Decarbonizing Heavy Industry—Found Energy’s Revolutionary Approach to Clean Energy Transportation and Waste Conversion
The Problem
Heavy industries like maritime shipping, steel, and cement production contribute approximately 30% of global greenhouse gas (GHG) emissions. They rely on energy-dense fuels like coal and diesel and often operate in remote areas where renewable energy grids are inaccessible.
Decarbonizing these industries is critical but presents a significant challenge due to their immense energy demands and fossil fuel dependence.
Found Energy’s breakthrough technology offers a solution by converting aluminum waste into clean, renewable energy. This innovation provides a scalable and sustainable alternative to traditional fossil fuels, while relying on a source material that is easily available across heavy industries. It has the potential to replace an important part of their energy needs while dramatically reducing their carbon footprint.
The Technology
Found Energy’s technology efficiently transforms aluminum waste into two critical energy outputs: hydrogen gas and thermal energy. This process not only powers industrial operations but also supports the circular economy by recycling aluminum hydroxide (ATH) back into aluminum production, thus reducing waste and minimizing raw material consumption.
The core of Found Energy’s solution lies in the chemical reaction between aluminum and water, which generates hydrogen gas, heat, and ATH, a precursor to alumina. Each ton of aluminum waste yields 8.6 MWh of energy, split between hydrogen gas (51%) and thermal energy (49%). Hydrogen is used as clean fuel, while the thermal energy supports high-temperature industrial processes. The ATH byproduct is reprocessed into alumina, completing a fully circular system.
This technology not only displaces fossil fuels like coal and diesel but also significantly reduces landfill contributions by converting aluminum waste into energy and valuable materials. The result is a cleaner, more efficient industrial energy solution that supports decarbonization in sectors that are historically challenging to green.
Boundless’ Role
To quantify the environmental benefits of their process, Boundless's team produced an independent Environmental Impact Analysis using their proprietary framework, which includes seven Environmental Key Performance Indicators (EKPIs) and industry-specific benchmarking. Boundless also conducted a comprehensive Greenhouse Gas (GHG) Assessment of Found Energy's technology.
The Boundless methodology is grounded in the internationally standardized Life Cycle Assessment (LCA) methodology, evaluating the environmental impact from waste collection through energy generation and ATH recycling. This data-driven approach combines current emissions analysis with market penetration projections, enabling Found Energy to demonstrate both immediate benefits and long-term emissions reduction potential as their technology scales. The assessment methodology adheres to ISO 14040 and 14044 standards, providing Found Energy with defensible data validated by industry experts.
Key Findings from Boundless’ GHG Assessment Included:
- 118% Reduction in GHG Emissions Compared to Conventional Alumina Production: Found Energy's alumina production process achieved -0.285 kg of CO₂e per kilogram of alumina, compared to 1.62 kg of CO₂e using traditional methods. This negative emissions profile was primarily driven by avoided emissions from hydrogen co-production, which eliminated the need for conventional hydrogen production through carbon-intensive processes like steam methane reforming.
- Reduction in Landfill Waste: By converting aluminum scraps into energy and recyclable materials, Found Energy diverted metal waste from landfills while maximizing resource efficiency. The process generated minimal waste, with aluminum scrap waste typically representing only 0-2% of total mass according to industry experts.
- Reduced Dependency on Bauxite Mining: The technology reduced reliance on bauxite mining, which, despite recent sustainability efforts, continues to cause significant environmental impacts through heavy air pollution, water pollution, and land degradation in mining regions.
Additionally, Boundless Identified Alignment with Key United Nations Sustainable Development Goals (SDGs):
- SDG 9: Industry, Innovation, and Infrastructure
Found Energy's process exemplifies sustainable industrialization by establishing a circular economy that transforms aluminum waste into both alumina and hydrogen fuel through an innovative room-temperature reaction process. - SDG 12: Responsible Consumption and Production
The technology directly supports sustainable resource management by diverting aluminum waste from landfills and reducing dependency on raw material extraction. - SDG 13: Climate Action
Found Energy contributed to urgent climate action through demonstrated emissions reduction. Even without accounting for avoided emissions from co-product allocation, their process still achieved a significant reduction.
The Outcome: Positioning Found Energy as an Industry Leader
The Boundless Environmental Impact Report serves as a critical third-party validation tool for Found Energy's novel aluminum-to-energy technology. It was instrumental in Found Energy's decision-making process and client engagements, providing verified data on their carbon footprint and decarbonization potential. The GHG Assessment was particularly valuable given the innovative nature of their technology in the waste-to-value space, where few companies are working to extract energy from aluminum waste.
"As a company developing novel technology for aluminum energy extraction, having third-party validation is essential," says Peter Godart, Co-Founder & CEO of Found Energy. "In today's environment, where we're all trying to quantify impact and understand scope 1, 2, and 3 emissions, it is crucial for us to have precise measurements of not just our operations, but the value we can deliver to clients. The Boundless assessment helps us measure and communicate exactly what potential our technology can have in terms of decarbonization impact."
With their verified environmental credentials, Found Energy continues to advance their mission of transforming aluminum waste into clean energy and recyclable materials. Their unique approach to aluminum processing demonstrates how innovative circular economy solutions can help address the pressing challenge of industrial decarbonization, backed by rigorous environmental impact data.
