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      in Energy

      To decarbonize the chemical industry, electrify it

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      The chemical industry is the world’s largest industrial energy consumer and the third-largest source of industrial emissions, according to the International Energy Agency. In 2019, the industrial sector as a whole was responsible for 24 percent of global greenhouse gas emissions. And yet, as the world races to find pathways to decarbonization, the chemical industry has been largely untouched.

      “When it comes to climate action and dealing with the emissions that come from the chemical sector, the slow pace of progress is partly technical and partly driven by the hesitation on behalf of policymakers to overly impact the economic competitiveness of the sector,” says Dharik Mallapragada, a principal research scientist at the MIT Energy Initiative.

      With so many of the items we interact with in our daily lives — from soap to baking soda to fertilizer — deriving from products of the chemical industry, the sector has become a major source of economic activity and employment for many nations, including the United States and China. But as the global demand for chemical products continues to grow, so do the industry’s emissions.

      New sustainable chemical production methods need to be developed and deployed and current emission-intensive chemical production technologies need to be reconsidered, urge the authors of a new paper published in Joule. Researchers from DC-MUSE, a multi-institution research initiative, argue that electrification powered by low-carbon sources should be viewed more broadly as a viable decarbonization pathway for the chemical industry. In this paper, they shine a light on different potential methods to do just that.

      “Generally, the perception is that electrification can play a role in this sector — in a very narrow sense — in that it can replace fossil fuel combustion by providing the heat that the combustion is providing,” says Mallapragada, a member of DC-MUSE. “What we argue is that electrification could be much more than that.”

      The researchers outline four technological pathways — ranging from more mature, near-term options to less technologically mature options in need of research investment — and present the opportunities and challenges associated with each.

      The first two pathways directly replace fossil fuel-produced heat (which facilitates the reactions inherent in chemical production) with electricity or electrochemically generated hydrogen. The researchers suggest that both options could be deployed now and potentially be used to retrofit existing facilities. Electrolytic hydrogen is also highlighted as an opportunity to replace fossil fuel-produced hydrogen (a process that emits carbon dioxide) as a critical chemical feedstock. In 2020, fossil-based hydrogen supplied nearly all hydrogen demand (90 megatons) in the chemical and refining industries — hydrogen’s largest consumers.

      The researchers note that increasing the role of electricity in decarbonizing the chemical industry will directly affect the decarbonization of the power grid. They stress that to successfully implement these technologies, their operation must coordinate with the power grid in a mutually beneficial manner to avoid overburdening it. “If we’re going to be serious about decarbonizing the sector and relying on electricity for that, we have to be creative in how we use it,” says Mallapragada. “Otherwise we run the risk of having addressed one problem, while creating a massive problem for the grid in the process.”

      Electrified processes have the potential to be much more flexible than conventional fossil fuel-driven processes. This can reduce the cost of chemical production by allowing producers to shift electricity consumption to times when the cost of electricity is low. “Process flexibility is particularly impactful during stressed power grid conditions and can help better accommodate renewable generation resources, which are intermittent and are often poorly correlated with daily power grid cycles,” says Yury Dvorkin, an associate research professor at the Johns Hopkins Ralph O’Connor Sustainable Energy Institute. “It’s beneficial for potential adopters because it can help them avoid consuming electricity during high-price periods.”

      Dvorkin adds that some intermediate energy carriers, such as hydrogen, can potentially be used as highly efficient energy storage for day-to-day operations and as long-term energy storage. This would help support the power grid during extreme events when traditional and renewable generators may be unavailable. “The application of long-duration storage is of particular interest as this is a key enabler of a low-emissions society, yet not widespread beyond pumped hydro units,” he says. “However, as we envision electrified chemical manufacturing, it is important to ensure that the supplied electricity is sourced from low-emission generators to prevent emissions leakages from the chemical to power sector.” 

      The next two pathways introduced — utilizing electrochemistry and plasma — are less technologically mature but have the potential to replace energy- and carbon-intensive thermochemical processes currently used in the industry. By adopting electrochemical processes or plasma-driven reactions instead, chemical transformations can occur at lower temperatures and pressures, potentially enhancing efficiency. “These reaction pathways also have the potential to enable more flexible, grid-responsive plants and the deployment of modular manufacturing plants that leverage distributed chemical feedstocks such as biomass waste — further enhancing sustainability in chemical manufacturing,” says Miguel Modestino, the director of the Sustainable Engineering Initiative at the New York University Tandon School of Engineering.

      A large barrier to deep decarbonization of chemical manufacturing relates to its complex, multi-product nature. But, according to the researchers, each of these electricity-driven pathways supports chemical industry decarbonization for various feedstock choices and end-of-life disposal decisions. Each should be evaluated in comprehensive techno-economic and environmental life cycle assessments to weigh trade-offs and establish suitable cost and performance metrics.

      Regardless of the pathway chosen, the researchers stress the need for active research and development and deployment of these technologies. They also emphasize the importance of workforce training and development running in parallel to technology development. As André Taylor, the director of DC-MUSE, explains, “There is a healthy skepticism in the industry regarding electrification and adoption of these technologies, as it involves processing chemicals in a new way.” The workforce at different levels of the industry hasn’t necessarily been exposed to ideas related to the grid, electrochemistry, or plasma. The researchers say that workforce training at all levels will help build greater confidence in these different solutions and support customer-driven industry adoption.

      “There’s no silver bullet, which is kind of the standard line with all climate change solutions,” says Mallapragada. “Each option has pros and cons, as well as unique advantages. But being aware of the portfolio of options in which you can use electricity allows us to have a better chance of success and of reducing emissions — and doing so in a way that supports grid decarbonization.”

      This work was supported, in part, by the Alfred P. Sloan Foundation. More

    • 50 Shares199 Views

      in Environment

      Preparing to be prepared

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      The Kobe earthquake of 1995 devastated one of Japan’s major cities, leaving over 6,000 people dead while destroying or making unusable hundreds of thousands of structures. It toppled elevated freeway segments, wrecked mass transit systems, and damaged the city’s port capacity.

      “It was a shock to a highly engineered, urban city to have undergone that much destruction,” says Miho Mazereeuw, an associate professor at MIT who specializes in disaster resilience.

      Even in a country like Japan, with advanced engineering, and policies in place to update safety codes, natural forces can overwhelm the built environment.

      “There’s nothing that’s ever guaranteed safe,” says Mazereeuw, an associate professor of architecture and urbanism in MIT’s Department of Architecture and director of the Urban Risk Lab. “We [think that] through technology and engineering we can solve things and fight nature. Whereas it’s really that we’re living with nature. We’re part of this natural ecosystem.”

      That’s why Mazereeuw’s work on disaster resilience focuses on plans, people, and policies, well as technology and design to prepare for the future. In the Urban Risk Lab, which Mazereeuw founded, several projects are based on the design of physical objects, spaces, and software platforms, but many others involve community-level efforts, so that local governments have workable procedures in case of emergency.

      “What we can do for ourselves and each other is have plans in place so that if something does happen, the level of chaos and fear can be reduced and we can all be there to help each other through,” Mazereeuw says. When it comes to disaster preparedness, she adds, “Definitely a lot of it is on the built environment side of things, but a lot of it is also social, making sure that in our communities, we know who would need help, and we have those kinds of relationships beforehand.”

      The Kobe earthquake was a highly influential event for Mazereeuw. She has researched the response to it and has a book coming out about natural disasters, policies, and design in Japan. Beyond that, the Kobe event helped reinforce her sense that when it comes to disaster preparedness, progress can be made many ways. For her research, teaching, and innovative work at the Urban Risk Lab, Mazereeuw was granted tenure at MIT last year.

      Two cultures grappling with nature

      Mazereeuw has one Dutch parent and one Japanese parent, and both cultures helped produce her interest in managing natural forces. On her Dutch side, many family friends were involved with local government and water management — practically an existential issue in a country that sits largely below sea level.

      Mazereeuw’s parents, however, were living in Japan in 1995. And while they happened to be away while the Kobe earthquake hit, her Japanese links helped spur her interest in studying the event and its aftermath.

      “I think that was a wake-up call for me, too, about how we need to plan and design cities to reduce the impact of chaos at the time of disasters,” Mazereeuw says.

      Mazereeuw earned her undergraduate degree from Wesleyan University, majoring in earth and environmental sciences and in studio art. After working in an architectural office in Tokyo, she decided to attend graduate school, receiving her dual masters from Harvard University’s Graduate School of Design, with a thesis about Kobe and disaster readiness. She then worked in architecture offices, including the Office of Metropolitan Architecture in Rotterdam, but returned to academia to work on climate change and disaster resilience.   

      Mazereeuw’s book, “Design Before Disaster,” explores this subject in depth, from urban planning to coastal-safety strategies to community-based design frameworks, and is forthcoming from the University of Virginia Press.

      Since joining the MIT faculty, Mazereeuw has also devoted significant time to the launch and growth of the Urban Risk Lab, an interdisciplinary group working on an array of disaster-preparedness efforts. One such project has seen lab members work with local officials from many places — including Massachusetts, California, Georgia, and Puerto Rico — to add to their own disaster-preparedness planning.

      A plan developed by local officials with community input, Mazereeuw suggests, will likely function better than one produced by, say, consultants from outside a community, as she has seen happen many times: “A report on a dusty shelf isn’t actionable,” she says. “This way it’s a decision-making process by the people involved.”

      In a project based on physical design, the Urban Risk Lab has also been working with the U.S. Federal Emergency Management Agency on an effort to produce temporary postdisaster housing for the OCONUS region (Alaska, Hawaii, and other U.S. overseas territories). The lab’s design, called SEED (Shelter for Emergency Expansion Design), features a house that is compact enough to be shipped anywhere and unfolds on-site, while being sturdy enough to withstand follow-up events such as hurricanes, and durable enough to be incorporated into longer-term housing designs.

      “We felt it had to be really, really good quality, so it would be a resource, rather than something temporary that disintegrates after five years,” Mazereeuw says. “It’s built to be a small safety shelter but also could be part of a permanent house.”

      A grand challenge, and a plethora of projects

      Mazereeuw is also a co-lead of one of the five multiyear projects selected in 2022 to move forward as part of MIT’s Climate Grand Challenges competition. Along with Kerry Emanuel and Paul O’Gorman, of MIT’s Department of Earth, Atmospheric and Planetary Sciences, Mazereeuw will help direct a project advancing climate modeling by quantifying the risk of extreme weather events for specific locations. The idea is to help vulnerable urban centers and other communities prepare for such events.

      The Urban Risk Lab has many other kinds of projects in its portfolio, following Mazereeuw’s own interest in conceptualizing disaster preparedness broadly. In collaboration with officials in Japan, and with support from Google, lab members worked on interactive, real-time flood-mapping software, in which residents can help officials know where local flooding has reached emergency levels. The researchers also created an AI module to prioritize the information.

      “Residents really have the most localized information, which you can’t get from a satellite,” Mazereeuw says. “They’re also the ones who learn about it first, so they have a lot of information that emergency managers can use for their response. The program is really meant to be a conduit between the efforts of emergency managers and residents, so that information flow can go in both directions.”

      Lab members in the past have also mapped the porosity of the MIT campus, another effort that used firsthand knowledge. Additionally, lab members are currently engaging with a university in Chile to design tsunami response strategies; developing a community mapping toolkit for resilience planning in Thailand and Vietnam; and working with Mass Audubon to design interactive furniture for children to learn about ecology.  

      “Everything is tied together with this interest in raising awareness and engaging people,” Mazereeuw says.

      That also describes Mazereeuw’s attitude about participation in the Urban Risk Lab, a highly cross-disciplinary place with members who have gravitated to it from around MIT.

      “Our lab is extremely interdisciplinary,” Mazereeuw says. “We have students coming in from all over, from different parts of campus. We have computer science and engineering students coming into the lab and staying to get their graduate degrees alongside many architecture and planning students.” The lab also has five full-time researchers — Aditya Barve, Larisa Ovalles, Mayank Ojha, Eakapob Huangthananpan, and Saeko Baird — who lead their own projects and research groups.

      What those lab members have in common is a willingness to think proactively about reducing disaster impacts. Being prepared for those events itself requires preparation.

      Even in the design world, Mazereeuw says, “People are reactive. Because something has happened, that’s when they go in to help. But I think we can have a larger impact by anticipating and designing for these issues beforehand.” More

    • 175 Shares189 Views

      in Energy

      Computers that power self-driving cars could be a huge driver of global carbon emissions

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      In the future, the energy needed to run the powerful computers on board a global fleet of autonomous vehicles could generate as many greenhouse gas emissions as all the data centers in the world today.

      That is one key finding of a new study from MIT researchers that explored the potential energy consumption and related carbon emissions if autonomous vehicles are widely adopted.

      The data centers that house the physical computing infrastructure used for running applications are widely known for their large carbon footprint: They currently account for about 0.3 percent of global greenhouse gas emissions, or about as much carbon as the country of Argentina produces annually, according to the International Energy Agency. Realizing that less attention has been paid to the potential footprint of autonomous vehicles, the MIT researchers built a statistical model to study the problem. They determined that 1 billion autonomous vehicles, each driving for one hour per day with a computer consuming 840 watts, would consume enough energy to generate about the same amount of emissions as data centers currently do.

      The researchers also found that in over 90 percent of modeled scenarios, to keep autonomous vehicle emissions from zooming past current data center emissions, each vehicle must use less than 1.2 kilowatts of power for computing, which would require more efficient hardware. In one scenario — where 95 percent of the global fleet of vehicles is autonomous in 2050, computational workloads double every three years, and the world continues to decarbonize at the current rate — they found that hardware efficiency would need to double faster than every 1.1 years to keep emissions under those levels.

      “If we just keep the business-as-usual trends in decarbonization and the current rate of hardware efficiency improvements, it doesn’t seem like it is going to be enough to constrain the emissions from computing onboard autonomous vehicles. This has the potential to become an enormous problem. But if we get ahead of it, we could design more efficient autonomous vehicles that have a smaller carbon footprint from the start,” says first author Soumya Sudhakar, a graduate student in aeronautics and astronautics.

      Sudhakar wrote the paper with her co-advisors Vivienne Sze, associate professor in the Department of Electrical Engineering and Computer Science (EECS) and a member of the Research Laboratory of Electronics (RLE); and Sertac Karaman, associate professor of aeronautics and astronautics and director of the Laboratory for Information and Decision Systems (LIDS). The research appears today in the January-February issue of IEEE Micro.

      Modeling emissions

      The researchers built a framework to explore the operational emissions from computers on board a global fleet of electric vehicles that are fully autonomous, meaning they don’t require a back-up human driver.

      The model is a function of the number of vehicles in the global fleet, the power of each computer on each vehicle, the hours driven by each vehicle, and the carbon intensity of the electricity powering each computer.

      “On its own, that looks like a deceptively simple equation. But each of those variables contains a lot of uncertainty because we are considering an emerging application that is not here yet,” Sudhakar says.

      For instance, some research suggests that the amount of time driven in autonomous vehicles might increase because people can multitask while driving and the young and the elderly could drive more. But other research suggests that time spent driving might decrease because algorithms could find optimal routes that get people to their destinations faster.

      In addition to considering these uncertainties, the researchers also needed to model advanced computing hardware and software that doesn’t exist yet.

      To accomplish that, they modeled the workload of a popular algorithm for autonomous vehicles, known as a multitask deep neural network because it can perform many tasks at once. They explored how much energy this deep neural network would consume if it were processing many high-resolution inputs from many cameras with high frame rates, simultaneously.

      When they used the probabilistic model to explore different scenarios, Sudhakar was surprised by how quickly the algorithms’ workload added up.

      For example, if an autonomous vehicle has 10 deep neural networks processing images from 10 cameras, and that vehicle drives for one hour a day, it will make 21.6 million inferences each day. One billion vehicles would make 21.6 quadrillion inferences. To put that into perspective, all of Facebook’s data centers worldwide make a few trillion inferences each day (1 quadrillion is 1,000 trillion).

      “After seeing the results, this makes a lot of sense, but it is not something that is on a lot of people’s radar. These vehicles could actually be using a ton of computer power. They have a 360-degree view of the world, so while we have two eyes, they may have 20 eyes, looking all over the place and trying to understand all the things that are happening at the same time,” Karaman says.

      Autonomous vehicles would be used for moving goods, as well as people, so there could be a massive amount of computing power distributed along global supply chains, he says. And their model only considers computing — it doesn’t take into account the energy consumed by vehicle sensors or the emissions generated during manufacturing.

      Keeping emissions in check

      To keep emissions from spiraling out of control, the researchers found that each autonomous vehicle needs to consume less than 1.2 kilowatts of energy for computing. For that to be possible, computing hardware must become more efficient at a significantly faster pace, doubling in efficiency about every 1.1 years.

      One way to boost that efficiency could be to use more specialized hardware, which is designed to run specific driving algorithms. Because researchers know the navigation and perception tasks required for autonomous driving, it could be easier to design specialized hardware for those tasks, Sudhakar says. But vehicles tend to have 10- or 20-year lifespans, so one challenge in developing specialized hardware would be to “future-proof” it so it can run new algorithms.

      In the future, researchers could also make the algorithms more efficient, so they would need less computing power. However, this is also challenging because trading off some accuracy for more efficiency could hamper vehicle safety.

      Now that they have demonstrated this framework, the researchers want to continue exploring hardware efficiency and algorithm improvements. In addition, they say their model can be enhanced by characterizing embodied carbon from autonomous vehicles — the carbon emissions generated when a car is manufactured — and emissions from a vehicle’s sensors.

      While there are still many scenarios to explore, the researchers hope that this work sheds light on a potential problem people may not have considered.

      “We are hoping that people will think of emissions and carbon efficiency as important metrics to consider in their designs. The energy consumption of an autonomous vehicle is really critical, not just for extending the battery life, but also for sustainability,” says Sze.

      This research was funded, in part, by the National Science Foundation and the MIT-Accenture Fellowship. More

    • 113 Shares159 Views

      in Energy

      A new way to assess radiation damage in reactors

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      A new method could greatly reduce the time and expense needed for certain important safety checks in nuclear power reactors. The approach could save money and increase total power output in the short run, and it might increase plants’ safe operating lifetimes in the long run.

      One of the most effective ways to control greenhouse gas emissions, many analysts argue, is to prolong the lifetimes of existing nuclear power plants. But extending these plants beyond their originally permitted operating lifetimes requires monitoring the condition of many of their critical components to ensure that damage from heat and radiation has not led, and will not lead, to unsafe cracking or embrittlement.

      Today, testing of a reactor’s stainless steel components — which make up much of the plumbing systems that prevent heat buildup, as well as many other parts — requires removing test pieces, known as coupons, of the same kind of steel that are left adjacent to the actual components so they experience the same conditions. Or, it requires the removal of a tiny piece of the actual operating component. Both approaches are done during costly shutdowns of the reactor, prolonging these scheduled outages and costing millions of dollars per day.

      Now, researchers at MIT and elsewhere have come up with a new, inexpensive, hands-off test that can produce similar information about the condition of these reactor components, with far less time required during a shutdown. The findings are reported today in the journal Acta Materiala in a paper by MIT professor of nuclear science and engineering Michael Short; Saleem Al Dajani ’19 SM ’20, who did his master’s work at MIT on this project and is now a doctoral student at the King Abdullah University of Science and Technology (KAUST) in Saudi Arabia; and 13 others at MIT and other institutions.

      The test involves aiming laser beams at the stainless steel material, which generates surface acoustic waves (SAWs) on the surface. Another set of laser beams is then used to detect and measure the frequencies of these SAWs. Tests on material aged identically to nuclear power plants showed that the waves produced a distinctive double-peaked spectral signature when the material was degraded.

      Short and Al Dajani embarked on the process in 2018, looking for a more rapid way to detect a specific kind of degradation, called spinodal decomposition, that can take place in austenitic stainless steel, which is used for components such as the 2- to 3-foot wide pipes that carry coolant water to and from the reactor core. This process can lead to embrittlement, cracking, and potential failure in the event of an emergency.

      While spinodal decomposition is not the only type of degradation that can occur in reactor components, it is a primary concern for the lifetime and sustainability of nuclear reactors, Short says.

      “We were looking for a signal that can link material embrittlement with properties we can measure, that can be used to estimate lifetimes of structural materials,” Al Dajani says.

      They decided to try a technique Short and his students and collaborators had expanded upon, called transient grating spectroscopy, or TGS, on samples of reactor materials known to have experienced spinodal decomposition as a result of their reactor-like thermal aging history. The method uses laser beams to stimulate, and then measure, SAWs on a material. The idea was that the decomposition should slow down the rate of heat flow through the material, that slowdown would be detectable by the TGS method.

      However, it turns out there was no such slowdown. “We went in with a hypothesis about what we would see, and we were wrong,” Short says.

      That’s often the way things work out in science, he says. “You go in guns blazing, looking for a certain thing, for a great reason, and you turn out to be wrong. But if you look carefully, you find other patterns in the data that reveal what nature actually has to say.”

      Instead, what showed up in the data was that, while a material would usually produce a single frequency peak for the material’s SAWs, in the degraded samples there was a splitting into two peaks.

      “It was a very clear pattern in the data,” Short recalls. “We just didn’t expect it, but it was right there screaming at us in the measurements.”

      Cast austenitic stainless steels like those used in reactor components are what’s known as duplex steels, actually a mixture of two different crystal structures in the same material by design. But while one of the two types is quite impervious to spinodal decomposition, the other is quite vulnerable to it. When the material starts to degrade, the difference shows up in the different frequency responses of the material, which is what the team found in their data.

      That finding was a total surprise, though. “Some of my current and former students didn’t believe it was happening,” Short says. “We were unable to convince our own team this was happening, with the initial statistics we had.” So, they went back and carried out further tests, which continued to strengthen the significance of the results. They reached a point where the confidence level was 99.9 percent that spinodal decomposition was indeed coincident with the wave peak separation.

      “Our discussions with those who opposed our initial hypotheses ended up taking our work to the next level,” Al Dajani says.

      The tests they did used large lab-based lasers and optical systems, so the next step, which the researchers are hard at work on, is miniaturizing the whole system into something that can be an easily portable test kit to use to check reactor components on-site, reducing the length of shutdowns. “We’re making great strides, but we still have some way to go,” he says.

      But when they achieve that next step, he says, it could make a significant difference. “Every day that your nuclear plant goes down, for a typical gigawatt-scale reactor, you lose about $2 million a day in lost electricity,” Al Dajani says, “so shortening outages is a huge thing in the industry right now.”

      He adds that the team’s goal was to find ways to enable existing plants to operate longer: “Let them be down for less time and be as safe or safer than they are right now — not cutting corners, but using smart science to get us the same information with far less effort.” And that’s what this new technique seems to offer.

      Short hopes that this could help to enable the extension of power plant operating licenses for some additional decades without compromising safety, by enabling frequent, simple and inexpensive testing of the key components. Existing, large-scale plants “generate just shy of a billion dollars in carbon-free electricity per plant each year,” he says, whereas bringing a new plant online can take more than a decade. “To bridge that gap, keeping our current nukes online is the single biggest thing we can do to fight climate change.”

      The team included researchers at MIT, Idaho National Laboratory, Manchester University and Imperial College London in the UK, Oak Ridge National Laboratory, the Electric Power Research Institute, Northeastern University, the University of California at Berkeley, and KAUST. The work was supported by the International Design Center at MIT and the Singapore University of Technology and Design, the U.S. Nuclear Regulatory Commission, and the U.S. National Science Foundation. More

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      in Environment

      Sustainable supply chains put the customer first

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      When we consider the supply chain, we typically think of factories, ships, trucks, and warehouses. Yet, the customer side is equally important, especially in efforts to make our distribution networks more sustainable. Customers are an untapped resource in building sustainability, says Josué C. Velázquez Martínez, a research scientist at MIT Center for Transportation and Logistics. 

      Velázquez Martínez, who is director of MIT’s Sustainable Supply Chain Lab, investigates how customer-facing supply chains can be made more environmentally and socially sustainable. One way is a Green Button project that explores how to optimize e-commerce delivery schedules to reduce carbon emissions and persuade customers to use less carbon-intensive four- or five-day shipping options instead of one or two days. Velázquez Martínez has also launched the MIT Low Income Firms Transformation (LIFT) Lab that is researching ways to improve micro-retailer supply chains in the developing world to provide owners with the necessary tools for survival.  

      “The definition of sustainable supply chain keeps evolving because things that were sustainable 20 to 30 years ago are not as sustainable now,” says Velázquez Martínez. “Today, there are more companies that are capturing information to build strategies for environmental, economic, and social sustainability. They are investing in alternative energy and other solutions to make the supply chain more environmentally friendly and are tracking their suppliers and identifying key vulnerabilities. A big part of this is an attempt to create fairer conditions for people who work in supply chains or are dependent on them.”

      Play video

      The move toward sustainable supply chain is being driven as much by people as by companies, whether they are playing the role of selective consumer or voting citizens. The consumer aspect is often overlooked, says Velázquez Martínez. “Consumers are the ones who move the supply chain. We are looking at how companies can provide transparency to involve customers in their sustainability strategy.” 

      Proposed solutions for sustainability are not always as effective as promised. Some fashion rental schemes fall into this category, says Velázquez Martínez. “There are many new rental companies that are trying to get more use out of clothes to offset the emissions associated with production. We recently researched the environmental impact of monthly subscription models where consumers pay a fee to receive clothes for a month before returning them, as well as peer-to-peer sharing models.” 

      The researchers found that while rental services generally have a lower carbon footprint than retail sales, hidden emissions from logistics played a surprisingly large role. “First, you need to deliver the clothes and pick them up, and there are high return rates,” says Velázquez Martínez. “When you factor in dry cleaning and packaging emissions, the rental models in some cases have a worse carbon footprint than buying new clothes.” Peer-to-peer sharing could be better, he adds, but that depends on how far the consumers travel to meet-up points. 

      Typically, says Velázquez Martínez, garment types that are frequently used are not well suited to rental models. “But for specialty clothes such as wedding dresses or prom dresses, it is better to rent.” 

      Waiting a few days to save the planet 

      Even before the pandemic, online retailing gained a second wind due to low-cost same- and next-day delivery options. While e-commerce may have its drawbacks as a contributor to social isolation and reduced competition, it has proven itself to be far more eco-friendly than brick-and-mortar shopping, not to mention a lot more convenient. Yet rapid deliveries are cutting into online-shopping’s carbon-cutting advantage.

      In 2019, MIT’s Sustainable Supply Chain Lab launched a Green Bottle project to study the rapid delivery phenomenon. The project has been “testing whether consumers would be willing to delay their e-commerce deliveries to reduce the environmental impact of fast shipping,” says Velázquez Martínez. “Many companies such as Walmart and Target have followed Amazon’s 2019 strategy of moving from two-day to same-day delivery. Instead of sending a fully loaded truck to a neighborhood every few days, they now send multiple trucks to that neighborhood every day, and there are more days when trucks are targeting each neighborhood. All this increases carbon emissions and makes it hard for shippers to consolidate. ”  

      Working with Coppel, one of Mexico’s largest retailers, the Green Button project inspired a related Consolidation Ecommerce Project that built a large-scale mathematical model to provide a strategy for consolidation. The model determined what delivery time window each neighborhood demands and then calculated the best day to deliver to each neighborhood to meet the desired window while minimizing carbon emissions. 

      No matter what mixture of delivery times was used, the consolidation model helped retailers schedule deliveries more efficiently. Yet, the biggest cuts in emissions emerged when customers were willing to wait several days.

      Play video

      “When we ran a month-long simulation comparing our model for four-to-five-day delivery with Coppel’s existing model for one- or two-day delivery, we saw savings in fuel consumption of over 50 percent on certain routes” says Velázquez Martínez. “This is huge compared to other strategies for squeezing more efficiency from the last-mile supply chain, such as routing optimization, where savings are close to 5 percent. The optimal solution depends on factors such as the capacity for consolidation, the frequency of delivery, the store capacity, and the impact on inbound operations.” 

      The researchers next set out to determine if customers could be persuaded to wait longer for deliveries. Considering that the price differential is low or nonexistent, this was a considerable challenge. Yet, the same day habit is only a few years old, and some consumers have come to realize they don’t always need rapid deliveries. “Some consumers who order by rapid delivery find they are too busy to open the packages right away,” says Velázquez Martínez.  

      Trees beat kilograms of CO2

      The researchers set out to find if consumers would be willing to sacrifice a bit of convenience if they knew they were helping to reduce climate change. The Green Button project tested different public outreach strategies. For one test group, they reported the carbon impact of delivery times in kilograms of carbon dioxide (CO2). Another group received the information expressed in terms of the energy required to recycle a certain amount of garbage. A third group learned about emissions in terms of the number of trees required to trap the carbon. “Explaining the impact in terms of trees led to almost 90 percent willing to wait another day or two,” says Velázquez Martínez. “This is compared to less than 40 percent for the group that received the data in kilograms of CO2.” 

      Another surprise was that there was no difference in response based on income, gender, or age. “Most studies of green consumers suggest they are predominantly high income, female, highly educated, or younger,” says Velázquez Martínez. “However, our results show that the differences were the same between low and high income, women and men, and younger and older people. We have shown that disclosing emissions transparently and making the consumer a part of the strategy can be a new opportunity for more consumer-driven logistics sustainability.” 

      The researchers are now developing similar models for business-to-business (B2B) e-commerce. “We found that B2B supply chain emissions are often high because many shipping companies require strict delivery windows,” says Velázquez Martínez.  

      The B2B models drill down to examine the Corporate Value Chain (Scope 3) emissions of suppliers. “Although some shipping companies are now asking their suppliers to review emissions, it is a challenge to create a transparent supply chain,” says Velázquez Martínez.  “Technological innovations have made it easier, starting with RFID [radio frequency identification], and then real-time GPS mapping and blockchain. But these technologies need to be more accessible and affordable, and we need more companies willing to use them.” 

      Some companies have been hesitant to dig too deeply into their supply chain, fearing they might uncover a scandal that might risk their reputation, says Velázquez Martínez. Other organizations are forced to look at the issue when nongovernmental organizations research sustainability issues such as social injustice in sweat shops and conflict mineral mines. 

      One challenge to building a transparent supply chain is that “in many companies, the sustainability teams are separate from the rest of the company,” says Velázquez Martínez. “Even if the CEOs receive information on sustainability issues, it often doesn’t filter down because the information does not belong to the planners or managers. We are pushing companies to not only account for sustainability factors in supply chain network design but also examine daily operations that affect sustainability. This is a big topic now: How can we translate sustainability information into something that everybody can understand and use?” 

      LIFT Lab lifts micro-retailers  

      In 2016, Velázquez Martínez launched the MIT GeneSys project to gain insights into micro and small enterprises (MSEs) in developing countries. The project released a GeneSys mobile app, which was used by more than 500 students throughout Latin America to collect data on more than 800 microfirms. In 2022, he launched the LIFT Lab, which focuses more specifically on studying and improving the supply chain for MSEs.  

      Worldwide, some 90 percent of companies have fewer than 10 employees. In Latin America and the Caribbean, companies with fewer than 50 employees represent 99 percent of all companies and 47 percent of employment. 

      Although MSEs represent much of the world’s economy, they are poorly understood, notes Velázquez Martínez. “Those tiny businesses are driving a lot of the economy and serve as important customers for the large companies working in developing countries. They range from small businesses down to people trying to get some money to eat by selling cakes or tacos through their windows.”  

      The MIT LIFT Lab researchers investigated whether MSE supply chain issues could help shed light on why many Latin American countries have been limited to marginal increases in gross domestic product. “Large companies from the developed world that are operating in Latin America, such as Unilever, Walmart, and Coca-Cola, have huge growth there, in some cases higher than they have in the developed world,” says Velázquez Martínez. “Yet, the countries are not developing as fast as we would expect.” 

      The LIFT Lab data showed that while the multinationals are thriving in Latin America, the local MSEs are decreasing in productivity. The study also found the trend has worsened with Covid-19.  

      The LIFT Lab’s first big project, which is sponsored by Mexican beverage and retail company FEMSA, is studying supply chains in Mexico. The study spans 200,000 micro-retailers and 300,000 consumers. In a collaboration with Tecnológico de Monterrey, hundreds of students are helping with a field study.  

      “We are looking at supply chain management and business capabilities and identifying the challenges to adoption of technology and digitalization,” says Velázquez Martínez. “We want to find the best ways for micro-firms to work with suppliers and consumers by identifying the consumers who access this market, as well as the products and services that can best help the micro-firms drive growth.” 

      Based on the earlier research by GeneSys, Velázquez Martínez has developed some hypotheses for potential improvements for micro-retailer supply chain, starting with payment terms. “We found that the micro-firms often get the worst purchasing deals. Owners without credit cards and with limited cash often buy in smaller amounts at much higher prices than retailers like Walmart. The big suppliers are squeezing them.” 

      While large retailers usually get 60 to 120 days to pay, micro-retailers “either pay at the moment of the transaction or in advance,” says Velázquez Martínez. “In a study of 500 micro-retailers in five countries in Latin America, we found the average payment time was minus seven days payment in advance. These terms reduce cash availability and often lead to bankruptcy.” 

      LIFT Lab is working with suppliers to persuade them to offer a minimum payment time of two weeks. “We can show the suppliers that the change in terms will let them move more product and increase sales,” says Velázquez Martínez. “Meanwhile, the micro-retailers gain higher profits and become more stable, even if they may pay a bit more.” 

      LIFT Lab is also looking at ways that micro-retailers can leverage smartphones for digitalization and planning. “Some of these companies are keeping records on napkins,” says Velázquez Martínez. “By using a cellphone, they can charge orders to suppliers and communicate with consumers. We are testing different dashboards for mobile apps to help with planning and financial performance. We are also recommending services the stores can provide, such as paying electricity or water bills. The idea is to build more capabilities and knowledge and increase business competencies for the supply chain that are tailored for micro-retailers.” 

      From a financial perspective, micro-retailers are not always the most efficient way to move products. Yet they also play an important role in building social cohesion within neighborhoods. By offering more services, the corner bodega can bring people together in ways that are impossible with e-commerce and big-box stores.  

      Whether the consumers are micro-firms buying from suppliers or e-commerce customers waiting for packages, “transparency is key to building a sustainable supply chain,” says Velázquez Martínez. “To change consumer habits, consumers need to be better educated on the impacts of their behaviors. With consumer-facing logistics, ‘The last shall be first, and the first last.’” More

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      in Energy

      Manufacturing a cleaner future

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      Manufacturing had a big summer. The CHIPS and Science Act, signed into law in August, represents a massive investment in U.S. domestic manufacturing. The act aims to drastically expand the U.S. semiconductor industry, strengthen supply chains, and invest in R&D for new technological breakthroughs. According to John Hart, professor of mechanical engineering and director of the Laboratory for Manufacturing and Productivity at MIT, the CHIPS Act is just the latest example of significantly increased interest in manufacturing in recent years.

      “You have multiple forces working together: reflections from the pandemic’s impact on supply chains, the geopolitical situation around the world, and the urgency and importance of sustainability,” says Hart. “This has now aligned incentives among government, industry, and the investment community to accelerate innovation in manufacturing and industrial technology.”

      Hand-in-hand with this increased focus on manufacturing is a need to prioritize sustainability.

      Roughly one-quarter of greenhouse gas emissions came from industry and manufacturing in 2020. Factories and plants can also deplete local water reserves and generate vast amounts of waste, some of which can be toxic.

      To address these issues and drive the transition to a low-carbon economy, new products and industrial processes must be developed alongside sustainable manufacturing technologies. Hart sees mechanical engineers as playing a crucial role in this transition.

      “Mechanical engineers can uniquely solve critical problems that require next-generation hardware technologies, and know how to bring their solutions to scale,” says Hart.

      Several fast-growing companies founded by faculty and alumni from MIT’s Department of Mechanical Engineering offer solutions for manufacturing’s environmental problem, paving the path for a more sustainable future.

      Gradiant: Cleantech water solutions

      Manufacturing requires water, and lots of it. A medium-sized semiconductor fabrication plant uses upward of 10 million gallons of water a day. In a world increasingly plagued by droughts, this dependence on water poses a major challenge.

      Gradiant offers a solution to this water problem. Co-founded by Anurag Bajpayee SM ’08, PhD ’12 and Prakash Govindan PhD ’12, the company is a pioneer in sustainable — or “cleantech” — water projects.

      As doctoral students in the Rohsenow Kendall Heat Transfer Laboratory, Bajpayee and Govindan shared a pragmatism and penchant for action. They both worked on desalination research — Bajpayee with Professor Gang Chen and Govindan with Professor John Lienhard.

      Inspired by a childhood spent during a severe drought in Chennai, India, Govindan developed for his PhD a humidification-dehumidification technology that mimicked natural rainfall cycles. It was with this piece of technology, which they named Carrier Gas Extraction (CGE), that the duo founded Gradiant in 2013.

      The key to CGE lies in a proprietary algorithm that accounts for variability in the quality and quantity in wastewater feed. At the heart of the algorithm is a nondimensional number, which Govindan proposes one day be called the “Lienhard Number,” after his doctoral advisor.

      “When the water quality varies in the system, our technology automatically sends a signal to motors within the plant to adjust the flow rates to bring back the nondimensional number to a value of one. Once it’s brought back to a value of one, you’re running in optimal condition,” explains Govindan, who serves as chief operating officer of Gradiant.

      This system can treat and clean the wastewater produced by a manufacturing plant for reuse, ultimately conserving millions of gallons of water each year.

      As the company has grown, the Gradiant team has added new technologies to their arsenal, including Selective Contaminant Extraction, a cost-efficient method that removes only specific contaminants, and a brine-concentration method called Counter-Flow Reverse Osmosis. They now offer a full technology stack of water and wastewater treatment solutions to clients in industries including pharmaceuticals, energy, mining, food and beverage, and the ever-growing semiconductor industry.

      “We are an end-to-end water solutions provider. We have a portfolio of proprietary technologies and will pick and choose from our ‘quiver’ depending on a customer’s needs,” says Bajpayee, who serves as CEO of Gradiant. “Customers look at us as their water partner. We can take care of their water problem end-to-end so they can focus on their core business.”

      Gradiant has seen explosive growth over the past decade. With 450 water and wastewater treatment plants built to date, they treat the equivalent of 5 million households’ worth of water each day. Recent acquisitions saw their total employees rise to above 500.

      The diversity of Gradiant’s solutions is reflected in their clients, who include Pfizer, AB InBev, and Coca-Cola. They also count semiconductor giants like Micron Technology, GlobalFoundries, Intel, and TSMC among their customers.

      “Over the last few years, we have really developed our capabilities and reputation serving semiconductor wastewater and semiconductor ultrapure water,” says Bajpayee.

      Semiconductor manufacturers require ultrapure water for fabrication. Unlike drinking water, which has a total dissolved solids range in the parts per million, water used to manufacture microchips has a range in the parts per billion or quadrillion.

      Currently, the average recycling rate at semiconductor fabrication plants — or fabs — in Singapore is only 43 percent. Using Gradiant’s technologies, these fabs can recycle 98-99 percent of the 10 million gallons of water they require daily. This reused water is pure enough to be put back into the manufacturing process.

      “What we’ve done is eliminated the discharge of this contaminated water and nearly eliminated the dependence of the semiconductor fab on the public water supply,” adds Bajpayee.

      With new regulations being introduced, pressure is increasing for fabs to improve their water use, making sustainability even more important to brand owners and their stakeholders.

      As the domestic semiconductor industry expands in light of the CHIPS and Science Act, Gradiant sees an opportunity to bring their semiconductor water treatment technologies to more factories in the United States.

      Via Separations: Efficient chemical filtration

      Like Bajpayee and Govindan, Shreya Dave ’09, SM ’12, PhD ’16 focused on desalination for her doctoral thesis. Under the guidance of her advisor Jeffrey Grossman, professor of materials science and engineering, Dave built a membrane that could enable more efficient and cheaper desalination.

      A thorough cost and market analysis brought Dave to the conclusion that the desalination membrane she developed would not make it to commercialization.

      “The current technologies are just really good at what they do. They’re low-cost, mass produced, and they worked. There was no room in the market for our technology,” says Dave.

      Shortly after defending her thesis, she read a commentary article in the journal Nature that changed everything. The article outlined a problem. Chemical separations that are central to many manufacturing processes require a huge amount of energy. Industry needed more efficient and cheaper membranes. Dave thought she might have a solution.

      After determining there was an economic opportunity, Dave, Grossman, and Brent Keller PhD ’16 founded Via Separations in 2017. Shortly thereafter, they were chosen as one of the first companies to receive funding from MIT’s venture firm, The Engine.

      Currently, industrial filtration is done by heating chemicals at very high temperatures to separate compounds. Dave likens it to making pasta by boiling all of the water off until it evaporates and all you are left with is the pasta noodles. In manufacturing, this method of chemical separation is extremely energy-intensive and inefficient.

      Via Separations has created the chemical equivalent of a “pasta strainer.” Rather than using heat to separate, their membranes “strain” chemical compounds. This method of chemical filtration uses 90 percent less energy than standard methods.

      While most membranes are made of polymers, Via Separations’ membranes are made with graphene oxide, which can withstand high temperatures and harsh conditions. The membrane is calibrated to the customer’s needs by altering the pore size and tuning the surface chemistry.

      Currently, Dave and her team are focusing on the pulp and paper industry as their beachhead market. They have developed a system that makes the recovery of a substance known as “black liquor” more energy efficient.

      “When tree becomes paper, only one-third of the biomass is used for the paper. Currently the most valuable use for the remaining two-thirds not needed for paper is to take it from a pretty dilute stream to a pretty concentrated stream using evaporators by boiling off the water,” says Dave.

      This black liquor is then burned. Most of the resulting energy is used to power the filtration process.

      “This closed-loop system accounts for an enormous amount of energy consumption in the U.S. We can make that process 84 percent more efficient by putting the ‘pasta strainer’ in front of the boiler,” adds Dave.

      VulcanForms: Additive manufacturing at industrial scale

      The first semester John Hart taught at MIT was a fruitful one. He taught a course on 3D printing, broadly known as additive manufacturing (AM). While it wasn’t his main research focus at the time, he found the topic fascinating. So did many of the students in the class, including Martin Feldmann MEng ’14.

      After graduating with his MEng in advanced manufacturing, Feldmann joined Hart’s research group full time. There, they bonded over their shared interest in AM. They saw an opportunity to innovate with an established metal AM technology, known as laser powder bed fusion, and came up with a concept to realize metal AM at an industrial scale.

      The pair co-founded VulcanForms in 2015.

      “We have developed a machine architecture for metal AM that can build parts with exceptional quality and productivity,” says Hart. “And, we have integrated our machines in a fully digital production system, combining AM, postprocessing, and precision machining.”

      Unlike other companies that sell 3D printers for others to produce parts, VulcanForms makes and sells parts for their customers using their fleet of industrial machines. VulcanForms has grown to nearly 400 employees. Last year, the team opened their first production factory, known as “VulcanOne,” in Devens, Massachusetts.

      The quality and precision with which VulcanForms produces parts is critical for products like medical implants, heat exchangers, and aircraft engines. Their machines can print layers of metal thinner than a human hair.

      “We’re producing components that are difficult, or in some cases impossible to manufacture otherwise,” adds Hart, who sits on the company’s board of directors.

      The technologies developed at VulcanForms may help lead to a more sustainable way to manufacture parts and products, both directly through the additive process and indirectly through more efficient, agile supply chains.

      One way that VulcanForms, and AM in general, promotes sustainability is through material savings.

      Many of the materials VulcanForms uses, such as titanium alloys, require a great deal of energy to produce. When titanium parts are 3D-printed, substantially less of the material is used than in a traditional machining process. This material efficiency is where Hart sees AM making a large impact in terms of energy savings.

      Hart also points out that AM can accelerate innovation in clean energy technologies, ranging from more efficient jet engines to future fusion reactors.

      “Companies seeking to de-risk and scale clean energy technologies require know-how and access to advanced manufacturing capability, and industrial additive manufacturing is transformative in this regard,” Hart adds.

      LiquiGlide: Reducing waste by removing friction

      There is an unlikely culprit when it comes to waste in manufacturing and consumer products: friction. Kripa Varanasi, professor of mechanical engineering, and the team at LiquiGlide are on a mission to create a frictionless future, and substantially reduce waste in the process.

      Founded in 2012 by Varanasi and alum David Smith SM ’11, LiquiGlide designs custom coatings that enable liquids to “glide” on surfaces. Every last drop of a product can be used, whether it’s being squeezed out of a tube of toothpaste or drained from a 500-liter tank at a manufacturing plant. Making containers frictionless substantially minimizes wasted product, and eliminates the need to clean a container before recycling or reusing.

      Since launching, the company has found great success in consumer products. Customer Colgate utilized LiquiGlide’s technologies in the design of the Colgate Elixir toothpaste bottle, which has been honored with several industry awards for design. In a collaboration with world- renowned designer Yves Béhar, LiquiGlide is applying their technology to beauty and personal care product packaging. Meanwhile, the U.S. Food and Drug Administration has granted them a Device Master Filing, opening up opportunities for the technology to be used in medical devices, drug delivery, and biopharmaceuticals.

      In 2016, the company developed a system to make manufacturing containers frictionless. Called CleanTanX, the technology is used to treat the surfaces of tanks, funnels, and hoppers, preventing materials from sticking to the side. The system can reduce material waste by up to 99 percent.

      “This could really change the game. It saves wasted product, reduces wastewater generated from cleaning tanks, and can help make the manufacturing process zero-waste,” says Varanasi, who serves as chair at LiquiGlide.

      LiquiGlide works by creating a coating made of a textured solid and liquid lubricant on the container surface. When applied to a container, the lubricant remains infused within the texture. Capillary forces stabilize and allow the liquid to spread on the surface, creating a continuously lubricated surface that any viscous material can slide right down. The company uses a thermodynamic algorithm to determine the combinations of safe solids and liquids depending on the product, whether it’s toothpaste or paint.

      The company has built a robotic spraying system that can treat large vats and tanks at manufacturing plants on site. In addition to saving companies millions of dollars in wasted product, LiquiGlide drastically reduces the amount of water needed to regularly clean these containers, which normally have product stuck to the sides.

      “Normally when you empty everything out of a tank, you still have residue that needs to be cleaned with a tremendous amount of water. In agrochemicals, for example, there are strict regulations about how to deal with the resulting wastewater, which is toxic. All of that can be eliminated with LiquiGlide,” says Varanasi.

      While the closure of many manufacturing facilities early in the pandemic slowed down the rollout of CleanTanX pilots at plants, things have picked up in recent months. As manufacturing ramps up both globally and domestically, Varanasi sees a growing need for LiquiGlide’s technologies, especially for liquids like semiconductor slurry.

      Companies like Gradiant, Via Separations, VulcanForms, and LiquiGlide demonstrate that an expansion in manufacturing industries does not need to come at a steep environmental cost. It is possible for manufacturing to be scaled up in a sustainable way.

      “Manufacturing has always been the backbone of what we do as mechanical engineers. At MIT in particular, there is always a drive to make manufacturing sustainable,” says Evelyn Wang, Ford Professor of Engineering and former head of the Department of Mechanical Engineering. “It’s amazing to see how startups that have an origin in our department are looking at every aspect of the manufacturing process and figuring out how to improve it for the health of our planet.”

      As legislation like the CHIPS and Science Act fuels growth in manufacturing, there will be an increased need for startups and companies that develop solutions to mitigate the environmental impact, bringing us closer to a more sustainable future. More

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      in Energy

      MIT scientists contribute to National Ignition Facility fusion milestone

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      On Monday, Dec. 5, at around 1 a.m., a tiny sphere of deuterium-tritium fuel surrounded by a cylindrical can of gold called a hohlraum was targeted by 192 lasers at the National Ignition Facility (NIF) at Lawrence Livermore National Laboratory (LLNL) in California. Over the course of billionths of a second, the lasers fired, generating X-rays inside the gold can, and imploding the sphere of fuel.

      On that morning, for the first time ever, the lasers delivered 2.1 megajoules of energy and yielded 3.15 megajoules in return, achieving a historic fusion energy gain well above 1 — a result verified by diagnostic tools developed by the MIT Plasma Science and Fusion Center (PSFC). The use of these tools and their importance was referenced by Arthur Pak, a LLNL staff scientist who spoke at a U.S. Department of Energy press event on Dec. 13 announcing the NIF’s success.

      Johan Frenje, head of the PSFC High-Energy-Density Physics division, notes that this milestone “will have profound implications for laboratory fusion research in general.”

      Since the late 1950s, researchers worldwide have pursued fusion ignition and energy gain in a laboratory, considering it one of the grand challenges of the 21st century. Ignition can only be reached when the internal fusion heating power is high enough to overcome the physical processes that cool the fusion plasma, creating a positive thermodynamic feedback loop that very rapidly increases the plasma temperature. In the case of inertial confinement fusion, the method used at the NIF, ignition can initiate a “fuel burn propagation” into the surrounding dense and cold fuel, and when done correctly, enable fusion-energy gain.

      Frenje and his PSFC division initially designed dozens of diagnostic systems that were implemented at the NIF, including the vitally important magnetic recoil neutron spectrometer (MRS), which measures the neutron energy spectrum, the data from which fusion yield, plasma ion temperature, and spherical fuel pellet compression (“fuel areal density”) can be determined. Overseen by PSFC Research Scientist Maria Gatu Johnson since 2013, the MRS is one of two systems at the NIF relied upon to measure the absolute neutron yield from the Dec. 5 experiment because of its unique ability to accurately interpret an implosion’s neutron signals.

      “Before the announcement of this historic achievement could be made, the LLNL team wanted to wait until Maria had analyzed the MRS data to an adequate level for a fusion yield to be determined,” says Frenje.

      Response around MIT to NIF’s announcement has been enthusiastic and hopeful. “This is the kind of breakthrough that ignites the imagination,” says Vice President for Research Maria Zuber, “reminding us of the wonder of discovery and the possibilities of human ingenuity. Although we have a long, hard path ahead of us before fusion can deliver clean energy to the electrical grid, we should find much reason for optimism in today’s announcement. Innovation in science and technology holds great power and promise to address some of the world’s biggest challenges, including climate change.”

      Frenje also credits the rest of the team at the PSFC’s High-Energy-Density Physics division, the Laboratory for Laser Energetics at the University of Rochester, LLNL, and other collaborators for their support and involvement in this research, as well as the National Nuclear Security Administration of the Department of Energy, which has funded much of their work since the early 1990s. He is also proud of the number of MIT PhDs that have been generated by the High-Energy-Density Physics Division and subsequently hired by LLNL, including the experimental lead for this experiment, Alex Zylstra PhD ’15.

      “This is really a team effort,” says Frenje. “Without the scientific dialogue and the extensive know-how at the HEDP Division, the critical contributions made by the MRS system would not have happened.” More

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      in Energy

      Pursuing a practical approach to research

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      Koroush Shirvan, the John Clark Hardwick Career Development Professor in the Department of Nuclear Science and Engineering (NSE), knows that the nuclear industry has traditionally been wary of innovations until they are shown to have proven utility. As a result, he has relentlessly focused on practical applications in his research, work that has netted him the 2022 Reactor Technology Award from the American Nuclear Society. “The award has usually recognized practical contributions to the field of reactor design and has not often gone to academia,” Shirvan says.

      One of these “practical contributions” is in the field of accident-tolerant fuels, a program launched by the U.S. Nuclear Regulatory Commission in the wake of the 2011 Fukushima Daiichi incident. The goal within this program, says Shirvan, is to develop new forms of nuclear fuels that can tolerate heat. His team, with students from over 16 countries, is working on numerous possibilities that range in composition and method of production.

      Another aspect of Shirvan’s research focuses on how radiation impacts heat transfer mechanisms in the reactor. The team found fuel corrosion to be the driving force. “[The research] informs how nuclear fuels perform in the reactor, from a practical point of view,” Shirvan says.

      Optimizing nuclear reactor design

      A summer internship when Shirvan was an undergraduate at the University of Florida at Gainesville seeded his drive to focus on practical applications in his studies. A nearby nuclear utility was losing millions because of crud accumulating on fuel rods. Over time, the company was solving the problem by using more fuel, before it had extracted all the life from earlier batches.

      Placement of fuel rods in nuclear reactors is a complex problem with many factors — the life of the fuel, location of hot spots — affecting outcomes. Nuclear reactors change their configuration of fuel rods every 18-24 months to optimize close to 15-20 constraints, leading to roughly 200-800 assemblies. The mind-boggling nature of the problem means that plants have to rely on experienced engineers.

      During his internship, Shirvan optimized the program used to place fuel rods in the reactor. He found that certain rods in assemblies were more prone to the crud deposits, and reworked their configurations, optimizing for these rods’ performance instead of adding assemblies.

      In recent years, Shirvan has applied a branch of artificial intelligence — reinforcement learning — to the configuration problem and created a software program used by the largest U.S. nuclear utility. “This program gives even a layperson the ability to reconfigure the fuels and the reactor without having expert knowledge,” Shirvan says.

      From advanced math to counting jelly beans

      Shirvan’s own expertise in nuclear science and engineering developed quite organically. He grew up in Tehran, Iran, and when he was 14 the family moved to Gainesville, where Shirvan’s aunt and family live. He remembers an awkward couple of years at the new high school where he was grouped in with newly arrived international students, and placed in entry-level classes. “I went from doing advanced mathematics in Iran to counting jelly beans,” he laughs.

      Shirvan applied to the University of Florida for his undergraduate studies since it made economic sense; the school gave full scholarships to Floridian students who received a certain minimum SAT score. Shirvan qualified. His uncle, who was a professor in the nuclear engineering department then, encouraged Shirvan to take classes in the department. Under his uncle’s mentorship, the courses Shirvan took, and his internship, cemented his love of the interdisciplinary approach that the field demanded.

      Having always known that he wanted to teach — he remembers finishing his math tests early in Tehran so he could earn the reward of being class monitor — Shirvan knew graduate school was next. His uncle encouraged him to apply to MIT and to the University of Michigan, home to reputable programs in the field. Shirvan chose MIT because “only at MIT was there a program on nuclear design. There were faculty dedicated to designing new reactors, looking at multiple disciplines, and putting all of that together.” He went on to pursue his master’s and doctoral studies at NSE under the supervision of Professor Mujid Kazimi, focusing on compact pressurized and boiling water reactor designs. When Kazimi passed away suddenly in 2015, Shirvan was a research scientist, and switched to tenure track to guide the professor’s team.

      Another project that Shirvan took in 2015: leadership of MIT’s course on nuclear reactor technology for utility executives. Offered only by the Institute, the program is an introduction to nuclear engineering and safety for personnel who might not have much background in the area. “It’s a great course because you get to see what the real problems are in the energy sector … like grid stability,” Shirvan says.

      A multipronged approach to savings

      Another very real problem nuclear utilities face is cost. Contrary to what one hears on the news, one of the biggest stumbling blocks to building new nuclear facilities in the United States is cost, which today can be up to three times that of renewables, Shirvan says. While many approaches such as advanced manufacturing have been tried, Shirvan believes that the solution to decrease expenditures lies in designing more compact reactors.

      His team has developed an open-source advanced nuclear cost tool and has focused on two different designs: a small water reactor using compact steam technology and a horizontal gas reactor. Compactness also means making fuels more efficient, as Shirvan’s work does, and in improving the heat exchange device. It’s all back to the basics and bringing “commercial viable arguments in with your research,” Shirvan explains.

      Shirvan is excited about the future of the U.S. nuclear industry, and that the 2022 Inflation Reduction Act grants the same subsidies to nuclear as it does for renewables. In this new level playing field, advanced nuclear still has a long way to go in terms of affordability, he admits. “It’s time to push forward with cost-effective design,” Shirvan says, “I look forward to supporting this by continuing to guide these efforts with research from my team.” More