A novel chemical method for producing hydrogen by water split reaction, at near neutral pH conditions and without requiring preheating of the reactant materials is presented. “AlumiFuel^TM” a product of aluminum metal and catalyst is exposed to water, when a chemical reaction is initiated and hydrogen is generated. Catalyst utilization accelerates the progressive pitting of metallic aluminum to prevent further metal passivation. This water-split chemical reaction of aluminum and water is essentially a catastrophic corrosion process producing hydrogen on site, on demand. Aluminum metal used for “AlumiFuel^TM” production may be obtained from refined metal industry, from aluminum metal waste or from the dust generated during aluminum metal cutting. The metal aluminum and catalyst are mixed in pulverized form for uniform distribution. Processed “AlumiFuel^TM”, a fire resistant powder at ambient temperature and pressure, can be stored under dry conditions for invariable time period. Alternatively “AlumiFuel^TM” can be combined with the catalyst in a reactor just prior to reaction. “AlumiFuel^TM” is capable of generating hydrogen at low pressures as well as at elevated pressures of about 6000 psig or more with any desired limit based upon reactor vessel's rating standards.

Reaction is exothermic and generates hydrogen very quickly in over 90 % yield. Heat generated during the reaction can be applied for additional power generations. Simple chemistry of reaction, benign nature of reactants/ byproducts and inexpensive cost for the balance of plan are additional assets of the process. Hydrogen production can be customized to meet the consumer requirements adjusting for pressure, temperature and hydrogen flow rates. Hydrogen generation method is safe, environmentally friendly and supplies high purity hydrogen free from any carbon dioxide (CO₂), carbon monoxide (CO), other pollutants, or gases. Reaction products can be completely recycled using existing infrastructure or discarded without contamination concerns. “AlumiFuel^TM” can be formulated and self-regulated with respect to power needs.

The effectiveness of the technique in driving aluminum-water reactions has been studied critically. The primary objective of the study was to maximize the energy efficiency, the ratio of the chemical energy output from the “AlumiFuel^TM” energy input. The overall energy efficiency depends primarily on the “AlumiFuel^TM” parameters, physical parameters of the metal fuel powder, and geometrical arrangements of the reactant. Under an optimized set of experimental variables, the maximum theoretical energy efficiency was achieved. Reaction can be modified to deliver hydrogen fuel as needed, for example reaction can be performed in shorter span to obtain higher gas flow supply or controlled to produce hydrogen in lower quantities for a prolonged duration alleviating the need for high pressure hydrogen storage or bulky hydride storage. Utilizing water split chemistry and processing techniques H₂ is produced at low pressures in a continuous fashion, with a low thermal signature, and variable flow rates requiring no energy inputs. Hydrogen delivery system can be scaled as desired, for example, for use in portable devices, such as electronics and transportable equipment, or for emergency and household power supplies.