The present work aims to explain the aluminum hydrolysis reaction kinetics based on properly chosen theoretical model with machined aluminum waste chips and alkali solutions up to 1M as a promoter, and to estimate overall reaction profit. In order to obtain results of better accuracy, we work with flat Al waste chips because a flat surface is preferable to maximally increase the time for created hydrogen bubbles to reach the critical gas pressure. At describing the reaction kinetics, flat shape allows using a planar one-dimensional shrinking core model instead of much complicated polydisperse spheric shrinking core model. We analyze the surface chemical reaction and mass transfer rate steps to obtain the first order rate constant for surface reaction and the diffusion coefficient of aqueous reactant in the byproduct layer, respectively. With our reactor we achieved H2 yield of 1145 mL per 1 g Al with 1M NaOH, which is 92% of the theoretical maximum. At estimation of the profit, we pay much attention to the loss of alkaline and find a crucial dependence on its price. Nevertheless, in terms of consumed and originated materials for sale, conversion of the aluminum waste material into green hydrogen by properly chosen reaction parameters has a positive profit even by consuming alkali of chemical grade.

In this work various sample of primary aluminum dross were investigated for composition and evaluation of hydrogen generation via hydrolysis in low concentration alkali solution. Composi-tion revealed low to moderate aluminium content and hydrolysis reactions showed low hydrogen generation volumes per sample mass as well as purity, where composition plays substantial role in the hydrogen evolution, yet showing that there is possible place for dross use in hydrogen generation. It was revealed that some dross samples in addition to hydrogen also release methane via hydrolysis. Rection rate was obtained by the shrinking core model, written for spherical solid particles. Sample composition on hydrogen generation volume is compared to known literature.