Startup Launches Groundbreaking Test of Aluminum as Zero-Carbon Fuel

A Boston-based startup, Found Energy, is set to conduct what is being hailed as the largest real-world test of aluminum as a zero-carbon fuel. Founded by Peter Godart, the company aims to utilize scraps of aluminum metal to provide energy for industrial processes, effectively reducing reliance on fossil fuels. The initiative follows years of development, during which Found Energy focused on ways to efficiently release energy from aluminum.

The company recently activated a large-scale aluminum-powered engine, which Godart claims is the biggest aluminum-water reactor ever built. This reactor is scheduled for installation at a tool manufacturing facility in the southeastern United States in January 2026. The facility plans to use the aluminum waste generated during its operations as fuel. While the manufacturer remains unnamed until an official announcement, the project’s success could herald a significant shift in how aluminum scrap is utilized.

The core process involves a reaction between aluminum and water, releasing heat and hydrogen gas. This reaction occurs at room temperature, making it highly efficient compared to conventional methods. Godart explained, “I can just keep this reaction going by adding more water,” as he demonstrated the process in a laboratory setting. The high heat generated could potentially mitigate the greenhouse gas emissions produced by industries that find it challenging to transition to electric power, such as cement production and metal refining.

Aluminum as a Fuel Source: Challenges and Innovations

Despite the promising aspects of aluminum as a fuel, challenges persist. One significant barrier is the oxidized layer that forms on aluminum when it starts to react, effectively stifling further combustion. This phenomenon has caused many in the scientific community to question the viability of aluminum as a fuel source. Geoff Scamans, a metallurgist at Brunel University, voiced skepticism, stating, “This potential use of aluminum crops up every few years and has no possibility of success.”

Nonetheless, Godart believes that Found Energy has made a breakthrough. The team reimagined the role of catalysts in the reaction process. Instead of merely speeding up the interaction between aluminum and water, they developed a catalyst that can be dissolved into the aluminum, enhancing the reaction’s efficiency. This innovative approach allows for more of the aluminum to react with water, producing greater quantities of hydrogen and heat.

During a recent demonstration, Godart showcased the reaction in their research and development lab, highlighting the efficiency of their method. “We just made a boiler,” he remarked, indicating the steam produced by the reaction. The company has successfully powered the engine to a targeted output of 100 kilowatts, comparable to the energy produced by a small diesel engine.

Future Applications and Industry Impact

As Found Energy prepares to deploy its engine at the manufacturing site, the potential applications for this technology extend beyond initial projects. Godart envisions the engine powering various industrial processes, especially within the aluminum recycling and refining sectors. Many aluminum recyclers have expressed interest in transforming their difficult-to-recycle aluminum waste into clean energy.

According to the International Aluminium Institute, an estimated 3 million metric tons of aluminum collected for recycling globally goes unrecycled each year, while an additional 9 million metric tons is not collected at all. This represents a significant opportunity for Found Energy, which could assist in addressing this waste issue while providing a viable energy source.

While the immediate goal is to supply heat and hydrogen for industrial processes, the long-term vision includes a closed-loop system where aluminum hydroxide produced during the reaction could be recharged back into aluminum metal using clean electricity. Godart suggests that this approach could meet a substantial portion of global industrial heat demand, potentially utilizing around 300 million metric tons of aluminum, which represents about 4% of the Earth’s aluminum reserves.

Despite the ambitious plans, challenges remain regarding the energy requirements for recharging the aluminum hydroxide. Jeffrey Rissman, an expert in industrial decarbonization, noted that while this energy storage technology could be beneficial, it will require a consistent supply of low-cost clean electricity.

As Found Energy moves forward with its groundbreaking project, Godart remains optimistic about the potential of aluminum as a sustainable energy source. “We actually believe this can probably do half a megawatt,” he stated, hinting at the unexploited capabilities of the engine. The success of this initiative could pave the way for a future where aluminum waste is not just a byproduct but a vital component in the transition to cleaner industrial processes.