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Engineers Develop Nanofiltration Process to Capture and Recycle Aluminum from Manufacturing Waste

MIT Engineers Develop Membrane Technology to Reduce Waste and Improve Efficiency in Aluminum Production

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The researchers demonstrated the membrane’s performance in lab-scale experiments, pictured, using a novel membrane to filter various solutions that were similar in content to the waste streams produced by aluminum plants. Credits:Photo: Trent Lee

Aluminum, the second-most-produced metal in the world after steel, is a crucial material in industries ranging from packaging to electronics and aerospace. With global demand projected to rise by 40 percent by the end of the decade, aluminum production is set to significantly increase, bringing with it heightened environmental concerns. A new breakthrough from MIT engineers aims to tackle one of the major challenges of aluminum production—waste.

The research team at the Massachusetts Institute of Technology (MIT) has developed a novel nanofiltration membrane that could drastically reduce the hazardous waste generated during aluminum manufacturing. This membrane could potentially help aluminum plants recycle aluminum ions that would otherwise be lost in waste streams, enabling upcycling and reducing environmental impacts.

“Our membrane technology not only cuts down on hazardous waste but also enables a circular economy for aluminum by reducing the need for new mining,” said John Lienhard, the Abdul Latif Jameel Professor of Water in MIT’s Department of Mechanical Engineering, according to a press release issued by MIT. He is also the director of the Abdul Latif Jameel Water and Food Systems Lab (J-WAFS). “This offers a promising solution to address environmental concerns while meeting the growing demand for aluminum.”

In a study published this week in ACS Sustainable Chemistry and Engineering, Lienhard and his colleagues demonstrated the membrane’s effectiveness in laboratory experiments. They found that the membrane was able to capture more than 99 percent of aluminum ions from solutions that closely mimicked the waste streams produced by aluminum plants.

If scaled up, this technology could reduce the amount of wasted aluminum and improve the overall environmental quality of the waste produced by these plants.

The Aluminum Production Problem

Aluminum production starts with the mining of bauxite, an ore rich in aluminum. The bauxite undergoes chemical processing to separate aluminum oxide (alumina) from other impurities. This alumina is then transported to refineries, where it is placed in electrolysis vats containing molten cryolite. Through electrolysis, alumina breaks down, and pure aluminum is separated out.

However, over time, the cryolite electrolyte accumulates impurities, including sodium, lithium, and potassium ions, which reduce its effectiveness in the process. When these impurities reach critical levels, the cryolite must be replaced, creating a hazardous sludge that contains residual aluminum and other pollutants. The amount of aluminum lost in this waste can be substantial.

“We learned that for a traditional aluminum plant, something like 2,800 tons of aluminum are wasted per year,” said Trent Lee, lead author of the study and an MIT mechanical engineering undergraduate. “We were looking at ways that the industry can be more efficient, and we found cryolite waste hadn’t been well-researched in terms of recycling some of its waste products.”

A Membrane for Efficiency

In their new work, Lienhard’s team developed a membrane capable of selectively filtering aluminum from cryolite waste. The goal was to recover aluminum ions while allowing other less problematic ions, such as sodium, to pass through. The captured aluminum could then be reused in the electrolysis process, reducing the need for new materials and increasing overall efficiency.

The new membrane technology is based on a design used in conventional water treatment plants. These membranes, made from polymer materials, are perforated with tiny pores that selectively allow certain ions and molecules to pass through. In collaboration with the Japanese membrane company Nitto Denko, the MIT team adapted this technology to capture aluminum ions specifically.

The aluminum ions in cryolite waste carry a higher positive charge than sodium and other cations, which makes them easier to isolate. By applying a thin, positively charged coating to the membrane, the researchers were able to create a barrier that repels aluminum ions while allowing the other, less positively charged ions to flow through.

“We found that the membrane consistently captured 99.5 percent of aluminum ions while allowing sodium and other cations to pass,” explained Zi Hao Foo, a postdoctoral researcher at the University of California, Berkeley, and co-author of the study. “We also tested the membrane in solutions of varying pH levels, and it maintained its performance, even in highly acidic conditions.”

Scaling Up for Industry

The team’s experimental membrane is about the size of a playing card, but to treat cryolite waste in an industrial-scale aluminum production plant, they envision a scaled-up version similar to those used in desalination plants. In these plants, long sheets of membrane are rolled into spirals, allowing water to flow through them efficiently.

“This paper shows the viability of membranes for innovations in circular economies,” said Lee. “This membrane provides the dual benefit of upcycling aluminum while reducing hazardous waste.”

By applying this membrane technology, the aluminum industry could significantly cut down on waste and reduce its environmental footprint, all while improving efficiency and meeting the rising global demand for aluminum.

Looking Ahead

With their breakthrough in nanofiltration technology, MIT engineers have opened the door to a more sustainable and circular approach to aluminum production. By reclaiming valuable aluminum from waste streams, they are not only advancing the efficiency of aluminum manufacturing but also helping to address the environmental challenges posed by an industry poised for rapid growth in the coming years

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Earth

Life may have learned to breathe oxygen hundreds of millions of years earlier than thought

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MIT Study Suggests Life Used Oxygen Far Earlier Than Thought
Researchers mapped enzyme sequences from thousands of modern species onto the evolutionary tree of life. The analysis suggests that soon after cyanobacteria began producing oxygen, other organisms evolved enzymes to use it. Credits: Image: MIT News; figure courtesy of the researchers

Early life on Earth has found an interetsing turning point. A new study by researchers at Massachusetts Institute of Technology suggests that some of Earth’s earliest life forms may have evolved the ability to use oxygen hundreds of millions of years before it became a permanent part of the planet’s atmosphere.

Oxygen is essential to most life on Earth today, but it was not always abundant. Scientists have long believed that oxygen only became a stable component of the atmosphere around 2.3 billion years ago, during a turning point known as the Great Oxidation Event (GOE). The new findings indicate that biological use of oxygen may have begun much earlier, potentially reshaping scientists’ understanding of how life evolved on Earth.

The study, published in the journal Palaeogeography, Palaeoclimatology, Palaeoecology, traces the evolutionary origins of a key enzyme that allows organisms to use oxygen for aerobic respiration. This enzyme is present in most oxygen-breathing life forms today, from bacteria to humans.

MIT geobiologists found that the enzyme likely evolved during the Mesoarchean era, between 3.2 and 2.8 billion years ago—several hundred million years before the Great Oxidation Event.

The findings may help answer a long-standing mystery in Earth’s history: why it took so long for oxygen to accumulate in the atmosphere. Scientists know that cyanobacteria, the first organisms capable of producing oxygen through photosynthesis, emerged around 2.9 billion years ago. Yet atmospheric oxygen levels remained low for hundreds of millions of years after their appearance.

While geochemical reactions with rocks were previously thought to be the main reason oxygen failed to build up early on, the MIT study suggests biology itself may also have played a role. Early organisms that evolved the oxygen-using enzyme may have consumed small amounts of oxygen as soon as it was produced, limiting how much could accumulate in the atmosphere.

“This does dramatically change the story of aerobic respiration,” said Fatima Husain, postdoctoral researcher in MIT’s Department of Earth, Atmospheric and Planetary Sciences, said in a media statement. “Our study adds to this very recently emerging story that life may have used oxygen much earlier than previously thought. It shows us how incredibly innovative life is at all periods in Earth’s history.”

The research team analysed thousands of genetic sequences of heme-copper oxygen reductases—enzymes essential for aerobic respiration—across a wide range of modern organisms. By mapping these sequences onto an evolutionary tree and anchoring them with fossil and geological evidence, the researchers were able to estimate when the enzyme first emerged.

“The puzzle pieces are fitting together and really underscore how life was able to diversify and live in this new, oxygenated world

Tracing the enzyme back through time, the team concluded that oxygen use likely appeared soon after cyanobacteria began producing oxygen. Organisms living close to these microbes may have rapidly consumed the oxygen they released, delaying its escape into the atmosphere.

“Considered all together, MIT research has filled in the gaps in our knowledge of how Earth’s oxygenation proceeded,” Husain said. “The puzzle pieces are fitting together and really underscore how life was able to diversify and live in this new, oxygenated world.”

The study adds to a growing body of evidence suggesting that life on Earth adapted to oxygen far earlier than previously believed, offering new insights into how biological innovation shaped the planet’s atmosphere and the evolution of complex life.

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Earth

The Heat Trap: How Climate Change Is Pushing Extreme Weather Into New Parts of the World

MIT scientists say a hidden feature of the atmosphere is allowing dangerous humid heat to build up in parts of the world that were once considered climatically mild — setting the stage for longer heat waves and more violent storms.

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The Heat Trap: How Climate Change Is Pushing Extreme Weather Into New Parts of the World
Image credit: Franz Bachinger/ Pixabay

For decades, long spells of suffocating heat followed by explosive thunderstorms were largely confined to the tropics. But that pattern is now spreading into the planet’s midlatitudes, and researchers at the Massachusetts Institute of Technology believe they know why.

In a new study published in Science Advances, MIT scientists have identified atmospheric inversions — layers of warm air sitting over cooler air near the ground — as a critical factor controlling how hot, humid, and storm-prone a region can become. Their findings suggest that parts of the United States and East Asia could face unfamiliar and dangerous combinations of oppressive heat and extreme rainfall as the climate continues to warm.

Inversions are already notorious for trapping air pollution close to the ground. The MIT team now shows they also act like thermal lids, allowing heat and moisture to accumulate near the surface for days at a time. The longer an inversion persists, the more unbearable the humid heat becomes. And when that lid finally breaks, the stored energy can be released violently, fuelling intense thunderstorms and heavy downpours.

“Our analysis shows that the eastern and midwestern regions of U.S. and the eastern Asian regions may be new hotspots for humid heat in the future climate,” said Funing Li, a postdoctoral researcher in MIT’s Department of Earth, Atmospheric and Planetary Sciences, in a media statement.

The mechanism is especially important in midlatitude regions, where inversions are common. In the US, areas east of the Rocky Mountains frequently experience warm air aloft flowing over cooler surface air — a configuration that can linger and intensify under climate change.

“As the climate warms, theoretically the atmosphere will be able to hold more moisture,” said Talia Tamarin-Brodsky, an assistant professor at MIT and co-author of the study, in a media statement. “Which is why new regions in the midlatitudes could experience moist heat waves that will cause stress that they weren’t used to before.”

Why heat doesn’t always break

Under normal conditions, rising surface temperatures trigger convection: warm air rises, cool air sinks, clouds form, and storms develop that can eventually cool things down. But the researchers approached the problem differently, asking what actually limits how much heat and moisture can build up before convection begins.

By analysing the total energy of air near the surface — combining both dry heat and moisture — they found that inversions dramatically raise that limit. When warm air caps cooler air below, surface air must accumulate far more energy before it can rise through the barrier. The stronger and more stable the inversion, the more extreme the heat and humidity must become.

“This increasing inversion has two effects: more severe humid heat waves, and less frequent but more extreme convective storms,” Tamarin-Brodsky said.

A Midwest warning sign

Inversions can form overnight, when the ground cools rapidly, or when cool marine air slides under warmer air inland. But in the central United States, geography plays a key role.

“The Great Plains and the Midwest have had many inversions historically due to the Rocky Mountains,” Li said in a media statement. “The mountains act as an efficient elevated heat source, and westerly winds carry this relatively warm air downstream into the central and midwestern U.S., where it can help create a persistent temperature inversion that caps colder air near the surface.”

As global warming strengthens and stabilises these atmospheric layers, the researchers warn that regions like the Midwest may be pushed toward climate extremes once associated with far warmer parts of the world.

“In a future climate for the Midwest, they may experience both more severe thunderstorms and more extreme humid heat waves,” Tamarin-Brodsky said in a media statement. “Our theory gives an understanding of the limit for humid heat and severe convection for these communities that will be future heat wave and thunderstorm hotspots.”

The study offers climate scientists a new way to assess regional risk — and a stark reminder that climate change is not just intensifying known hazards, but exporting them to places unprepared for their consequences.

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Climate Extremes in 2025 Exposed Inequality and the Limits of Adaptation, Scientists Warn

2025 Wasn’t Just Hot — It Pushed the World to the Edge of Climate Survival

Dipin Damodharan

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Climate Extremes in 2025 Exposed Inequality and the Limits of Adaptation, Scientists Warn
Image credit: RDNE Stock project/Pexels

Extreme weather events intensified across the globe in 2025, disproportionately impacting vulnerable communities and pushing many regions close to the limits of adaptation, according to the latest annual report by World Weather Attribution (WWA). Despite the absence of a strong El Niño, global temperatures remained exceptionally high, making 2025 one of the hottest years on record and underscoring the growing influence of human-induced climate change.

The report, Unequal Evidence and Impacts, Limits to Adaptation: Extreme Weather in 2025, analysed 22 major extreme weather events in depth, selected from 157 climate disasters that met humanitarian impact thresholds worldwide. Floods and heatwaves were the most frequent, with 49 events each, followed by storms (38), wildfires (11), droughts (7) and cold spells (3).

Although 2025 occurred under weak La Niña conditions—typically associated with cooler global temperatures—the three-year global temperature average crossed the 1.5°C warming threshold for the first time. Scientists attribute this persistent heat to rising greenhouse gas emissions, which continue to override natural climate variability.

“Each year, the risks of climate change become less hypothetical and more brutal reality,” said Friederike Otto, Professor of Climate Science at Imperial College London and co-founder of World Weather Attribution, in a statement. “Our report shows that despite efforts to cut carbon emissions, they have fallen short in preventing global temperature rise and the worst impacts. Decision-makers must face the reality that their continued reliance on fossil fuels is costing lives, billions in economic losses, and causing irreversible damage to communities worldwide”

Heatwaves: the deadliest disaster of 2025

Heatwaves emerged as the deadliest extreme weather event of the year. In Europe alone, an estimated 24,400 people died during a single summer heatwave between June and August, across 854 cities representing nearly 30% of the continent’s population.

In South Sudan, human-induced climate change made a February heatwave 4°C hotter than it would have been in a pre-industrial climate, turning what was once a rare event into one expected every two years. Schools were closed nationwide after dozens of children collapsed from heat exhaustion, highlighting how extreme heat disrupts education and deepens gender and social inequalities.

Floods, storms and data gaps in the Global South

Floods were the most frequently triggered hazard studied by WWA in 2025, with devastating impacts reported in Pakistan, Sri Lanka, Indonesia, Botswana and the Mississippi River Basin. However, nearly one-quarter of attribution studies remained inconclusive, largely due to poor weather data and limitations in climate models, particularly in the Global South.  

This uneven scientific evidence mirrors broader climate injustice. Many regions experiencing the most severe impacts lack dense weather station networks, making it difficult to quantify the role of climate change precisely—even when human suffering is evident.

Wildfires and storms pushed adaptation limits

The report also documented record-breaking wildfires, including the most economically destructive fires in modern US history in Los Angeles, which caused an estimated $30 billion in insured losses and were linked to around 400 deaths. Climate change increased the likelihood of extreme fire weather by 35%, driven by hotter, drier, and windier conditions.  

Tropical cyclones further illustrated the limits of adaptation. Hurricane Melissa, which struck the Caribbean, produced rainfall intensities at least 9% higher due to climate change. While early warnings and evacuations in Jamaica and Cuba saved lives, the storm still caused widespread damage, demonstrating that preparedness alone cannot fully offset intensifying extremes

A new era of dangerous extremes

“2025 showed us that we are now in a persistent new era of dangerous, extreme weather,” said Theodore Keeping, researcher at Imperial College London, in a statement. “The evidence of the severe, real impacts of climate change are more clear than ever, and it is essential that action is taken to stop fossil fuel emissions, and to help the world’s most vulnerable prepare for the devastating impacts of increasingly extreme weather.”

Echoing this concern, Sjoukje Philip, researcher at the Royal Netherlands Meteorological Institute (KNMI), noted in a statement that natural climate variability alone cannot explain the year’s extreme heat. “The continuous rise in greenhouse gas emissions has pushed our climate into a new, more extreme state, where even small increases in global temperatures now trigger disproportionately severe impacts”

Emissions cuts are non-negotiable

While the report emphasises the importance of adaptation—such as early warning systems, urban planning, and ecosystem restoration—it concludes that rapid and deep reductions in fossil fuel emissions remain essential to avoid the worst climate impacts.

As the WWA scientists warn, without decisive global action, extreme weather events like those seen in 2025 will no longer be exceptions, but the defining feature of a warming world.

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