Aluminum scrap is one of the most common materials found on military bases and aircraft carriers worldwide. Now, the U.S. Army has tapped Georgia Tech to help turn that waste into power that can be generated off the grid and on demand. 

The Army Research Office awarded Georgia Tech and its partners $20 million to develop scalable, efficient methods for transforming aluminum into hydrogen energy. The project could lead to a new, low-cost, clean, and efficient energy source powered by discarded materials. 

Aaron Stebner, professor and Eugene C. Gwaltney Jr. Chair in Manufacturing in the George W. Woodruff School of Mechanical Engineering and professor in the School of Materials Science and Engineering, will oversee the multi-year effort at Georgia Tech together with Scott McWhorter, lead for Federal Initiatives at the Strategic Energy Institute.

In addition to several team members from Georgia Tech and the Georgia Tech Research Institute, the project includes researchers from Fort Valley State University, the 21st Century Partnership, MatSys, and Drexel University. 

“Aluminum already reacts with water — even wastewater and floodwater — to create hydrogen gas, power, and thermal energy,” McWhorter said. “If aluminum can be efficiently upcycled into stored energy, it could be a game-changer.” 

The team’s goal is to experiment with aluminum’s material properties so it can be inexpensively manufactured to create a highly effective reaction that produces low-cost, clean hydrogen.

“Having this ability would allow military bases to be less dependent on the use of a foreign country’s electrical grids,” said Stebner, who is also co-director of Georgia Artificial Intelligence in Manufacturing and faculty at the Georgia Tech Manufacturing Institute. 

Manufacturing Aluminum

Several years ago, the Army Research Lab discovered and patented the basic technology for recycling aluminum to produce hydrogen gas. However, current manufacturing methods require too much energy for the amount of hydrogen energy produced.  

To make the technology viable and effective, Stebner and his colleagues will research alternate manufacturing processes and then develop automated methods for safely producing and storing stable aluminum. They also plan to optimize these processes using digital twin technologies.

Currently, manufacturers use large machines to grind up and tumble the aluminum in very controlled environments, because stray aluminum powder can be explosive. These methods are very costly. 

Stebner and the team are looking into small, modular technologies that could allow for convenient, onsite energy generation. According to Stebner, they are interested in determining how these smaller machines could be so efficient that they could be powered using solar panels. 

Stebner envisions that a field of solar panels could power the aluminum-processing modules — the aluminum recycling could be done while the sun shines and produce power 24/7. 

Sustainable Impact 

Once they have developed the manufacturing techniques and processes, the team plans to test their efficacy by generating power for rural Georgia communities. Success here would prove the technology could be viable for military deployments and other off-grid scenarios. 

“The Deep South — especially middle and southern Georgia, Alabama, Mississippi, and Louisiana — often has enormous energy disruptions during hurricanes or power outages due to flooding and severe rains,” Stebner said. “Manufacturers can be hesitant to build big plants there, because the grids aren’t as stable. This same technology that the Army plans to use for remote military bases could be a game-changer in rural Georgia.”

If power is unexpectedly cut in those areas, floodwater could then be used to make hydrogen gas. While hydrogen has not yet had its day in the sun, it has great potential as an alternative to fossil fuels, Stebner says. 

“From a sustainability perspective, any time you can take something that’s already waste — like scrap aluminum and wastewater — and turn it into a high-value product that can be used to power communities, that is a huge win.” 

Funding: Army Research Office