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Houston researchers reach 'surprising' revelation in materials recycling efforts

keep it clean

A team led by Matteo Pasquali, director of Rice’s Carbon Hub, has unveiled how carbon nanotube fibers can be a sustainable alternative to materials like steel, copper and aluminum. Photo by Jeff Fitlow/ Courtesy Rice University

Researchers at Rice University have published a study in the journal Carbon that demonstrates how carbon nanotube (CNT) fibers can be fully recycled without any loss in their structure or properties.

The discovery shows that CNT fibers could be used as a sustainable alternative to traditional materials like metals, polymers and the larger, harder-to-recycle carbon fibers, which the team hopes can pave the way for more sustainable and efficient recycling efforts.

“Recycling has long been a challenge in the materials industry — metals recycling is often inefficient and energy intensive, polymers tend to lose their properties after reprocessing and carbon fibers cannot be recycled at all, only downcycled by chopping them up into short pieces,” corresponding author Matteo Pasquali, director of Rice’s Carbon Hub and the A.J. Hartsook Professor of Chemical and Biomolecular Engineering, Materials Science and NanoEngineering and Chemistry, explained in a news release. “As CNT fibers are being scaled up, we asked whether and how these new materials could be recycled in the future .... We expected that recycling would be difficult and would lead to significant loss of properties. Surprisingly, we found that carbon nanotube fibers far exceed the recyclability potential of existing engineered materials, offering a solution to a major environmental issue.”

Rice researchers used a solution-spun CNT fiber that was created by dissolving fiber-grade commercial CNTs in chlorosulfonic acid, according to Rice. Mixing the two fibers led to complete redissolution and no sign of separation of the two source materials into different liquid phases. This redissolved material was spun into a mixed-source recycled fiber that retained the same structure and alignment, which was unprecedented.

Pasquali explained in a video release that the new material has properties that overlap with and could be a replacement for carbon fibers, kevlar, steel, copper and aluminum.

“This preservation of quality means CNT fibers can be used and reused in demanding applications without compromising performance, thus extending their lifecycle and reducing the need for new raw materials,” co-first author Ivan R. Siqueira, a recent doctoral graduate in Rice’s Department of Chemical and Biomolecular Engineering, said in a news release.

Other co-authors of the paper are Rice graduate alumni Oliver Dewey, now of DexMat; Steven Williams; Cedric Ginestra, now of LyondellBasell; Yingru Song, now a postdoctoral fellow at Purdue University; Rice undergraduate alumnus Juan De La Garza, now of Axiom Space; and Geoff Wehmeyer, assistant professor of mechanical engineering.

The research is part of the broader program of the Rice-led Carbon Hub, an initiative to develop a zero-emissions future. The work was also supported by the Department of Energy’s Advanced Research Project Agency, the Air Force Office of Scientific Research and a number of other organizations.

Pasquali recently led another team of Rice researchers to land a $4.1 million grant to optimize CNT synthesis. The funds came from Rice’s Carbon Hub and The Kavli Foundation. Read more here.

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Two Rice University lab-stage innovations focused on clean energy are receiving fresh funding to get them closer to commercialization. Photo courtesy of Rice University

2 Houston cleantech research projects score grants from new program

fresh funding

Four Houston research projects are splitting hundreds of thousands of dollars in grant funding from Rice University, and two specifically are targeting energy tech solutions.

After announcing the One Small Step Grant program in September to support Rice-developed, lab-stage innovations, the university has named its inaugural recipients. After receiving nearly 30 applicants, four research projects were selected to share $360,000 in grant funding.

“Being able to fund near-commercial projects represents a leap forward in our mission of supporting the cutting-edge work of our faculty and students and helping bring those to market,” Adrian Trömel, assistant vice president for strategy and investments, says in a news release. “Feedback from industry and investors show that they’re excited on how the One Small Step grants help derisk these technologies, getting them ready to launch. Watch this space for the next generation of leading deeptech companies.”

The selected projects include two focused on clean energy solutions:

  • Solidec, founded by Ryan Duchanois and Yang Xia from Rice Professor Haotian Wang's Lab, is a room temperature, solid-state direct air capture technology. The project received a $100,000 award.
  • HornetX, led by Rice Professor Aditya Mohite's Lab, aims to produce highly stable green hydrogen using a perovskite-based photoelectrochemical cell with leading efficiency. The project received a $80,000 award.

The Office of Innovation created an investment advisory committee — made up of entrepreneurs, investors and corporate executives across industries — to select these recipients. The grant program was funded by the Office of Innovation, with support from Breakthrough Energy Fellows for climate and energy projects

“The inaugural winners of the One Small Step Grant represent the innovative spirit and dedication to excellence that defines our students and faculty," Rice Chief Innovation Officer Paul Cherukuri says. "We are proud to support these groundbreaking projects on their journey from lab to market."

The other two funded projects include a novel, hydrogel-encapsulated engineered "cell factories" for the minimally invasive treatment of endometriosis and covalent organic framework-based photocatalysts for instream remediation of PFAS (per- and polyfluoroalkyl substances) from water.

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This article originally ran on InnovationMap.

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Japanese company launches solar module manufacturing at Houston-area plant

solar plant

A local subsidiary of a Japanese solar equipment manufacturer recently began producing solar modules at a new plant in Humble.

TOYO Co. Ltd.’s TOYO Solar LLC subsidiary can produce 1 gigawatt worth of solar modules per year at a 567,140-square-foot plant it leases in Lovett Industrial’s Nexus North Logistics Park on Greens Road. TOYO Solar’s next phase will accommodate 2.5 gigawatts’ worth of solar module manufacturing. The subsidiary eventually plans to expand manufacturing capacity to 6.5 gigawatts.

For now, TOYO Solar operates only one assembly line at the Humble plant. Once TOYO Solar has five assembly lines up and running, it could employ as many as 750 manufacturing workers there, according to Connect CRE.

TOYO says the plant enlarges its U.S. footprint “to be closer to the majority of its clients, meet the demand for American-made solar panels, and contribute to the growing demand for secure, sustainable energy solutions as demands on the grid continue to rise.”

Last month, TOYO purchased the remaining 24.99 percent stake in TOYO Solar to make it a wholly owned subsidiary. TOYO entered the Houston-area market through its 2024 acquisition of a majority stake in Solar Plus Technology Texas LLC.

Record $9.6M fine for Houston-based co. after Gulf of Mexico oil spill

In the news

Pipeline safety regulators on Monday, January 5, assessed their largest fine ever against the company responsible for leaking 1.1 million gallons of oil into the Gulf off the coast of Louisiana in 2023. But the $9.6 million fine isn’t likely to be a major burden for Third Coast to pay.

This single fine is close to the normal total of $8 million to $10 million in all fines that the Pipeline and Hazardous Materials Safety Administration hands out each year. But Third Coast has a stake in some 1,900 miles of pipelines, and in September, the Houston-based company announced that it had secured a nearly $1 billion loan.

Pipeline Safety Trust Executive Director Bill Caram said this spill “resulted from a company-wide systemic failure, indicating the operator’s fundamental inability to implement pipeline safety regulations,” so the record fine is appropriate and welcome.

“However, even record fines often fail to be financially meaningful to pipeline operators. The proposed fine represents less than 3% of Third Coast Midstream’s estimated annual earnings,” Caram said. “True deterrence requires penalties that make noncompliance more expensive than compliance.”

The agency said Third Coast didn't establish proper emergency procedures, which is part of why the National Transportation Safety Board found that operators failed to shut down the pipeline for nearly 13 hours after their gauges first hinted at a problem. PHMSA also said the company didn't adequately assess the risks or properly maintain the 18-inch Main Pass Oil Gathering pipeline.

The agency said the company “failed to perform new integrity analyses or evaluations following changes in circumstances that identified new and elevated risk factors” for the pipeline.

That echoed what the NTSB said in its final report in June, that “Third Coast missed several opportunities to evaluate how geohazards may threaten the integrity of their pipeline. Information widely available within the industry suggested that land movement related to hurricane activity was a threat to pipelines.”

The NTSB said the leak off the coast of Louisiana was the result of underwater landslides, caused by hazards such as hurricanes, that Third Coast, the pipeline owner, failed to address despite the threats being well known in the industry.

A Third Coast spokesperson said the company has been working to address regulators' concerns about the leak, so it was taken aback by some of the details the agency included in its allegations and the size of the fine.

“After constructive engagement with PHMSA over the last two years, we were surprised to see aspects of the recent allegations that we believe are inaccurate and exceed established precedent. We will address these concerns with the agency moving forward," the company spokesperson said.

The amount of oil spilled in this incident was far less than the 2010 BP oil disaster, when 134 million gallons were released in the weeks following an oil rig explosion, but it could have been much smaller if workers in the Third Coast control room had acted more quickly, the NTSB said.

40+ climatetech startups join Greentown, including a dozen from Houston

green team

More than 40 climatetech startups joined the Greentown Labs Houston community in the second half of 2025. Twelve hail from the Bayou City.

The companies are among a group of nearly 70 that joined the climatetech incubator, which is co-located in Houston and Boston, in Q3 and Q4.

The new companies that have joined the Houston incubator specialize in a variety of clean energy applications, from green hydrogen-producing water-splitting cycles to drones that service wind turbines.

The local startups that joined Greentown Houston include:

  • Houston-based Wise Energie, which delivers turnkey microgrids that blend vertical-axis wind, solar PV, and battery storage into a single, silent system.
  • The Woodlands-based Resollant, which is developing compact, zero-emissions hydrogen and carbon reactors to provide low-cost, scalable clean hydrogen and high-purity carbon for the energy and manufacturing sectors.
  • Houston-based ClarityCastle, which designs and manufactures modular, soundproof work pods that replace traditional drywall construction with reusable, low-waste alternatives made from recycled materials.
  • Houston-based WattSto Energy, which manufactures vanadium redox flow batteries to deliver long-duration storage for both grid-scale projects and off-grid microgrids.
  • Houston-based AMPeers, which delivers advanced, high-temperature superconductors in the U.S. at a fraction of traditional costs.
  • Houston-based Biosimo, which is developing bio-based platform chemicals, pioneering sustainable chemistry for a healthier planet and economy.
  • Houston-based Ententia, which offers purpose-built, generative AI for industry.
  • Houston-based GeoKiln Energy Innovation, which is developing a new way to produce clean hydrogen by accelerating natural geologic reactions in iron-rich rock formations using precision electrical heating.
  • Houston-based Timbergrove, which builds AI and IoT solutions that connect and optimize assets—boosting visibility, safety, and efficiency.
  • Houston-based dataVediK, which combines energy-domain expertise with advanced machine learning and intelligent automation to empower organizations to achieve operational excellence and accelerate their sustainability goals.
  • Houston-based Resonant Thermal Systems, which uses a resonant energy-transfer (RET) system to extract critical minerals from industrial and natural brines without using membranes or grid electricity.
  • Houston-based Torres Orbital Mining (TOM),which develops autonomous excavation systems for extreme environments on Earth and the moon, enabling safe, data-driven resource recovery and laying the groundwork for sustainable off-world industry.

Other startups from around the world joined the Houston incubator in the same time period, including:

More than 100 startups joined Greentown this year, according to an end-of-year reflection shared by Greentown CEO Georgina Campbell Flatter.

Flatter joined Greentown in the top leadership role in February 2025. She succeeded former CEO and president Kevin Knobloch, who stepped down in July 2024.

"I moved back to the United States in March 2025 after six years overseas—2,000 miles, three children, and one very patient husband later. Over these months, I’ve had the chance to hear from the entrepreneurs, industry leaders, investors, and partners who make this community thrive. What I’ve experienced has left me brimming with urgent optimism for the future we’re building together," she said in the release.

According to Flatter, Greentown alumni raised more than $2 billion this year and created more than 3,000 jobs.

"Greentown startups and ecosystem leaders—from Boston, Houston, and beyond—are showing that we can move further and faster together. That we don’t have to choose between more energy or lower emissions, or between increasing sustainability and boosting profit. I call this the power of 'and,'" Flatter added. "We’re working for energy and climate, innovation and scale, legacy industry and startups, prosperity for people and planet. The 'and' is where possibility expands."

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