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    Engineers develop an efficient process to make fuel from carbon dioxide

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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    Rafael Mariano Grossi speaks about nuclear power’s role at a critical moment in history

    On Sept. 22, Rafael Mariano Grossi, director general of the International Atomic Energy Agency (IAEA), delivered the 2023 David J. Rose Lecture in Nuclear Technology at MIT. This lecture series was started nearly 40 years ago in honor of the late Professor David Rose — a nuclear engineering professor and fusion technology pioneer. In addition to his scientific contributions, Rose was invested in the ethical issues associated with new technologies. His widow, Renate Rose, who spoke briefly before Grossi’s lecture, said that her husband adamantly called for the abolishment of nuclear weapons, insisting that all science should serve the common good and that every scientist should follow his or her conscience.

    In his prefatory remarks, MIT Vice Provost Richard Lester, a former PhD student of David Rose, said that even today, he still feels the influence of his thesis advisor, many decades after they’d worked together. Lester called it a “great honor” to introduce Grossi, noting that the director general was guiding the agency through an especially demanding time. “His presence with us is a reminder that the biggest challenges we face today are truly global challenges, and that international organizations like the IAEA have a central role to play in resolving them.”

    The title of Grossi’s talk was “The IAEA at the Crossroads of History,” and he made a strong case for this being a critical juncture, or “inflection point,” for nuclear power. He started his speech, however, with somewhat of an historical footnote, discussing a letter that Rose sent in 1977 to Sigvard Eklund, IAEA’s then-director general. Rose urged the IAEA to establish a coordinated worldwide program in controlled fusion research. It took a while for the idea to gain traction, but international collaboration in fusion formally began in 1985, eight years after Rose’s proposal. “I thought I would begin with this story, because it shows that cooperation between MIT and the IAEA goes back a long way,” Grossi said.

    2023 David J. Rose Lecture in Nuclear TechnologyVideo: MIT Department of Nuclear Science and Engineering

    Overall, he painted a mostly encouraging picture for the future of nuclear power, largely based on its potential to generate electricity or thermal energy without adding greenhouse gases to the atmosphere. In the face of rapidly-unfolding climate change, Grossi said, “low-carbon nuclear power is now seen as part of [the] solution by an increasing number of people. It’s getting harder to be an environmentalist in good faith who is against nuclear.”

    Public acceptance is growing throughout the world, he added. In Sweden, where people had long protested against radioactive waste transport, a poll now shows that more than 85 percent of the people approve of the nation’s high-level waste handling and disposal facilities. Even Finland’s Green Party has embraced nuclear power, Grossi said. “I don’t think we could imagine a pro-nuclear Green Party five years ago, let alone in 1970 or ’80.”

    Fifty-seven nuclear reactors are being constructed right now in 17 countries. One of the world’s newest facilities, the Barakah nuclear power plant in the United Arab Emirates, “was built on ground rich in oil and natural gas,” he said. In China, the world’s first pebble-bed high-temperature reactor has been operating for two years, offering potential advantages in safety, efficiency, and modularity. For countries that don’t have any nuclear plants, small modular reactors of this kind “offer the chance of a more gradual and affordable way to scale up nuclear power,” Grossi noted. The IAEA is working with countries like Ghana, Kenya, and Senegal to help them develop the safety and regulatory infrastructures that would be needed to build and responsibly operate modular nuclear reactors like this.

    Grossi also discussed a number of lesser-known projects the IAEA is engaged in that have little to do with power generation. Seventy percent of the people in Africa, for example, have no access to radiotherapy to fight cancer. To this end, the IAEA is now helping to provide radiotherapy services in Tanzania and other African countries. At the IAEA’s Marine Environmental Laboratories in Monaco, researchers are using isotopic tracing techniques to study the impact of microplastic pollution on the oceans. The Covid-19 pandemic illustrated the potentially devastating effects of zoonotic diseases that can infect humans with animal-borne viruses. To counteract this threat, the IAEA has sent hundreds of reverse transcription-polymerase chain reaction (RT-PCR) machines — capable of detecting specific genetic materials in pathogens — to more than 130 countries.

    Meanwhile, new risks have emerged from the war in Ukraine, where fighting has raged for a year-and-a-half near the six nuclear reactors in Zaporizhzhia — Europe’s largest nuclear power plant. Early in the conflict, the IAEA sent a team of experts to monitor the plant and to do everything possible to prevent a nuclear accident that would bring “even more misery to people who are already suffering so much,” Grossi said. A major accident, he added, would likely stall investments in nuclear power at a time when its future prospects were starting to brighten.

    At the end of his talk, Grossi returned to the subject of fusion, which he expects to become an important energy source, perhaps in the not-too-distant future. He was encouraged by the visit he’d just had to the MIT spinoff company, Commonwealth Fusion Systems. With regard to fusion, he said, “for the first time, all the pieces of the puzzle are there: the physics, the policy drivers, and the investment.” In fact, an agreement was signed on the day of his lecture, which made MIT’s Plasma Science and Fusion Center an IAEA collaboration center — the second such center in the United States.

    “When I think of all the new forms of collaboration happening today, I imagine Professor Rose would be delighted,” Grossi said. “It really is something to hold [his] letter and know how much progress has been made since 1977 in fusion. I look forward to our collaboration going forward.” More

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    3 Questions: What should scientists and the public know about nuclear waste?

    Many researchers see an expansion of nuclear power, which produces no greenhouse gas emissions from its power generation, as an essential component of strategies to combat global climate change. Yet there is still strong resistance to such expansion, and much of that is based on the issue of how to safely dispose of the resulting radioactive waste material. MIT recently convened a workshop to help nuclear engineers, policymakers, and academics learn about approaches to communicating accurate information about the management of nuclear waste to students and the public, in hopes of allaying fears and encouraging support for the development of new, safer nuclear power plants around the world.

    Organized by Haruko Wainwright, an MIT assistant professor of nuclear science and engineering and of civil and environmental engineering, the workshop included professors, researchers, industry representatives, and government officials, and was designed to emphasize the multidisciplinary nature of the issue. MIT News asked Wainwright to describe the workshop and its conclusions, which she reported on in a paper just published in the Journal of Environmental Radioactivity.

    Q: What was the main objective of the this workshop?

    A: There is a growing concern that, in spite of much excitement about new nuclear reactor deployment and nuclear energy for tackling climate change, relatively less attention is being paid to the thorny question of long-term management of the spent fuel (waste) from these reactors. The government and industry have embraced consent-based siting approaches — that is, finding sites to store and dispose nuclear waste through broad community participation with equity and environmental justice considered. However, many of us in academia feel that those in the industry are missing key facts to communicate to the public.

    Understanding and managing nuclear waste requires a multidisciplinary expertise in nuclear, civil, and chemical engineering as well as environmental and earth sciences. For example, the amount of waste per se, which is always very small for nuclear systems, is not the only factor determining the environmental impacts because some radionuclides in the waste are vastly more mobile than others, and thus can spread farther and more quickly. Nuclear engineers, environmental scientists, and others need to work together to predict the environmental impacts of radionuclides in the waste generated by the new reactors, and to develop waste isolation strategies for an extended time.

    We organized this workshop to ensure this collaborative approach is mastered from the start. A second objective was to develop a blueprint for educating next-generation engineers and scientists about nuclear waste and shaping a more broadly educated group of nuclear and general engineers.

    Q: What kinds of innovative teaching practices were discussed and recommended, and are there examples of these practices in action?

     A: Some participants teach project-based or simulation-based courses of real-world situations. For example, students are divided into several groups representing various stakeholders — such as the public, policymakers, scientists, and governments — and discuss the potential siting of a nuclear waste repository in a community. Such a course helps the students to consider the perspectives of different groups, understand a plurality of points of view, and learn how to communicate their ideas and concerns effectively. Other courses may ask students to synthesize key technical facts and numbers, and to develop a Congressional testimony statement or an opinion article for newspapers. 

    Q: What are some of the biggest misconceptions people have about nuclear waste, and how do you think these misconceptions can be addressed?

    A: The workshop participants agreed that the broader and life-cycle perspectives are important. Within the nuclear energy life cycle, for example, people focus disproportionally on high-level radioactive waste or spent fuel, which has been highly regulated and well managed. Nuclear systems also produce secondary waste, including low-level waste and uranium mining waste, which gets less attention.

    The participants also believe that the nuclear industry has been exemplary in leading the environmental and waste isolation science and technologies. Nuclear waste disposal strategies were developed in the 1950s, much earlier than other hazardous waste which began to receive serious regulation only in the 1970s. In addition, current nuclear waste disposal practices consider the compliance periods of isolation for thousands of years, while other hazardous waste disposal is not required to consider beyond 30 years, although some waste has an essentially infinite longevity, for example, mercury or lead. Finally, there is relatively unregulated waste — such as CO2 from fossil energy, agricultural effluents and other sources — that is released freely into the biosphere and is already impacting our environment. Yet, many people remain more concerned about the relatively well-regulated nuclear waste than about all these unregulated sources.

    Interestingly, many engineers — even nuclear engineers — do not know these facts. We believe that we need to teach students not just cutting-edge technologies, but also broader perspectives, including the history of industries and regulations, as well as environmental science.

    At the same time, we need to move the nuclear community to think more holistically about waste and its environmental impacts from the early stages of design of nuclear systems. We should design new reactors from the “waste up.”  We believe that the nuclear industry should continue to lead waste-management technologies and strategies, and also encourage other industries to adopt lifecycle approaches about their own waste to improve the overall sustainability. More

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    MIT design would harness 40 percent of the sun’s heat to produce clean hydrogen fuel

    MIT engineers aim to produce totally green, carbon-free hydrogen fuel with a new, train-like system of reactors that is driven solely by the sun.

    In a study appearing today in Solar Energy Journal, the engineers lay out the conceptual design for a system that can efficiently produce “solar thermochemical hydrogen.” The system harnesses the sun’s heat to directly split water and generate hydrogen — a clean fuel that can power long-distance trucks, ships, and planes, while in the process emitting no greenhouse gas emissions.

    Today, hydrogen is largely produced through processes that involve natural gas and other fossil fuels, making the otherwise green fuel more of a “grey” energy source when considered from the start of its production to its end use. In contrast, solar thermochemical hydrogen, or STCH, offers a totally emissions-free alternative, as it relies entirely on renewable solar energy to drive hydrogen production. But so far, existing STCH designs have limited efficiency: Only about 7 percent of incoming sunlight is used to make hydrogen. The results so far have been low-yield and high-cost.

    In a big step toward realizing solar-made fuels, the MIT team estimates its new design could harness up to 40 percent of the sun’s heat to generate that much more hydrogen. The increase in efficiency could drive down the system’s overall cost, making STCH a potentially scalable, affordable option to help decarbonize the transportation industry.

    “We’re thinking of hydrogen as the fuel of the future, and there’s a need to generate it cheaply and at scale,” says the study’s lead author, Ahmed Ghoniem, the Ronald C. Crane Professor of Mechanical Engineering at MIT. “We’re trying to achieve the Department of Energy’s goal, which is to make green hydrogen by 2030, at $1 per kilogram. To improve the economics, we have to improve the efficiency and make sure most of the solar energy we collect is used in the production of hydrogen.”

    Ghoniem’s study co-authors are Aniket Patankar, first author and MIT postdoc; Harry Tuller, MIT professor of materials science and engineering; Xiao-Yu Wu of the University of Waterloo; and Wonjae Choi at Ewha Womans University in South Korea.

    Solar stations

    Similar to other proposed designs, the MIT system would be paired with an existing source of solar heat, such as a concentrated solar plant (CSP) — a circular array of hundreds of mirrors that collect and reflect sunlight to a central receiving tower. An STCH system then absorbs the receiver’s heat and directs it to split water and produce hydrogen. This process is very different from electrolysis, which uses electricity instead of heat to split water.

    At the heart of a conceptual STCH system is a two-step thermochemical reaction. In the first step, water in the form of steam is exposed to a metal. This causes the metal to grab oxygen from steam, leaving hydrogen behind. This metal “oxidation” is similar to the rusting of iron in the presence of water, but it occurs much faster. Once hydrogen is separated, the oxidized (or rusted) metal is reheated in a vacuum, which acts to reverse the rusting process and regenerate the metal. With the oxygen removed, the metal can be cooled and exposed to steam again to produce more hydrogen. This process can be repeated hundreds of times.

    The MIT system is designed to optimize this process. The system as a whole resembles a train of box-shaped reactors running on a circular track. In practice, this track would be set around a solar thermal source, such as a CSP tower. Each reactor in the train would house the metal that undergoes the redox, or reversible rusting, process.

    Each reactor would first pass through a hot station, where it would be exposed to the sun’s heat at temperatures of up to 1,500 degrees Celsius. This extreme heat would effectively pull oxygen out of a reactor’s metal. That metal would then be in a “reduced” state — ready to grab oxygen from steam. For this to happen, the reactor would move to a cooler station at temperatures around 1,000 C, where it would be exposed to steam to produce hydrogen.

    Rust and rails

    Other similar STCH concepts have run up against a common obstacle: what to do with the heat released by the reduced reactor as it is cooled. Without recovering and reusing this heat, the system’s efficiency is too low to be practical.

    A second challenge has to do with creating an energy-efficient vacuum where metal can de-rust. Some prototypes generate a vacuum using mechanical pumps, though the pumps are too energy-intensive and costly for large-scale hydrogen production.

    To address these challenges, the MIT design incorporates several energy-saving workarounds. To recover most of the heat that would otherwise escape from the system, reactors on opposite sides of the circular track are allowed to exchange heat through thermal radiation; hot reactors get cooled while cool reactors get heated. This keeps the heat within the system. The researchers also added a second set of reactors that would circle around the first train, moving in the opposite direction. This outer train of reactors would operate at generally cooler temperatures and would be used to evacuate oxygen from the hotter inner train, without the need for energy-consuming mechanical pumps.

    These outer reactors would carry a second type of metal that can also easily oxidize. As they circle around, the outer reactors would absorb oxygen from the inner reactors, effectively de-rusting the original metal, without having to use energy-intensive vacuum pumps. Both reactor trains would  run continuously and would enerate separate streams of pure hydrogen and oxygen.

    The researchers carried out detailed simulations of the conceptual design, and found that it would significantly boost the efficiency of solar thermochemical hydrogen production, from 7 percent, as previous designs have demonstrated, to 40 percent.

    “We have to think of every bit of energy in the system, and how to use it, to minimize the cost,” Ghoniem says. “And with this design, we found that everything can be powered by heat coming from the sun. It is able to use 40 percent of the sun’s heat to produce hydrogen.”

    “If this can be realized, it could drastically change our energy future — namely, enabling hydrogen production, 24/7,” says Christopher Muhich, an assistant professor of chemical engineering at Arizona State University, who was not involved in the research. “The ability to make hydrogen is the linchpin to producing liquid fuels from sunlight.”

    In the next year, the team will be building a prototype of the system that they plan to test in concentrated solar power facilities at laboratories of the Department of Energy, which is currently funding the project.

    “When fully implemented, this system would be housed in a little building in the middle of a solar field,” Patankar explains. “Inside the building, there could be one or more trains each having about 50 reactors. And we think this could be a modular system, where you can add reactors to a conveyor belt, to scale up hydrogen production.”

    This work was supported by the Centers for Mechanical Engineering Research and Education at MIT and SUSTech. More

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    Printing a new approach to fusion power plant materials

    When Alexander O’Brien sent in his application for graduate school at MIT’s Department of Nuclear Science and Engineering, he had a germ of a research idea already brewing. So when he received a phone call from Professor Mingda Li, he shared it: The student from Arkansas wanted to explore the design of materials that could hold nuclear reactors together.

    Li listened to him patiently and then said, “I think you’d be a really good fit for Professor Ju Li,” O’Brien remembers. Ju Li, the Battelle Energy Alliance Professor in Nuclear Engineering, had wanted to explore 3D printing for nuclear reactors and O’Brien seemed like the right candidate. “At that moment I decided to go to MIT if they accepted me,” O’Brien remembers.

    And they did.

    Under the advisement of Ju Li, the fourth-year doctoral student now explores 3D printing of ceramic-metal composites, materials that can be used to construct fusion power plants.

    An early interest in the sciences

    Growing up in Springdale, Arkansas as a self-described “band nerd,” O’Brien was particularly interested in chemistry and physics. It was one thing to mix baking soda and vinegar to make a “volcano” and quite another to understand why that was happening. “I just enjoyed understanding things on a deeper level and being able to figure out how the world works,” he says.

    At the same time, it was difficult to ignore the economics of energy playing out in his own backyard. When Arkansas, a place that had hardly ever seen earthquakes, started registering them in the wake of fracking in neighboring Oklahoma, it was “like a lightbulb moment” for O’Brien. “I knew this was going to create problems down the line, I knew there’s got to be a better way to do [energy],” he says.

    With the idea of energy alternatives simmering on the back burner, O’Brien enrolled for undergraduate studies at the University of Arkansas. He participated in the school’s marching band — “you show up a week before everyone else and there’s 400 people who automatically become your friends” — and enjoyed the social environment that a large state school could offer.

    O’Brien double-majored in chemical engineering and physics and appreciated “the ability to get your hands dirty on machinery to make things work.” Deciding to begin exploring his interest in energy alternatives, O’Brien researched transition metal dichalcogenides, coatings of which could catalyze the hydrogen evolution reaction and more easily create hydrogen gas, a green energy alternative.

    It was shortly after his sophomore year, however, that O’Brien really found his way in the field of energy alternatives — in nuclear engineering. The American Chemical Society was soliciting student applications for summer study of nuclear chemistry in San Jose, California. O’Brien applied and got accepted. “After years of knowing I wanted to work in green energy but not knowing what that looked like, I very quickly fell in love with [nuclear engineering],” he says. That summer also cemented O’Brien’s decision to attend graduate school. “I came away with this idea of ‘I need to go to grad school because I need to know more about this,’” he says.

    O’Brien especially appreciated an independent project, assigned as part of the summer program: He chose to research nuclear-powered spacecraft. In digging deeper, O’Brien discovered the challenges of powering spacecraft — nuclear was the most viable alternative, but it had to work around extraneous radiation sources in space. Getting to explore national laboratories near San Jose sealed the deal. “I got to visit the National Ignition Facility, which is the big fusion center up there, and just seeing that massive facility entirely designed around this one idea of fusion was kind of mind-blowing to me,” O’Brien says.

    A fresh blueprint for fusion power plants

    O’Brien’s current research at MIT’s Department of Nuclear Science and Engineering (NSE) is equally mind-blowing.

    As the design of new fusion devices kicks into gear, it’s becoming increasingly apparent that the materials we have been using just don’t hold up to the higher temperatures and radiation levels in operating environments, O’Brien says. Additive manufacturing, another term for 3D printing, “opens up a whole new realm of possibilities for what you can do with metals, which is exactly what you’re going to need [to build the next generation of fusion power plants],” he says.

    Metals and ceramics by themselves might not do the job of withstanding high temperatures (750 degrees Celsius is the target) and stresses and radiation, but together they might get there. Although such metal matrix composites have been around for decades, they have been impractical for use in reactors because they’re “difficult to make with any kind of uniformity and really limited in size scale,” O’Brien says. That’s because when you try to place ceramic nanoparticles into a pool of molten metal, they’re going to fall out in whichever direction they want. “3D printing quickly changes that story entirely, to the point where if you want to add these nanoparticles in very specific regions, you have the capability to do that,” O’Brien says.

    O’Brien’s work, which forms the basis of his doctoral thesis and a research paper in the journal Additive Manufacturing, involves implanting metals with ceramic nanoparticles. The net result is a metal matrix composite that is an ideal candidate for fusion devices, especially for the vacuum vessel component, which must be able to withstand high temperatures, extremely corrosive molten salts, and internal helium gas from nuclear transmutation.

    O’Brien’s work focuses on nickel superalloys like Inconel 718, which are especially robust candidates because they can withstand higher operating temperatures while retaining strength. Helium embrittlement, where bubbles of helium caused by fusion neutrons lead to weakness and failure, is a problem with Inconel 718, but composites exhibit potential to overcome this challenge.

    To create the composites, first a mechanical milling process coats the ceramic onto the metal particles. The ceramic nanoparticles act as reinforcing strength agents, especially at high temperatures, and make materials last longer. The nanoparticles also absorb helium and radiation defects when uniformly dispersed, which prevent these damage agents from all getting to the grain boundaries.

    The composite then goes through a 3D printing process called powder bed fusion (non-nuclear fusion), where a laser passes over a bed of this powder melting it into desired shapes. “By coating these particles with the ceramic and then only melting very specific regions, we keep the ceramics in the areas that we want, and then you can build up and have a uniform structure,” O’Brien says.

    Printing an exciting future

    The 3D printing of nuclear materials exhibits such promise that O’Brien is looking at pursuing the prospect after his doctoral studies. “The concept of these metal matrix composites and how they can enhance material property is really interesting,” he says. Scaling it up commercially through a startup company is on his radar.

    For now, O’Brien is enjoying research and catching an occasional Broadway show with his wife. While the band nerd doesn’t pick up his saxophone much anymore, he does enjoy driving up to New Hampshire and going backpacking. “That’s my newfound hobby,” O’Brien says, “since I started grad school.” More

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    Tracking US progress on the path to a decarbonized economy

    Investments in new technologies and infrastucture that help reduce greenhouse gas emissions — everything from electric vehicles to heat pumps — are growing rapidly in the United States. Now, a new database enables these investments to be comprehensively monitored in real-time, thereby helping to assess the efficacy of policies designed to spur clean investments and address climate change.

    The Clean Investment Monitor (CIM), developed by a team at MIT’s Center for Energy and Environmental Policy Research (CEEPR) led by Institute Innovation Fellow Brian Deese and in collaboration with the Rhodium Group, an independent research firm, provides a timely and methodologically consistent tracking of all announced public and private investments in the manufacture and deployment of clean technologies and infrastructure in the U.S. The CIM offers a means of assessing the country’s progress in transitioning to a cleaner economy and reducing greenhouse gas emissions.

    In the year from July 1, 2022, to June 30, 2023, data from the CIM show, clean investments nationwide totaled $213 billion. To put that figure in perspective, 18 states in the U.S. have GDPs each lower than $213 billion.

    “As clean technology becomes a larger and larger sector in the United States, its growth will have far-reaching implications — for our economy, for our leadership in innovation, and for reducing our greenhouse gas emissions,” says Deese, who served as the director of the White House National Economic Council from January 2021 to February 2023. “The Clean Investment Monitor is a tool designed to help us understand and assess this growth in a real-time, comprehensive way. Our hope is that the CIM will enhance research and improve public policies designed to accelerate the clean energy transition.”

    Launched on Sept. 13, the CIM shows that the $213 billion invested over the last year reflects a 37 percent increase from the $155 billion invested in the previous 12-month period. According to CIM data, the fastest growth has been in the manufacturing sector, where investment grew 125 percent year-on-year, particularly in electric vehicle and solar manufacturing.

    Beyond manufacturing, the CIM also provides data on investment in clean energy production, such as solar, wind, and nuclear; industrial decarbonization, such as sustainable aviation fuels; and retail investments by households and businesses in technologies like heat pumps and zero-emission vehicles. The CIM’s data goes back to 2018, providing a baseline before the passage of the legislation in 2021 and 2022.

    “We’re really excited to bring MIT’s analytical rigor to bear to help develop the Clean Investment Monitor,” says Christopher Knittel, the George P. Shultz Professor of Energy Economics at the MIT Sloan School of Management and CEEPR’s faculty director. “Bolstered by Brian’s keen understanding of the policy world, this tool is poised to become the go-to reference for anyone looking to understand clean investment flows and what drives them.”

    In 2021 and 2022, the U.S. federal government enacted a series of new laws that together aimed to catalyze the largest-ever national investment in clean energy technologies and related infrastructure. The Clean Investment Monitor can also be used to track how well the legislation is living up to expectations.

    The three pieces of federal legislation — the Infrastructure Investment and Jobs Act, enacted in 2021, and the Inflation Reduction Act (IRA) and the CHIPS and Science Act, both enacted in 2022 — provide grants, loans, loan guarantees, and tax incentives to spur investments in technologies that reduce greenhouse gas emissions.

    The effectiveness of the legislation in hastening the U.S. transition to a clean economy will be crucial in determining whether the country reaches its goal of reducing greenhouse gas emissions by 50 percent to 52 percent below 2005 levels in 2030. An analysis earlier this year estimated that the IRA will lead to a 43 percent to 48 percent decline in economywide emissions below 2005 levels by 2035, compared with 27 percent to 35 percent in a reference scenario without the law’s provisions, helping bring the U.S. goal closer in reach.

    The Clean Investment Monitor is available at cleaninvestmentmonitor.org. More

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    Study suggests energy-efficient route to capturing and converting CO2

    In the race to draw down greenhouse gas emissions around the world, scientists at MIT are looking to carbon-capture technologies to decarbonize the most stubborn industrial emitters.

    Steel, cement, and chemical manufacturing are especially difficult industries to decarbonize, as carbon and fossil fuels are inherent ingredients in their production. Technologies that can capture carbon emissions and convert them into forms that feed back into the production process could help to reduce the overall emissions from these “hard-to-abate” sectors.

    But thus far, experimental technologies that capture and convert carbon dioxide do so as two separate processes, that themselves require a huge amount of energy to run. The MIT team is looking to combine the two processes into one integrated and far more energy-efficient system that could potentially run on renewable energy to both capture and convert carbon dioxide from concentrated, industrial sources.

    In a study appearing today in ACS Catalysis, the researchers reveal the hidden functioning of how carbon dioxide can be both captured and converted through a single electrochemical process. The process involves using an electrode to attract carbon dioxide released from a sorbent, and to convert it into a reduced, reusable form.

    Others have reported similar demonstrations, but the mechanisms driving the electrochemical reaction have remained unclear. The MIT team carried out extensive experiments to determine that driver, and found that, in the end, it came down to the partial pressure of carbon dioxide. In other words, the more pure carbon dioxide that makes contact with the electrode, the more efficiently the electrode can capture and convert the molecule.

    Knowledge of this main driver, or “active species,” can help scientists tune and optimize similar electrochemical systems to efficiently capture and convert carbon dioxide in an integrated process.

    The study’s results imply that, while these electrochemical systems would probably not work for very dilute environments (for instance, to capture and convert carbon emissions directly from the air), they would be well-suited to the highly concentrated emissions generated by industrial processes, particularly those that have no obvious renewable alternative.

    “We can and should switch to renewables for electricity production. But deeply decarbonizing industries like cement or steel production is challenging and will take a longer time,” says study author Betar Gallant, the Class of 1922 Career Development Associate Professor at MIT. “Even if we get rid of all our power plants, we need some solutions to deal with the emissions from other industries in the shorter term, before we can fully decarbonize them. That’s where we see a sweet spot, where something like this system could fit.”

    The study’s MIT co-authors are lead author and postdoc Graham Leverick and graduate student Elizabeth Bernhardt, along with Aisyah Illyani Ismail, Jun Hui Law, Arif Arifutzzaman, and Mohamed Kheireddine Aroua of Sunway University in Malaysia.

    Breaking bonds

    Carbon-capture technologies are designed to capture emissions, or “flue gas,” from the smokestacks of power plants and manufacturing facilities. This is done primarily using large retrofits to funnel emissions into chambers filled with a “capture” solution — a mix of amines, or ammonia-based compounds, that chemically bind with carbon dioxide, producing a stable form that can be separated out from the rest of the flue gas.

    High temperatures are then applied, typically in the form of fossil-fuel-generated steam, to release the captured carbon dioxide from its amine bond. In its pure form, the gas can then be pumped into storage tanks or underground, mineralized, or further converted into chemicals or fuels.

    “Carbon capture is a mature technology, in that the chemistry has been known for about 100 years, but it requires really large installations, and is quite expensive and energy-intensive to run,” Gallant notes. “What we want are technologies that are more modular and flexible and can be adapted to more diverse sources of carbon dioxide. Electrochemical systems can help to address that.”

    Her group at MIT is developing an electrochemical system that both recovers the captured carbon dioxide and converts it into a reduced, usable product. Such an integrated system, rather than a decoupled one, she says, could be entirely powered with renewable electricity rather than fossil-fuel-derived steam.

    Their concept centers on an electrode that would fit into existing chambers of carbon-capture solutions. When a voltage is applied to the electrode, electrons flow onto the reactive form of carbon dioxide and convert it to a product using protons supplied from water. This makes the sorbent available to bind more carbon dioxide, rather than using steam to do the same.

    Gallant previously demonstrated this electrochemical process could work to capture and convert carbon dioxide into a solid carbonate form.

    “We showed that this electrochemical process was feasible in very early concepts,” she says. “Since then, there have been other studies focused on using this process to attempt to produce useful chemicals and fuels. But there’s been inconsistent explanations of how these reactions work, under the hood.”

    Solo CO2

    In the new study, the MIT team took a magnifying glass under the hood to tease out the specific reactions driving the electrochemical process. In the lab, they generated amine solutions that resemble the industrial capture solutions used to extract carbon dioxide from flue gas. They methodically altered various properties of each solution, such as the pH, concentration, and type of amine, then ran each solution past an electrode made from silver — a metal that is widely used in electrolysis studies and known to efficiently convert carbon dioxide to carbon monoxide. They then measured the concentration of carbon monoxide that was converted at the end of the reaction, and compared this number against that of every other solution they tested, to see which parameter had the most influence on how much carbon monoxide was produced.

    In the end, they found that what mattered most was not the type of amine used to initially capture carbon dioxide, as many have suspected. Instead, it was the concentration of solo, free-floating carbon dioxide molecules, which avoided bonding with amines but were nevertheless present in the solution. This “solo-CO2” determined the concentration of carbon monoxide that was ultimately produced.

    “We found that it’s easier to react this ‘solo’ CO2, as compared to CO2 that has been captured by the amine,” Leverick offers. “This tells future researchers that this process could be feasible for industrial streams, where high concentrations of carbon dioxide could efficiently be captured and converted into useful chemicals and fuels.”

    “This is not a removal technology, and it’s important to state that,” Gallant stresses. “The value that it does bring is that it allows us to recycle carbon dioxide some number of times while sustaining existing industrial processes, for fewer associated emissions. Ultimately, my dream is that electrochemical systems can be used to facilitate mineralization, and permanent storage of CO2 — a true removal technology. That’s a longer-term vision. And a lot of the science we’re starting to understand is a first step toward designing those processes.”

    This research is supported by Sunway University in Malaysia. More

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    Fast-tracking fusion energy’s arrival with AI and accessibility

    As the impacts of climate change continue to grow, so does interest in fusion’s potential as a clean energy source. While fusion reactions have been studied in laboratories since the 1930s, there are still many critical questions scientists must answer to make fusion power a reality, and time is of the essence. As part of their strategy to accelerate fusion energy’s arrival and reach carbon neutrality by 2050, the U.S. Department of Energy (DoE) has announced new funding for a project led by researchers at MIT’s Plasma Science and Fusion Center (PSFC) and four collaborating institutions.

    Cristina Rea, a research scientist and group leader at the PSFC, will serve as the primary investigator for the newly funded three-year collaboration to pilot the integration of fusion data into a system that can be read by AI-powered tools. The PSFC, together with scientists from the College of William and Mary, the University of Wisconsin at Madison, Auburn University, and the nonprofit HDF Group, plan to create a holistic fusion data platform, the elements of which could offer unprecedented access for researchers, especially underrepresented students. The project aims to encourage diverse participation in fusion and data science, both in academia and the workforce, through outreach programs led by the group’s co-investigators, of whom four out of five are women. 

    The DoE’s award, part of a $29 million funding package for seven projects across 19 institutions, will support the group’s efforts to distribute data produced by fusion devices like the PSFC’s Alcator C-Mod, a donut-shaped “tokamak” that utilized powerful magnets to control and confine fusion reactions. Alcator C-Mod operated from 1991 to 2016 and its data are still being studied, thanks in part to the PSFC’s commitment to the free exchange of knowledge.

    Currently, there are nearly 50 public experimental magnetic confinement-type fusion devices; however, both historical and current data from these devices can be difficult to access. Some fusion databases require signing user agreements, and not all data are catalogued and organized the same way. Moreover, it can be difficult to leverage machine learning, a class of AI tools, for data analysis and to enable scientific discovery without time-consuming data reorganization. The result is fewer scientists working on fusion, greater barriers to discovery, and a bottleneck in harnessing AI to accelerate progress.

    The project’s proposed data platform addresses technical barriers by being FAIR — Findable, Interoperable, Accessible, Reusable — and by adhering to UNESCO’s Open Science (OS) recommendations to improve the transparency and inclusivity of science; all of the researchers’ deliverables will adhere to FAIR and OS principles, as required by the DoE. The platform’s databases will be built using MDSplusML, an upgraded version of the MDSplus open-source software developed by PSFC researchers in the 1980s to catalogue the results of Alcator C-Mod’s experiments. Today, nearly 40 fusion research institutes use MDSplus to store and provide external access to their fusion data. The release of MDSplusML aims to continue that legacy of open collaboration.

    The researchers intend to address barriers to participation for women and disadvantaged groups not only by improving general access to fusion data, but also through a subsidized summer school that will focus on topics at the intersection of fusion and machine learning, which will be held at William and Mary for the next three years.

    Of the importance of their research, Rea says, “This project is about responding to the fusion community’s needs and setting ourselves up for success. Scientific advancements in fusion are enabled via multidisciplinary collaboration and cross-pollination, so accessibility is absolutely essential. I think we all understand now that diverse communities have more diverse ideas, and they allow faster problem-solving.”

    The collaboration’s work also aligns with vital areas of research identified in the International Atomic Energy Agency’s “AI for Fusion” Coordinated Research Project (CRP). Rea was selected as the technical coordinator for the IAEA’s CRP emphasizing community engagement and knowledge access to accelerate fusion research and development. In a letter of support written for the group’s proposed project, the IAEA stated that, “the work [the researchers] will carry out […] will be beneficial not only to our CRP but also to the international fusion community in large.”

    PSFC Director and Hitachi America Professor of Engineering Dennis Whyte adds, “I am thrilled to see PSFC and our collaborators be at the forefront of applying new AI tools while simultaneously encouraging and enabling extraction of critical data from our experiments.”

    “Having the opportunity to lead such an important project is extremely meaningful, and I feel a responsibility to show that women are leaders in STEM,” says Rea. “We have an incredible team, strongly motivated to improve our fusion ecosystem and to contribute to making fusion energy a reality.” More