineer a very strong quantum confinement effect while also fabricating an extremely thin barrier.“We have a lot of flexibility to design these material heterostructures so we can achieve a very thin tunneling barrier, which enables us to get very high current,” Shao says.Precisely fabricating devices that were small enough to accomplish this was a major challenge.“We are really into single-nanometer dimensions with this work. Very few groups in the world can make good transistors in that range. Yanjie is extraordinarily capable to craft such well-functioning transistors that are so extremely small,” says del Alamo.When the researchers tested their devices, the sharpness of the switching slope was below the fundamental limit that can be achieved with conventional silicon transistors. Their devices also performed about 20 times better than similar tunneling transistors.“This is the first time we have been able to achieve such sharp switching steepness with this design,” Shao adds.The researchers are now striving to enhance their fabrication methods to make transistors more uniform across an entire chip. With such small devices, even a 1-nanometer variance can change the behavior of the electrons and affect device operation. They are also exploring vertical fin-shaped structures, in addition to vertical nanowire transistors, which could potentially improve the uniformity of devices on a chip.“This work definitively steps in the right direction, significantly improving the broken-gap tunnel field effect transistor (TFET) performance. It demonstrates steep-slope together with a record drive-current. It highlights the importance of small dimensions, extreme confinement, and low-defectivity materials and interfaces in the fabricated broken-gap TFET. These features have been realized through a well-mastered and nanometer-size-controlled process,” says Aryan Afzalian, a principal member of the technical staff at the nanoelectronics research organization imec, who was not involved with this work.This research is funded, in part, by Intel Corporation. More

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    Smart handling of neutrons is crucial to fusion power success

    In fall 2009, when Ethan Peterson ’13 arrived at MIT as an undergraduate, he already had some ideas about possible career options. He’d always liked building things, even as a child, so he imagined his future work would involve engineering of some sort. He also liked physics. And he’d recently become intent on reducing our dependence on fossil fuels and simultaneously curbing greenhouse gas emissions, which made him consider studying solar and wind energy, among other renewable sources.Things crystallized for him in the spring semester of 2010, when he took an introductory course on nuclear fusion, taught by Anne White, during which he discovered that when a deuterium nucleus and a tritium nucleus combine to produce a helium nucleus, an energetic (14 mega electron volt) neutron — traveling at one-sixth the speed of light — is released. Moreover, 1020 (100 billion billion) of these neutrons would be produced every second that a 500-megawatt fusion power plant operates. “It was eye-opening for me to learn just how energy-dense the fusion process is,” says Peterson, who became the Class of 1956 Career Development Professor of nuclear science and engineering in July 2024. “I was struck by the richness and interdisciplinary nature of the fusion field. This was an engineering discipline where I could apply physics to solve a real-world problem in a way that was both interesting and beautiful.”He soon became a physics and nuclear engineering double major, and by the time he graduated from MIT in 2013, the U.S. Department of Energy (DoE) had already decided to cut funding for MIT’s Alcator C-Mod fusion project. In view of that facility’s impending closure, Peterson opted to pursue graduate studies at the University of Wisconsin. There, he acquired a basic science background in plasma physics, which is central not only to nuclear fusion but also to astrophysical phenomena such as the solar wind.When Peterson received his PhD from Wisconsin in 2019, nuclear fusion had rebounded at MIT with the launch, a year earlier, of the SPARC project — a collaborative effort being carried out with the newly founded MIT spinout Commonwealth Fusion Systems. He returned to his alma mater as a postdoc and then a research scientist in the Plasma Science and Fusion Center, taking his time, at first, to figure out how to best make his mark in the field.Minding your neutronsAround that time, Peterson was participating in a community planning process, sponsored by the DoE, that focused on critical gaps that needed to be closed for a successful fusion program. In the course of these discussions, he came to realize that inadequate attention had been paid to the handling of neutrons, which carry 80 percent of the energy coming out of a fusion reaction — energy that needs to be harnessed for electrical generation. However, these neutrons are so energetic that they can penetrate through many tens of centimeters of material, potentially undermining the structural integrity of components and damaging vital equipment such as superconducting magnets. Shielding is also essential for protecting humans from harmful radiation.One goal, Peterson says, is to minimize the number of neutrons that escape and, in so doing, to reduce the amount of lost energy. A complementary objective, he adds, “is to get neutrons to deposit heat where you want them to and to stop them from depositing heat where you don’t want them to.” These considerations, in turn, can have a profound influence on fusion reactor design. This branch of nuclear engineering, called neutronics — which analyzes where neutrons are created and where they end up going — has become Peterson’s specialty.It was never a high-profile area of research in the fusion community — as plasma physics, for example, has always garnered more of the spotlight and more of the funding. That’s exactly why Peterson has stepped up. “The impacts of neutrons on fusion reactor design haven’t been a high priority for a long time,” he says. “I felt that some initiative needed to be taken,” and that prompted him to make the switch from plasma physics to neutronics. It has been his principal focus ever since — as a postdoc, a research scientist, and now as a faculty member.A code to design byThe best way to get a neutron to transfer its energy is to make it collide with a light atom. Lithium, with an atomic number of three, or lithium-containing materials are normally good choices — and necessary for producing tritium fuel. The placement of lithium “blankets,” which are intended to absorb energy from neutrons and produce tritium, “is a critical part of the design of fusion reactors,” Peterson says. High-density materials, such as lead and tungsten, can be used, conversely, to block the passage of neutrons and other types of radiation. “You might want to layer these high- and low-density materials in a complicated way that isn’t immediately intuitive” he adds. Determining which materials to put where — and of what thickness and mass — amounts to a tricky optimization problem, which will affect the size, cost, and efficiency of a fusion power plant.To that end, Peterson has developed modelling tools that can make analyses of these sorts easier and faster, thereby facilitating the design process. “This has traditionally been the step that takes the longest time and causes the biggest holdups,” he says. The models and algorithms that he and his colleagues are devising are general enough, moreover, to be compatible with a diverse range of fusion power plant concepts, including those that use magnets or lasers to confine the plasma.Now that he’s become a professor, Peterson is in a position to introduce more people to nuclear engineering, and to neutronics in particular. “I love teaching and mentoring students, sharing the things I’m excited about,” he says. “I was inspired by all the professors I had in physics and nuclear engineering at MIT, and I hope to give back to the community in the same way.”He also believes that if you are going to work on fusion, there is no better place to be than MIT, “where the facilities are second-to-none. People here are extremely innovative and passionate. And the sheer number of people who excel in their fields is staggering.” Great ideas can sometimes be sparked by off-the-cuff conversations in the hallway — something that happens more frequently than you expect, Peterson remarks. “All of these things taken together makes MIT a very special place.” More

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    Study: Fusion energy could play a major role in the global response to climate change

    For many decades, fusion has been touted as the ultimate source of abundant, clean electricity. Now, as the world faces the need to reduce carbon emissions to prevent catastrophic climate change, making commercial fusion power a reality takes on new importance. In a power system dominated by low-carbon variable renewable energy sources (VREs) such as solar and wind, “firm” electricity sources are needed to kick in whenever demand exceeds supply — for example, when the sun isn’t shining or the wind isn’t blowing and energy storage systems aren’t up to the task. What is the potential role and value of fusion power plants (FPPs) in such a future electric power system — a system that is not only free of carbon emissions but also capable of meeting the dramatically increased global electricity demand expected in the coming decades?Working together for a year-and-a-half, investigators in the MIT Energy Initiative (MITEI) and the MIT Plasma Science and Fusion Center (PSFC) have been collaborating to answer that question. They found that — depending on its future cost and performance — fusion has the potential to be critically important to decarbonization. Under some conditions, the availability of FPPs could reduce the global cost of decarbonizing by trillions of dollars. More than 25 experts together examined the factors that will impact the deployment of FPPs, including costs, climate policy, operating characteristics, and other factors. They present their findings in a new report funded through MITEI and entitled “The Role of Fusion Energy in a Decarbonized Electricity System.”“Right now, there is great interest in fusion energy in many quarters — from the private sector to government to the general public,” says the study’s principal investigator (PI) Robert C. Armstrong, MITEI’s former director and the Chevron Professor of Chemical Engineering, Emeritus. “In undertaking this study, our goal was to provide a balanced, fact-based, analysis-driven guide to help us all understand the prospects for fusion going forward.” Accordingly, the study takes a multidisciplinary approach that combines economic modeling, electric grid modeling, techno-economic analysis, and more to examine important factors that are likely to shape the future deployment and utilization of fusion energy. The investigators from MITEI provided the energy systems modeling capability, while the PSFC participants provided the fusion expertise.Fusion technologies may be a decade away from commercial deployment, so the detailed technology and costs of future commercial FPPs are not known at this point. As a result, the MIT research team focused on determining what cost levels fusion plants must reach by 2050 to achieve strong market penetration and make a significant contribution to the decarbonization of global electricity supply in the latter half of the century.The value of having FPPs available on an electric grid will depend on what other options are available, so to perform their analyses, the researchers needed estimates of the future cost and performance of those options, including conventional fossil fuel generators, nuclear fission power plants, VRE generators, and energy storage technologies, as well as electricity demand for specific regions of the world. To find the most reliable data, they searched the published literature as well as results of previous MITEI and PSFC analyses.Overall, the analyses showed that — while the technology demands of harnessing fusion energy are formidable — so are the potential economic and environmental payoffs of adding this firm, low-carbon technology to the world’s portfolio of energy options.Perhaps the most remarkable finding is the “societal value” of having commercial FPPs available. “Limiting warming to 1.5 degrees C requires that the world invest in wind, solar, storage, grid infrastructure, and everything else needed to decarbonize the electric power system,” explains Randall Field, executive director of the fusion study and MITEI’s director of research. “The cost of that task can be far lower when FPPs are available as a source of clean, firm electricity.” And the benefit varies depending on the cost of the FPPs. For example, assuming that the cost of building a FPP is $8,000 per kilowatt (kW) in 2050 and falls to $4,300/kW in 2100, the global cost of decarbonizing electric power drops by $3.6 trillion. If the cost of a FPP is $5,600/kW in 2050 and falls to $3,000/kW in 2100, the savings from having the fusion plants available would be $8.7 trillion. (Those calculations are based on differences in global gross domestic product and assume a discount rate of 6 percent. The undiscounted value is about 20 times larger.)The goal of other analyses was to determine the scale of deployment worldwide at selected FPP costs. Again, the results are striking. For a deep decarbonization scenario, the total global share of electricity generation from fusion in 2100 ranges from less than 10 percent if the cost of fusion is high to more than 50 percent if the cost of fusion is low.Other analyses showed that the scale and timing of fusion deployment vary in different parts of the world. Early deployment of fusion can be expected in wealthy nations such as European countries and the United States that have the most aggressive decarbonization policies. But certain other locations — for example, India and the continent of Africa — will have great growth in fusion deployment in the second half of the century due to a large increase in demand for electricity during that time. “In the U.S. and Europe, the amount of demand growth will be low, so it’ll be a matter of switching away from dirty fuels to fusion,” explains Sergey Paltsev, deputy director of the MIT Center for Sustainability Science and Strategy and a senior research scientist at MITEI. “But in India and Africa, for example, the tremendous growth in overall electricity demand will be met with significant amounts of fusion along with other low-carbon generation resources in the later part of the century.”A set of analyses focusing on nine subregions of the United States showed that the availability and cost of other low-carbon technologies, as well as how tightly carbon emissions are constrained, have a major impact on how FPPs would be deployed and used. In a decarbonized world, FPPs will have the highest penetration in locations with poor diversity, capacity, and quality of renewable resources, and limits on carbon emissions will have a big impact. For example, the Atlantic and Southeast subregions have low renewable resources. In those subregions, wind can produce only a small fraction of the electricity needed, even with maximum onshore wind buildout. Thus, fusion is needed in those subregions, even when carbon constraints are relatively lenient, and any available FPPs would be running much of the time. In contrast, the Central subregion of the United States has excellent renewable resources, especially wind. Thus, fusion competes in the Central subregion only when limits on carbon emissions are very strict, and FPPs will typically be operated only when the renewables can’t meet demand.An analysis of the power system that serves the New England states provided remarkably detailed results. Using a modeling tool developed at MITEI, the fusion team explored the impact of using different assumptions about not just cost and emissions limits but even such details as potential land-use constraints affecting the use of specific VREs. This approach enabled them to calculate the FPP cost at which fusion units begin to be installed. They were also able to investigate how that “threshold” cost changed with changes in the cap on carbon emissions. The method can even show at what price FPPs begin to replace other specific generating sources. In one set of runs, they determined the cost at which FPPs would begin to displace floating platform offshore wind and rooftop solar.“This study is an important contribution to fusion commercialization because it provides economic targets for the use of fusion in the electricity markets,” notes Dennis G. Whyte, co-PI of the fusion study, former director of the PSFC, and the Hitachi America Professor of Engineering in the Department of Nuclear Science and Engineering. “It better quantifies the technical design challenges for fusion developers with respect to pricing, availability, and flexibility to meet changing demand in the future.”The researchers stress that while fission power plants are included in the analyses, they did not perform a “head-to-head” comparison between fission and fusion, because there are too many unknowns. Fusion and nuclear fission are both firm, low-carbon electricity-generating technologies; but unlike fission, fusion doesn’t use fissile materials as fuels, and it doesn’t generate long-lived nuclear fuel waste that must be managed. As a result, the regulatory requirements for FPPs will be very different from the regulations for today’s fission power plants — but precisely how they will differ is unclear. Likewise, the future public perception and social acceptance of each of these technologies cannot be projected, but could have a major influence on what generation technologies are used to meet future demand.The results of the study convey several messages about the future of fusion. For example, it’s clear that regulation can be a potentially large cost driver. This should motivate fusion companies to minimize their regulatory and environmental footprint with respect to fuels and activated materials. It should also encourage governments to adopt appropriate and effective regulatory policies to maximize their ability to use fusion energy in achieving their decarbonization goals. And for companies developing fusion technologies, the study’s message is clearly stated in the report: “If the cost and performance targets identified in this report can be achieved, our analysis shows that fusion energy can play a major role in meeting future electricity needs and achieving global net-zero carbon goals.” More