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MIT engineers develop scalable green hydrogen from scrap aluminum and seawater

A cradle-to-grave analysis reports a carbon footprint of just 1.45 kg of CO₂ per kilogram of hydrogen alongside production of valuable boehmite

MIT engineers have developed a new aluminum-based process to produce hydrogen gas, that they are testing on a variety of applications, including an aluminum-powered electric vehicle.
making hydrogen from soda cans

Overview

  • MIT researchers led by Aly Kombargi published a method that reacts recycled aluminum pellets treated with a gallium-indium alloy and seawater to generate hydrogen gas
  • Life cycle assessment shows the technique emits only 1.45 kg of CO₂ per kilogram of hydrogen, nearly 90% less than fossil-fuel-based processes
  • Hydrogen production costs are estimated at about $9 per kilogram, making it competitive with wind- and solar-powered green hydrogen
  • The reaction produces boehmite, a high-value aluminum oxide used in semiconductors and industrial products, which could help offset overall costs
  • The team demonstrated compact reactors powering an electric bike and envisions coastal fuel stations where aluminum pellets generate hydrogen on demand