Development and demonstration of a deployable apparatus for generating hydrogen from the hydrolysis of aluminum via sodium hydroxide

Emergency and backup power is often enabled through the use of petrochemical based fuels and combustion-based generator systems, and while reliable, these backup power systems fail when petrochemical supplies are disrupted due to refinery, oil outages, or transportation delays. Fuel cells in some cases can serve as a backup to these traditional generators, but they also are fuel-limited to supplies of available energy sources. Recent work conducted in our laboratories focused on the development of a “backup” emergency hydrogen generation system that could be employed when existing energy stockpiles have failed or depleted. Specifically, aluminum metal can be used to generate hydrogen for fuel cells via hydrolysis with sodium hydroxide. In this paper, we summarize the engineering work to produce a deployable aluminum to hydrogen generator which is capable of producing 3.75 kg of hydrogen per day from scrap aluminum feedstocks. The generator was built upon an aircraft deployable pallet, allowing for hydrogen to be generated remotely in cases of power and fuel outages.