DISMI – Dept. of Sciences and Methods for Engineering
University of Modena and Reggio Emilia
Via Amendola 2, Pad. Morselli – 42122 Reggio Emilia – Italy
Aluminium as an Energy Carrier for Green Hydrogen Production: from Lab-Scale Prototype to Industrial System
This work presents a comprehensive overview of a long-term research effort aimed at developing aluminum as an efficient energy carrier for green hydrogen production. The study builds on more than fifteen years of experimental and numerical investigations conducted at the University of Modena and Reggio Emilia, progressing from early laboratory prototypes to systems approaching industrial readiness. The underlying reaction—between aluminum and water to produce hydrogen, alumina, and heat—is highly exothermic and enables a circular process in which alumina can be fully recycled back into aluminum. This makes aluminum a promising medium for energy storage and decarbonization strategies.
The research examines two main technological approaches: liquid aluminum injection and aluminum powder combustion. Dedicated test benches, CFD simulations, and advanced diagnostics such as shadowgraphy, gas chromatography, and X‑ray diffractometry have been used to characterize reaction efficiency, hydrogen yield, and material transformation. Particular attention is given to the influence of temperature and residence time on alumina formation and hydrogen production. Results show a clear correlation between temperature and conversion rate, with alumina contents reaching up to 97% at 1000°C and hydrogen concentrations rising significantly with increasing thermal input.
With the construction of a full laboratory reactor and upcoming real‑environment testing planned in the near future, this research marks a significant step toward the industrial deployment of metal‑fuel–based hydrogen systems.
