A closed-loop system for the storage, transportation, and hydrolysis of metallic fuels for hydrogen supply.

Abstract

This invention discloses a closed-loop system for the storage, transportation, and hydrolysis hydrogen supply of metallic fuels, belonging to the field of hydrogen energy storage and transportation technology. This invention aims to solve the problems of high cost, infrastructure dependence, and lack of recyclability in existing hydrogen storage technologies. The system includes: a porous metallic fuel preparation unit for preparing standardized porous metallic fuel flakes from metal powder; a hydrolysis hydrogen supply device for containing the fuel flakes and controllingly circulating water to carry out the hydrolysis reaction, generating hydrogen and metal hydroxide; a metal hydroxide recovery unit for collecting the metal hydroxide; and a metal regeneration unit for converting the metal hydroxide into metal powder for return, or for purification and sale, with new powder purchased as a replacement. The fuel flakes are stacked or wound, with micron-level gaps between the layers, and a catalyst is added to accelerate the reaction. Through system integration and closed-loop design, this invention achieves efficient recycling of metallic fuels, low storage and transportation costs, and completely eliminates dependence on hydrogen refueling stations and hydrogen pipelines, providing a new path for large-scale, low-cost, and cross-regional deployment of hydrogen energy.

Description

Technical Field

[0001] This invention belongs to the field of hydrogen energy storage and transportation and metal fuel technology, specifically relating to a system for supplying hydrogen through hydrolysis of metal fuels and realizing closed-loop recycling of products.

[0002] Inventive Concept (I) Existing Technological Dilemmas and the "Combination Explosion" Problem

[0003] Through long-term research, the inventors discovered an extremely large network of technical pathways for converting metallic magnesium (or aluminum) into a highly reactive form that can be hydrolyzed. These pathways include, but are not limited to:

[0004]

[0005] Each of the aforementioned paths contains multiple sub-options, and their permutations and combinations constitute an exponentially growing "combinatorial explosion" problem. Those skilled in the art, if employing traditional "trial and error methods" or "single-factor optimization," will be trapped in an endless selection dilemma, unable to find the optimal solution that balances activity, operability, cost, and recyclability within limited time and resources.

[0006] (II) System Optimization and Path Selection

[0007] In response to the aforementioned "combination explosion" problem, the inventors, based on a systematic analysis of electrochemical principles, materials science, engineering thermophysics, and cost models, established the following optimization principles:

[0008] 1. Maximize the reaction interface: The active material needs to have a sufficiently high specific surface area to ensure the hydrolysis reaction rate.

[0009] 2. Mass transfer channel optimization: The structure needs to provide a smooth and uniform transport path for water and hydrogen to avoid blockage of the passivation layer.

[0010] 3. Structural stability: The material should maintain its macroscopic shape during hydrogenation, hydrolysis, and regeneration cycles to prevent pulverization and loss.

[0011] 4. Engineering and standardization: The final form should facilitate automated filling, storage, transportation and recycling.

[0012] 5. Controllable cost: The preparation process should be mature and low-cost, and the by-products should have high added value.

[0013] Based on the above principles, the inventors compared dozens of physical structural paths one by one:

[0014] Powder: Although it meets the requirement of "high specific surface area" (principle 1), the "mass transfer channels" are uncontrollable and easy to block (principle 2), and the "structural stability" is poor and cannot be standardized (principle 4).

[0015] Threads / foams: They have good structural stability (principle 3), but the control precision of specific surface area and mass transfer channels is insufficient (principals 1 and 2), and the preparation cost is relatively high (principle 5).

[0016] Foil: Mass transfer channels are completely missing (Principle 2), and are excluded.

[0017] MOF: Too costly (Principle 5), excluded.

[0018] Ultimately, the "porous sintered sheet" structure emerged as the most suitable approach. It utilizes powder metallurgy to sinter metal powder particles at contact points, forming a structure with the following characteristics:

[0019] High and controllable specific surface area (satisfying principle 1)

[0020] Connectable and designable pores (satisfying principle 2)

[0021] Good mechanical strength and shape retention (satisfies principle 3)

[0022] It can be mass-produced using mature coating and winding processes, and is easy to standardize (meeting principle 4).

[0023] The raw material is industrial metal powder, the process is mature, and the cost is controllable (meeting principle 5).

[0024] (III) From Structural Innovation to System Closed Loop

[0025] After determining that the "porous sintered sheet" was the optimal physical structure, the inventors further validated it within a complete "storage-transportation-hydrolysis-recycling" system. By designing a stacking / winding filling method, reserving micron-level gaps between layers, and introducing a conductive support layer and catalyst, this invention amplifies the advantages of the microstructure into a system-level performance breakthrough, ultimately solving all the engineering challenges brought about by the powder morphology, and for the first time realizing a closed-loop process for metal fuels from "preparation-use-recycling-regeneration".

[0026] (iv) Core Contributions of the Invention

[0027] The core contribution of this invention lies in revealing the fundamental path for the recycling of metal fuels at the system level. This involves transforming the traditionally "one-time consumption" metal hydrolysis method into a closed-loop, profitable hydrogen supply model through a closed-loop architecture of "porous matrix - hydrolysis hydrogen supply - product recovery - regeneration and reuse." This path identification does not rely on breakthroughs in any specific equipment, but rather on a systematic analysis and path optimization based on technological, economic, and infrastructure constraints. It points the way for the development of metal fuel hydrogen production from "point-based improvements" to "system integration." The technical solution of this invention features hydrolysis, which can release hydrogen not only from metal hydrides but also from water. Its mass energy density far exceeds that of other technologies in the industry (for example, magnesium hydride hydrolysis can reach a mass energy density of 15.2%, more than twice the amount of hydrogen released by non-hydrolysis methods). Once this technology route was introduced, it attracted the attention and recognition of many leading companies in the energy and chemical industries and national-level consulting institutions. After several years of in-depth research and continuous iteration, its industrial application prospects have become increasingly clear, providing a practical new path for the large-scale, low-cost, and cross-regional deployment of hydrogen energy.

[0028] (V) System optimization from "feasible technology" to "industrializable technology"

[0029] The inventors confirmed the feasibility of the technology by conducting a field study of the magnesium hydride hydrolysis hydrogen production technology developed by Hiroyuki Uesugi's team in Japan: the team had already built a small-scale pilot production line, achieving the conversion from metallic magnesium to magnesium hydride, and completing its integration with a small fuel cell. However, this technology suffers from the following fatal flaws, preventing its large-scale commercial application:

[0030] 1. Single-use and not closed-loop: This solution treats magnesium hydroxide as a single-use consumable and does not include a recycling and regeneration process for magnesium hydroxide. The overall economic viability cannot support large-scale promotion.

[0031] 2. Insufficient engineering capabilities: Its hydrogen generator releases hydrogen slowly, which cannot meet the demand for rapid and controllable industrial-grade hydrogen supply; the equipment design remains at the laboratory or pilot stage, lacking standardized, modular, and scalable engineering solutions.

[0032] 3. Limited technical approach and lack of systematic optimization: The inventor team has long been limited to the specific technical form of "magnesium ingot sheet pressing" and has not systematically compared and optimized dozens of physical structures such as powder, wire, foam, and foil, resulting in long-term stagnation of their technology and inability to break through cost and performance bottlenecks.

[0034] In stark contrast, this invention is not a simple imitation or partial improvement of the Japanese team's technology, but a complete reconstruction at the system level:

[0035] Through systematic optimization, the "porous sintered sheet" was selected as the optimal form from dozens of physical structures, completely solving engineering problems such as powder flying, uneven reaction, and difficult recycling.

[0036] Through a full-process closed-loop design, for the first time, the five links of "preparation - storage and transportation - hydrolysis - recycling - regeneration" were integrated into a standardized and modular system, realizing the recycling of metal fuels.

[0037] Through business model innovation, flexible paths such as "selling and exchanging for new ones" were introduced, enabling by-products (high-purity magnesium hydroxide / aluminum hydroxide) to directly enter the high-end chemical market, significantly enhancing the full-cycle economy.

[0038] [[ID=1))) Therefore, the contribution of this invention does not lie in the fact that "it is discovered that magnesium can be hydrolyzed to produce hydrogen" (which has already been verified by Japanese teams), nor in "manufacturing a new device", but in identifying and打通 a complete path from a system engineering perspective to transform this "feasible technology" into an "industrializable technology". The identification of this path depends on a comprehensive investigation of the global technology roadmap in this field, a systematic comparison of dozens of physical structures, a profound insight into engineering bottlenecks, and a careful design of the commercialization model. Background Art

[0039] As a clean energy source, the key bottleneck in the large-scale application of hydrogen energy lies in the storage and transportation link. Existing mainstream hydrogen storage technologies include high-pressure gaseous hydrogen storage, liquid hydrogen storage, organic liquid hydrogen storage, ammonia / alcohol hydrogen storage, pipeline hydrogen transportation, solid hydrogen storage (such as hydrogen release from the thermal decomposition of magnesium hydride), and metal hydrolysis method, and each technology has insurmountable defects.

[0040] 1. High-pressure gaseous hydrogen storage

[0041] High-pressure gaseous hydrogen storage (35 - 70 MPa) is currently the most widely used technology, but its disadvantages are very prominent:

[0042] High energy consumption: Compressing hydrogen to 70 MPa requires a large amount of electric energy (about 2 - 3 kWh / kg H2), and the heat effect during the compression process is significant;突出 safety hazards: The storage tank bears extremely high pressure for a long time. Once leaked or ruptured, hydrogen quickly diffuses to form a flammable cloud, which is extremely likely to cause an explosion. Globally, hydrogen refueling stations and hydrogen storage tank explosion accidents occur frequently, becoming a major safety hazard for urban operation. The on-vehicle hydrogen storage tank is like a "moving bomb", and the social acceptance is low; Low hydrogen storage density: Even with carbon fiber-wound storage tanks, the system-level volume energy density is only about 0.036 kg H2 / L, far lower than gasoline (about 0.11 kg H2 equivalent / L); Huge infrastructure investment: The investment in a single hydrogen refueling station is over tens of millions of yuan, and the land, approval, and operation costs are high, restricting the construction of the hydrogen energy network.

[0043] 2. Liquid hydrogen storage It should be noted that there is a possible error in the original text of . The word "打通" is directly translated as "打通" here, which might not be the most accurate expression in English. A more appropriate translation could be "establishing" or "opening up". The translation has been adjusted accordingly in the above content.

[0044] Although liquid hydrogen storage (-253℃) has a high volume density (approximately 0.071 kg H2 / L), it faces multiple challenges: extremely high liquefaction energy consumption: hydrogen liquefaction requires 10-15 kWh / kg H2, accounting for 30%-40% of the energy of hydrogen itself, making it uneconomical; unavoidable evaporation loss: even with top-tier insulated storage tanks, daily evaporation loss still reaches 1%-3%, resulting in significant losses during long-term storage or long-distance transportation; demanding conditions: it requires ultra-low temperature containers and complex insulation structures, leading to high manufacturing costs; operational risks: liquid hydrogen leaks can instantly create a cryogenic freezing zone, and when mixed with air, the explosion range is extremely wide.

[0045] 3. Organic liquid hydrogen storage

[0046] Organic liquid hydrogen storage (such as methylcyclohexane, dibenzyltoluene, etc.) utilizes hydrogenation / dehydrogenation reactions of unsaturated organic compounds to store and release hydrogen. Its drawbacks include:

[0047] High dehydrogenation temperature: typically requires temperatures above 300℃, and the reaction rate is slow, with catalysts prone to carbon buildup and deactivation; Incomplete hydrogen release: limited by thermodynamic equilibrium, the dehydrogenation conversion rate is usually only 80%-90%, with some hydrogen "locked" in organic matter and unusable; Solvent degradation and pollution: organic carriers gradually degrade during recycling, requiring periodic replacement, and wastewater treatment imposes an environmental burden; High catalyst cost: commonly uses precious metal catalysts (such as platinum and palladium), which are prone to poisoning and deactivation, further increasing costs; Low energy density: system-level hydrogen storage density (including storage tanks and heating devices) is typically below 5 wt%.

[0048] 4. Hydrogen transportation via pipeline

[0049] Pipeline hydrogen transportation was once highly anticipated, but its actual implementation faces serious challenges:

[0050] Hydrogen embrittlement: Hydrogen molecules penetrate the metal lattice, leading to decreased plasticity of the pipeline material and accelerated crack propagation. The mechanism of metal embrittlement in a hydrogen environment is not yet fully understood, and long-term operational safety cannot be guaranteed; Leakage risk: Hydrogen molecules are extremely small and easily leak through flanges, welds, and other parts, and leaks are difficult to detect; High construction costs: Dedicated hydrogen pipelines cost several times more than natural gas pipelines, and issues such as safety distances along the route and land acquisition must be considered; High risks of entering residential areas: Hydrogen pipelines entering residential and commercial areas pose a serious risk of explosions and leaks, resulting in extremely low public acceptance; Required gas storage facilities: Both the sending and receiving ends require large-scale hydrogen storage facilities to balance supply and demand, further increasing investment.

[0051] 5. Solid-state hydrogen storage (thermal decomposition of hydrogen by magnesium hydride)

[0052] Solid-state hydrogen storage (such as magnesium hydride powder) utilizes the reversible absorption and desorption of hydrogen by metal hydrides. Its advantages include high hydrogen storage density (theoretically 7.6 wt%) and relatively good safety, but it still has key drawbacks:

[0053] High hydrogen release temperature: Pure magnesium hydride requires temperatures above 300℃ to effectively release hydrogen, resulting in complex systems, high energy consumption, and slow start-up; Poor kinetic performance: Powdered materials have poor thermal conductivity, the thermal effect is concentrated during the reaction process, and they are prone to agglomeration and pulverization during cycling, leading to performance degradation; Low system-level energy density: To provide high temperatures, heating devices, insulation layers, and heat exchange systems are required, and the system-level hydrogen storage density is far lower than the theoretical value; Still dependent on infrastructure: Magnesium hydride production requires high-pressure hydrogen, and its storage and transportation still face the problem of hydrogen source.

[0054] 6. Ammonia / Alcohol Hydrogen Storage

[0055] Ammonia (NH3) and methanol (CH3OH) have been considered potential hydrogen carriers in recent years, capable of releasing hydrogen through cracking or reforming reactions. Typical reactions include:

[0056] Ammonia cracking: 2NH3 → N2 + 3H2 (requires 300-500℃, catalyst)

[0057] Methanol reforming: CH3OH + H2O → CO2 + 3H2 (requires 200-300℃, catalyst). Although this type of technology can utilize existing liquid fuel storage and transportation facilities, it still has significant drawbacks:

[0058] Cracking / reforming has high energy consumption: it requires high temperatures and the reaction is an endothermic process, which reduces system efficiency.

[0059] Carbon content issues: Methanol reforming products contain CO2 (which needs to be deeply removed if used in fuel cells), while ammonia cracking does not contain carbon, but the reaction process is energy-intensive and the catalyst is easily deactivated.

[0060] Difficult to recycle: Ammonia and methanol are primary energy sources that cannot be directly recycled after cracking, resulting in high costs throughout the entire lifecycle.

[0061] Toxicity and Safety: Ammonia is corrosive and toxic, and methanol is toxic, so there are high safety requirements for storage, transportation, and use.

[0062] Hydrogen purity is limited: cracked gas often contains unreacted substances or byproducts, requiring complex purification before it can be used in fuel cells.

[0063] Therefore, although ammonia / ethanol hydrogen storage has potential applications in specific scenarios, it has not fundamentally solved the core issues of hydrogen energy storage and transportation, such as cost, safety, and recycling.

[0064] 7. Metal hydrolysis method (traditional understanding)

[0065] Metal hydrolysis (such as the reaction of magnesium or aluminum with water) is another potential hydrogen supply pathway. Taking magnesium as an example, conventional thermal decomposition of hydrogen only releases the hydrogen stored in magnesium hydride (theoretically containing about 7.6 wt%); however, hydrolysis of hydrogen allows for the extraction of additional hydrogen from water, theoretically reaching a total hydrogen production of 15.2 wt%, nearly double that of thermal decomposition, significantly increasing the hydrogen supply capacity per unit mass of metal. For other metals such as aluminum, hydrolysis can also achieve higher hydrogen production rates than thermal decomposition, and aluminum, being abundant and inexpensive, has potential application value.

[0066] However, metal hydrolysis has long been considered to have two major obstacles: first, a dense hydroxide passivation layer easily forms on the metal surface, hindering the continued reaction; second, the metal hydroxide produced in the reaction needs to be electrolyzed or thermally reduced back to metal, and the traditional view is that this reduction process is too energy-intensive, making the overall cost unacceptable. Therefore, existing technological research has mostly focused on the thermal dehydrogenation pathway, attempting to lower the hydrogen release temperature of magnesium hydride through catalysts, nanotechnology, and other means, while metal hydrolysis is regarded as a "one-time consumption" route, and the problem of recycling its metal resources has not been systematically solved for a long time.

[0067] 8. Systemic defects and resource analysis of existing technologies

[0068] Through in-depth exchanges and collaborations with multiple research teams and enterprises both domestically and internationally, the inventors conducted on-site investigations and systematic analyses of the practical engineering challenges of existing metal hydrolysis hydrogen production technologies. They discovered that despite decades of research history in this field and the participation of numerous top research institutions and companies, existing technical solutions generally suffer from the following fundamental flaws, preventing them from achieving large-scale, low-cost, and closed-loop commercial applications. Simultaneously, these collaborations and investigations provided the crucial equipment and process foundation for the technical approach of this invention.

[0069] (1) Technical approach of Hiroyuki Uesugi's team in Japan (representative solution)

[0070] The inventor was invited to Japan multiple times to inspect the team's pilot production line and products. Their technical solution involves cutting magnesium ingots into thin sheets, pressing and stacking them, and then hydrogenating them to produce magnesium hydride sheets, intended for use in small-scale hydrogen generators for high-end consumer applications such as medical aesthetics. While this solution achieves the conversion from metallic magnesium to magnesium hydride and integrates it with small fuel cells, its technical architecture suffers from the following fatal flaws:

[0071] Unable to achieve resource closure: This solution treats magnesium hydride as a disposable consumable and does not include a recycling or regeneration process. While its application in the high-value-added medical aesthetics market allows it to withstand the high cost of single-use, this limitation prevents its expansion into large-scale civilian markets such as transportation and energy storage.

[0072] The reaction rate is slow and cannot be industrialized: its hydrogen generator releases hydrogen slowly, which cannot meet the demand for rapid and controllable industrial-grade hydrogen supply. This is due to the small specific surface area of ​​its "magnesium ingot sheet" structure, the limited reaction interface, and the lack of effective engineering design for the hydrolysis reaction (such as the absence of a forced water flow channel).

[0073] The technological approach was limited by the founder's vision: Although the team's founder, Hiroyuki Uesugi, possessed a series of patents, his technological approach remained at the level of "material preparation" and "single-use," lacking the ability to solve resource recycling and large-scale application from a systems engineering perspective. The inventor attempted to introduce domestic capital to assist in industrialization, but due to the other party's lack of open cooperation and systems engineering thinking, the cooperation failed to deepen, and the technology remained stagnant in the pilot-scale stage for a long time.

[0074] (2) Technical bottlenecks of mainstream domestic academic teams

[0075] Top domestic research institutions, represented by Academician Ding Wenjiang's team at Shanghai Jiao Tong University, have long been deeply involved in magnesium-based materials. They initially explored a route for hydrogen production via magnesium powder hydrolysis, but were ultimately forced to abandon this route due to the reaction termination problem caused by the magnesium hydroxide passivation layer during hydrolysis, and instead focused on thermal decomposition of hydrogen. While thermal decomposition of hydrogen avoids the passivation layer problem, it has the following disadvantages:

[0076] Hydrogen production is halved: thermal decomposition of hydrogen only releases the hydrogen stored in magnesium hydride (theoretical 7.6 wt%), while hydrolysis of hydrogen can extract additional hydrogen from water, nearly doubling the total hydrogen production.

[0077] High energy consumption and complex system: Thermal decomposition of hydrogen requires temperatures above 300°C, resulting in slow system start-up, high energy consumption, and a significant increase in equipment and operating costs.

[0078] (3) The "national team" in China's solid-state hydrogen storage field - Jiang Lijun's team from China Research Institute of Nonferrous Metals (formerly Beijing General Research Institute of Nonferrous Metals)

[0079] Professor Jiang Lijun's team is one of the earliest institutions in my country to engage in research on solid-state hydrogen storage technology, possessing profound technical expertise and engineering experience in areas such as magnesium hydride preparation and rare-earth hydrogen storage alloys. The inventor maintains long-term technical exchanges with this team and has established a strong cooperative relationship. This team can provide key hydrogenation furnace equipment, process parameters, and engineering experience for the large-scale preparation of magnesium hydride.

[0080] However, the team's technical approach has long focused on solid-state hydrogen storage (thermal decomposition of hydrogen), with its core research goal being to reduce the hydrogen release temperature of magnesium hydride and improve cycle stability. While this approach has made significant progress at the materials science level, it has consistently failed to fundamentally solve system-level problems such as high energy consumption, system complexity, and the inability to utilize hydrogen sources in water during thermal decomposition of hydrogen. Their technological achievements are mainly applied to specific fields with particular requirements for energy density and safety, making large-scale deployment in the cost-sensitive civilian market difficult.

[0081] (4) Common limitations of other research institutions

[0082] The inventors also surveyed relevant research at universities such as Xi'an Jiaotong University and found that such research was mostly academic exploration and generally suffered from the following problems:

[0083] Superficial and lacking sustained investment: Most of these are graduate-level projects, and the research ends after graduation, failing to develop systematic engineering solutions.

[0084] Reliance on chemical additives: To overcome the passivation layer problem, the method of adding weak acids, strong bases or expensive catalysts is often adopted. This not only increases costs and corrodes equipment, but also leads to a decrease in the purity of the by-product magnesium hydroxide, which loses its high-value utilization value and makes it difficult to meet the requirements of economic efficiency and environmental friendliness for commercial applications.

[0085] (5) Clarification of the concept of "single hydrolysis"

[0086] In recent years, controversial technological concepts such as the "Nanyang Youth Automobile Water-Hydrogen Engine" have emerged in society. These technologies typically claim that "cars can be powered simply by adding water," but in essence, they circumvent the law of conservation of energy by attempting to use water directly as an energy source. They lack a closed-loop design for recycling and regenerating metallic fuels, and are therefore generally considered by the scientific and engineering communities to be unfeasible.

[0087] The technical solution of this invention is fundamentally different from such concepts:

[0088] Following the principles of energy conservation and material cycling: This invention uses magnesium (or aluminum) as the energy carrier, with water serving only as a reactant to provide hydrogen. The metal reacts with water to form metal hydroxide, which can be converted back into metal through electrolysis or thermal reduction, achieving a closed-loop material cycle. The entire process strictly adheres to the laws of thermodynamics, achieving an economical balance between energy input (energy consumption for metal preparation) and energy output (calorific value of hydrogen).

[0089] Systematic Engineering Architecture: This invention is not a "single device" or "single reaction," but rather a complete system encompassing "metal fuel preparation - standardized storage and transportation - controlled hydrolysis hydrogen supply - high-value product recovery - metal regeneration and reuse." Each step utilizes mature industrial technologies and achieves collaboration through standardized interfaces.

[0090] A clear business model: This invention supports multiple business models such as "sales for new products" and "centralized recycling." Its byproducts (high-purity magnesium hydroxide / aluminum hydroxide) have clear and high-value market applications (such as flame retardants and pharmaceutical additives), making full-cycle economic viability possible, rather than relying on the fantasy of "producing hydrogen out of thin air." Therefore, this invention is a systematic, engineered, and commercial innovation in metal fuel recycling technology, fundamentally different from any previous technical solutions that attempted to circumvent energy conservation or lacked a closed-loop design.

[0091] (6) Industrial Cooperation and Future Prospects

[0092] Through extensive technical research and industry exchanges, the inventors have also established connections with leading enterprises and consulting firms in the energy and chemical industries, including China International Engineering Consulting Corporation, State Power Investment Corporation, China Energy Investment Corporation, China National Chemical Engineering Group Corporation, and Tongwei Group. These entities have shown great interest in the metal fuel closed-loop hydrogen supply technology proposed in this invention, recognizing its unique advantages in addressing core issues such as high hydrogen storage and transportation costs and heavy reliance on infrastructure. This positive feedback from industry further confirms that the technical approach of this invention possesses clear commercial prospects and industrial application value.

[0093] In summary, the above analysis shows that while existing technologies have made some progress in laboratories or specific high-end fields, their common problem lies in the lack of systematic engineering thinking. They are either hampered by the engineering challenges of powder form, trapped in the energy dilemma of pyrolysis pathways, or limited to single-use business models, failing to construct a complete closed loop of "preparation-storage-hydrolysis-recycling-regeneration." Even the top domestic solid-state hydrogen storage teams have not escaped the framework of pyrolysis for hydrogen. This invention, through in-depth communication with the aforementioned teams, has gained a profound understanding of the advantages, disadvantages, and bottlenecks of each technical route, and integrated available engineering resources (such as the hydrogenation furnace equipment from the GRINM Group), ultimately proposing this novel architecture that solves the problem from a systemic perspective.

[0094] 9. Strategic bottlenecks in hydrogen energy development: resource misallocation and infrastructure dependence

[0095] In March 2025, several national ministries jointly issued the "Notice on Carrying Out Pilot Work for High-Quality Development of the Hydrogen Energy Industry," launching pilot projects for the hydrogen energy industry in multiple city clusters, aiming to promote the large-scale application of hydrogen energy in transportation, industry, and energy storage. However, existing technological approaches still face two fundamental challenges in addressing the economic viability of the entire hydrogen energy supply chain: production, storage, transportation, refueling, and utilization.

[0096] (1) Resource misallocation and power transmission costs

[0097] my country's hydrogen energy resources and energy demand exhibit a significant spatial mismatch: the western and northern regions are rich in wind and solar resources, and the cost of producing green hydrogen can be as low as 15-25 yuan / kg (utilizing curtailed wind and solar power), but the energy load centers are concentrated in the eastern coastal areas. If the "western hydrogen production + long-distance storage and transportation" model is adopted, the cost of hydrogen storage and transportation will be as high as tens to hundreds of yuan / kg, making it economically unfeasible.

[0098] If the "western green electricity + ultra-high voltage power transmission + eastern hydrogen production" model is adopted, the following problems will be faced:

[0099] Ultra-high voltage transmission lines have long construction cycles and huge investments, and transmission losses increase with distance; new energy power (wind power, photovoltaic) has intermittent and fluctuating characteristics, and it is difficult to guarantee continuous production when directly used for water electrolysis to produce hydrogen, requiring large-scale energy storage devices, which further increases costs; land resources are scarce in the eastern region, and the construction of large-scale water electrolysis hydrogen production facilities faces multiple constraints such as land use, water use, and environmental impact assessment.

[0100] (2) Limitations of the hydrogen refueling station model

[0101] Currently, hydrogen energy pilot cities generally adopt "hydrogen production by water electrolysis at hydrogen refueling stations" as the main method for end-user hydrogen supply. This involves installing small water electrolysis devices at hydrogen refueling stations to produce hydrogen using grid electricity or localized green electricity, which is then used to directly refuel fuel cell vehicles. While this model avoids the costs of hydrogen storage and transportation, it has the following limitations:

[0102] The investment in a single hydrogen refueling station can reach tens of millions of yuan, with the main components being water electrolysis hydrogen production equipment, compressors, hydrogen storage tanks, and refueling machines, resulting in high depreciation and operating costs. Hydrogen refueling stations rely on a stable and inexpensive power supply. If grid electricity is used, the cost of hydrogen production fluctuates with electricity prices. If green electricity is used, energy storage is required, further increasing investment. The location of hydrogen refueling stations is constrained by factors such as urban planning, land availability, and safety distances, making it difficult to achieve "dense coverage like gas stations," thus limiting the promotion of hydrogen-powered transportation. This model cannot address the needs of non-transportation scenarios such as industrial hydrogen use, distributed power generation, and household energy supply.

[0103] (3) Existing technologies cannot fundamentally solve the above problems.

[0104] High-pressure gaseous hydrogen storage, liquid hydrogen storage, organic liquid hydrogen storage, and pipeline hydrogen transportation technologies are all constrained by high storage and transportation costs, infrastructure construction cycles, or energy efficiency losses, making it difficult to achieve large-scale, low-cost, and high-efficiency transmission of "western energy to eastern load centers" in the foreseeable future.

[0105] While solid-state hydrogen storage (such as the thermal decomposition of hydrogen by magnesium hydride) offers advantages in safety and storage density, its high hydrogen release temperature and reliance on hydrogen refueling infrastructure remain significant drawbacks, and it cannot utilize hydrogen sources found in water. In summary, current technologies lack a systematic solution that simultaneously addresses the three major issues of resource misallocation, infrastructure dependence, and end-user hydrogen supply costs. This invention is proposed against this backdrop, aiming to achieve a novel hydrogen energy supply model through a closed-loop metal fuel cycle system: "Western hydrogen / metal production → ambient temperature and pressure storage and transportation → Eastern water electrolysis hydrogen supply → centralized product recycling and regeneration." This model fundamentally eliminates dependence on hydrogen refueling stations and pipeline networks, paving a new path for the large-scale application of hydrogen energy.

[0106] 10. The starting point of this invention

[0107] The inventors have discovered through research that the aforementioned traditional viewpoints contain systematic misjudgments regarding metal hydrolysis methods:

[0108] Hydrogen production is severely underestimated: taking magnesium as an example, hydrolysis produces nearly twice as much hydrogen as thermal decomposition, which means that the energy consumed in the reduction of metal hydroxides can be covered by the value of the extra hydrogen.

[0109] The reduction cost is overestimated: With the continuous progress of industrial technologies such as electrolytic aluminum and electrolytic magnesium, the energy consumption for the reduction of metal hydroxides has been greatly reduced (e.g., the energy consumption for electrolytic magnesium has been reduced to 10-12 kWh / kg Mg). Combined with the additional hydrogen revenue, the full-cycle economics are competitive.

[0110] Infrastructure bottlenecks are being overlooked: The fundamental bottleneck restricting the development of hydrogen energy is not the cost of hydrogen production, but the supporting investment in hydrogen energy infrastructure.

[0111] The proposed closed-loop system for metal fuel storage, transportation, and hydrogen supply via hydrolysis utilizes standardized, porous sheets of metal fuel that can be stored and transported at ambient temperature and pressure. Users only need to add water to produce hydrogen, and the resulting metal hydroxide is centrally recycled. This model completely eliminates reliance on infrastructure such as high-pressure hydrogen refueling stations, liquid hydrogen tankers, and hydrogen pipelines. The metal fuel sheets can be distributed using existing civilian logistics networks such as convenience stores and gas stations, shifting the focus of hydrogen energy applications from "infrastructure construction first" to "fuel supply first," and is expected to drive the hydrogen energy industry into a period of explosive growth. Summary of the Invention

[0112] This invention aims to provide a closed-loop system for the storage, transportation, and hydrolysis hydrogen supply of metal fuels. It integrates mature technologies such as metal fuel preparation, hydrolysis hydrogen supply, metal hydroxide recovery, and metal regeneration, and achieves efficient recycling of metal resources through standardized interfaces and closed-loop control.

[0113] System Overall Architecture

[0114] This system consists of the following six subsystems, which are connected through standardized interfaces to form a complete closed loop: metal fuel preparation → storage and transportation → hydrolysis hydrogen supply → product recovery → metal regeneration → reuse.

[0115] Step 1: Preparation of Metal Fuel Sheets

[0116] Function

[0117] Metal powder is made into standardized sheets with a porous structure that can be rolled or stacked, serving as a fuel carrier for hydrogen supply via hydrolysis.

[0118] Technical solution

[0119] 1.1 Raw materials and particle size

[0120] Magnesium or aluminum powder is used, with a purity not lower than industrial grade standards. The selection of particle size should comprehensively consider the balance between raw material cost and hydrolysis reaction rate: excessively fine particles, while having a large specific surface area and fast reaction, are costly and prone to agglomeration; excessively coarse particles result in insufficient reaction interface, potentially leading to reaction termination due to the formation of a passivation layer. Those skilled in the art can select a specific particle size through conventional experiments based on the target application scenario and the above principles. As an example, industrial-grade metal powders in the range of 10-100 μm can be used, with 20-50 μm being a commonly used and preferred range.

[0121] 1.2 Conductive Support Layer and Composite Structure

[0122] To enhance the mechanical strength of the fuel pellets and construct the cathode of the galvanic cell, at least one conductive support layer can be introduced. The conductive support layer is a porous conductive material, and its selection should meet the requirements of corrosion resistance, conductivity, and bonding strength with the metal powder layer. After sintering, the conductive support layer forms a composite structure with the metal powder layer, which serves to: provide the mechanical strength required for winding or stacking; act as the cathode of the galvanic cell, accelerating electron transfer; and ensure that the porous structure does not obstruct water flow. As an example, the conductive support layer can be made of graphite felt, carbon fiber cloth, stainless steel mesh, or nickel mesh.

[0123] 1.3 Coating Process

[0124] Any existing method suitable for powder slurry coating is used to uniformly coat a slurry made by mixing metal powder with a binder and solvent onto the surface of a conductive support layer or a release substrate. The coating process should meet the following conditions: it should ensure uniform coating of the metal powder; the coating thickness should be controllable; and it should be suitable for continuous production. For example, the coating method includes, but is not limited to, blade coating, roller coating, tape casting, spraying, and screen printing. The thickness of the metal powder layer in the coated wet preform can be determined according to the target reaction rate and packing density requirements. For example, the thickness can be controlled within the range of 0.3-0.5 mm.

[0125] 1.4 Drying and Sintering

[0126] The drying and sintering processes should meet the following common principles:

[0127] dry:

[0128] Objective: To remove solvent and give the green body a certain mechanical strength; Principle: The drying temperature should be lower than the decomposition temperature of the binder to avoid cracking of the green body; The drying time should be sufficient to allow the solvent to evaporate completely.

[0129] sintering:

[0130] Objective: To enable the metal powder particles to form sintered necks and obtain a porous structure; to ensure complete thermal decomposition of the binder and avoid residue;

[0131] Principles: The sintering temperature should be lower than the melting point of the metal to avoid pore collapse; the holding time should be sufficient to allow the binder to decompose completely (residual amount less than 0.1%).

[0132] Atmosphere: Inert atmosphere (such as argon, nitrogen) or vacuum conditions to avoid metal oxidation.

[0133] Those skilled in the art can determine specific parameters through conventional experiments based on the selected metal powder, type of binder, and target porosity. For example, the drying temperature can be selected as 50-80℃, and the time as 1-4 hours; the sintering temperature can be selected as 50-100℃ below the metal melting point (e.g., 600-650℃ for magnesium, 600-660℃ for aluminum), and the time as 1-3 hours.

[0134] 1.5 Standardization and Packaging

[0135] The fuel pellets are cut to uniform specifications (e.g., A4 size, fixed width rolls) and sealed in an inert atmosphere or vacuum. The standardized dimensions and interface design allow the fuel pellets to be used in different types of hydrolysis hydrogen supply devices.

[0136] 1.6 Recycling and Reuse of Support Layer

[0137] The conductive support layer does not undergo chemical changes during the hydrolysis reaction and can be recycled and reused after the reaction is complete through cleaning, separation, and other operations. The support layer material is a corrosion-resistant and wear-resistant conductive porous material, which can be reused dozens to hundreds of times, further reducing the system operating cost.

[0138] Step 2: Hydrogenation of Metal Fuel Pieces (Optional)

[0139] Function

[0140] Convert metal fuel pellets into hydrogenated metal fuel pellets (such as magnesium hydride and aluminum hydride) for use in water self-sufficiency scenarios.

[0141] Technical solution

[0142] Using any existing metal hydride preparation method, metal fuel flakes are placed in a hydrogenation device and hydrogenated under a hydrogen atmosphere. The hydrogenation process should meet the following principles: the temperature and pressure should be sufficient to allow the metal to react with hydrogen, but avoid softening or structural damage to the metal; the holding time should be sufficient to allow the hydrogenation reaction to proceed fully; the hydrogenation device should have temperature and pressure control capabilities to ensure uniform reaction. As an example, for magnesium fuel flakes, hydrogenation can be carried out at 350-400℃ and 2-3MPa hydrogen pressure for 2-6 hours; for aluminum fuel flakes, the hydrogenation conditions are relatively harsh, and higher pressures or the addition of a catalyst may be used.

[0143] Step 3: Hydrolysis for hydrogen supply

[0144] 3.1 System Composition The water electrolysis hydrogen supply subsystem includes the following core components:

[0145] Water supply unit: Used to supply the reactor with the water required for hydrolysis. The water supply unit includes a water storage tank, water pump, flow control valve, check valve, and optional water purification devices (such as filters and softeners).

[0146] Reactor: Used to contain metal fuel pellets and provide a site for the hydrolysis reaction. The reactor is equipped with a fuel pellet loading port, a water inlet, a hydrogen outlet, a slag discharge port, and interfaces for temperature and pressure sensors.

[0147] Reaction control unit: Used to monitor parameters such as temperature, pressure, and hydrogen yield inside the reactor, and automatically adjust the influent flow rate, water temperature, and catalyst addition amount to achieve controllable hydrolysis reaction.

[0148] Catalyst addition unit: Used to add catalysts (such as aluminum chloride, magnesium chloride, carbon-based materials, etc.) to the influent to accelerate the hydrolysis reaction.

[0149] Hydrogen purification unit: used to treat the hydrogen produced by the reaction by removing water, drying, and deoxygenating it to meet the purity requirements of hydrogen for end use.

[0150] Water recycling unit (optional): When using hydrogenated metal fuel cells, the wastewater generated by fuel cell power generation can be recycled back to the water supply unit to achieve water self-sufficiency.

[0151] 3.2 Fuel Pellet Loading and Gap Design

[0152] Metal fuel flakes or hydrogenated metal fuel flakes are packed into the reactor in a stacked or wound manner. Spacer elements are provided between adjacent fuel flakes to form gaps through which water flows. The gap width should be selected to ensure that water flows evenly across the surface of the fuel flakes and promptly removes reaction products, while avoiding excessive reduction in the system's volumetric energy density. For example, the gap width can be 0.05-0.5 mm. Spacer elements can be implemented using protrusions on the fuel flake surface, sandwiched wire mesh, corrugated spacers, independent support ribs, etc., and their selection should meet the requirements of corrosion resistance, non-contamination of the reaction system, and compatibility with the fuel flake packing process.

[0153] 3.3 Reaction Start-up and Operating Modes Depending on the type of metal fuel pellets, this system supports two operating modes:

[0154] Mode A: Hydrogenated metal fuel cells (water-sustainable mode)

[0155] At startup, a small amount of initial water (approximately 15%-25% of the total mass of the fuel pellets) is injected into the reactor by the water supply unit to wet the surface of the fuel pellets, and the hydrolysis reaction begins.

[0156] The hydrogen produced by the reaction is purified and supplied to the fuel cell for power generation. The wastewater discharged from the fuel cell (with high purity) is returned to the water supply unit through the water recycling unit and re-enters the reactor.

[0157] Under normal operating conditions, the return water volume and the reaction water consumption reach a dynamic balance, requiring no continuous external water replenishment. Only a small amount of water needs to be added during startup and system maintenance.

[0158] Mode B: Metal Fuel Plates (External Water Replenishment Mode)

[0159] Throughout the reaction, the water supply unit continuously supplies water to the reactor, and the water supply rate is matched with the reaction rate.

[0160] The hydrogen produced by the reaction is purified and directly output to the terminal (fuel cell, hydrogen internal combustion engine or chemical plant), and the tailwater is not recirculated.

[0161] In this mode, the influent flow rate needs to be adjusted in real time according to the hydrogen production rate to maintain a stable liquid level in the reactor.

[0162] 3.4 Reaction Control Strategies

[0163] The hydrolysis reaction rate can be controlled synergistically through one or more of the following methods:

[0164]

[0165]

[0166] Those skilled in the art can determine the optimal combination of control parameters through conventional experiments based on the target hydrogen yield, reactor size, and fuel characteristics.

[0167] 3.5 Hydrogen Purification

[0168] The hydrogen gas produced by hydrolysis is processed by a purification unit before being output. Purification methods include, but are not limited to:

[0169] Condensation and dehydration: The hydrogen temperature is reduced to 5-15℃ by a cooler, causing most of the water vapor to condense and precipitate out.

[0170] Molecular sieve drying: Residual moisture is further removed through a molecular sieve adsorption bed, reducing the hydrogen dew point to below -40°C;

[0171] Deoxidation / Desulfurization: Depending on the purity requirements of the hydrogen used at the end, refining units such as deoxidizers and desulfurizers can be added.

[0172] 3.6 Safety Protection

[0173] The hydrogen electrolysis supply device also includes the following safety protection measures:

[0174] Electrical isolation unit: Prevents external power from being accidentally connected to the reactor, avoiding side reactions such as chlorine gas;

[0175] Metal depletion detection unit: By monitoring the pressure, temperature change rate or hydrogen production rate inside the reactor, it determines whether the metal fuel is depleted and automatically stops water intake and cuts off output;

[0176] Overpressure protection: Equipped with a safety valve or rupture disc, which automatically releases pressure when the pressure inside the reactor exceeds the set value;

[0177] Hydrogen leak detection: Hydrogen sensors are installed at key locations in the reactor and pipelines. Once a leak is detected, the water supply is immediately cut off and an alarm is triggered.

[0178] Step 4: Metal hydroxide recovery

[0179] Function

[0180] Collect the solid products (magnesium hydroxide or aluminum hydroxide) after the hydrolysis reaction to prepare for subsequent regeneration or sale.

[0181] Technical solution

[0182] The slurry discharged from the reactor is separated, washed, and dried using any existing solid-liquid separation method. The recovery process should meet the following principles: high separation efficiency, with a metal hydroxide recovery rate >95%; thorough washing to remove soluble impurities (such as residual catalysts and salts) and ensure product purity; and drying temperature below the decomposition temperature of the metal hydroxide to avoid product denaturation. For example, plate and frame filtration, centrifugation, and vacuum filtration can be used for solid-liquid separation; washing with pure water or dilute alkali solution is acceptable; and hot air drying at 50-80℃ or vacuum drying is recommended.

[0183] Step 5: Metal Recycling

[0184] Function

[0185] The recovered metal hydroxides can be converted into metal powder, or the metal resources can be recycled through sales and trade-ins.

[0186] The technical solution adopts one or more of the following methods to achieve the recycling of metal resources:

[0187] Path A: Closed-loop regeneration

[0188] Metal hydroxides can be reduced to metal powder using any of the existing technologies, including but not limited to: electrolysis (converting to chloride followed by molten salt electrolysis); thermal reduction (such as the Pidgeon process and the aluminothermic process); and plasma methods. The choice of regeneration method should comprehensively consider energy consumption, product purity, economies of scale, and market conditions.

[0189] Path B: Sales and Trade-ins

[0190] The recovered metal hydroxides are purified and sold as high-purity chemical raw materials (such as flame retardants, pharmaceutical additives, and environmentally friendly materials), with the proceeds used to purchase new metal powders to replace them. This approach is suitable for situations where the recovered products have high purity and the selling price is better than the regeneration cost.

[0191] Step 6: Closed-loop reuse

[0192] Function

[0193] The recycled metal powder or newly purchased metal powder is sent back to stage 1 to be remade into metal fuel pellets, thus realizing the recycling of metal resources.

[0194] Technical solution

[0195] Establish a standardized supply system for metal powders to ensure that the particle size, purity, and flowability of recycled metal powders meet the raw material requirements of Step 1. For metal powders regenerated by electrolysis or thermal reduction, particle size distribution can be adjusted through post-processing steps such as sieving, grading, and ball milling to meet powder production requirements. Key control indicators for closed-loop recycling include: metal recovery rate (target > 95%); performance consistency between recycled and newly purchased metal powders; and total life cycle cost (regeneration cost vs. sales and trade-in revenue).

[0196] Beneficial effects

[0197] 1. Closed-loop recycling of metal resources: Through recycling and regeneration, the metal loss rate is less than 5%, significantly reducing raw material costs;

[0198] 2. The hydrolysis reaction remains stable: Through porous structure, interlayer gaps, and multi-parameter synergistic control, the formation of a passivation layer is effectively prevented;

[0199] 3. Low storage and transportation costs: Metal fuel pellets can be stored and transported at room temperature and pressure, with a higher volumetric energy density than high-pressure gaseous hydrogen storage systems;

[0200] 4. High system integration: Mature technologies are used in each component, and the entire system is optimized through standardized interfaces and closed-loop control;

[0201] 5. Flexible business model: Supports multiple operating models such as "distributed hydrogen supply + centralized regeneration" and "sales and trade-in";

[0202] 6. Recyclable and reusable support layer: The conductive support layer can be used multiple times after cleaning, further reducing long-term operating costs;

[0203] 7. Eliminate dependence on infrastructure: Metal fuel pellets can be distributed using existing civilian logistics networks, eliminating the need to build dedicated facilities such as hydrogen refueling stations and hydrogen pipelines;

[0204] 8. Solve the problem of resource misallocation: Convert renewable energy in the west into metallic fuels, store and transport them to the east at normal temperature and pressure, realize efficient cross-regional allocation of energy, and avoid the constraints of fluctuations in ultra-high voltage power transmission. Attached Figure Description Figure 1 : Schematic diagram of the system structure of this invention Figure 2 Schematic diagram of porous metal fuel pellet stacking and gaps Figure 3 Schematic diagram of porous metal fuel flake winding, filling, and gap design. Figure 4 Metal fuel closed-loop cycle flow diagram Detailed Implementation

[0205] Example 1: Magnesium fuel pellet stacking, hydrolysis for hydrogen supply, and electrolytic regeneration

[0206] Following the method in step 1, 20-50 μm magnesium powder was selected and coated onto a stainless steel mesh support layer (single layer, 0.2 mm thick) using a scraper. The coated layer was then dried and sintered (argon, 620℃, 2 hours) to obtain magnesium fuel flakes. The fuel flakes were stacked and packed into a reactor, with 0.15 mm stainless steel wire mesh sandwiched between them as spacers. An aqueous solution containing 3% aluminum chloride was introduced, with the water temperature controlled at 50℃ and the influent flow rate at 30 mL / min. The reaction was carried out for 30 minutes, achieving a hydrogen conversion rate of 96%. The magnesium hydroxide slurry discharged after the reaction was filtered through a plate and frame filter, washed, and dried to obtain magnesium hydroxide powder. This powder was then converted into magnesium chloride and electrolyzed (temperature 700℃, current density 1.5 A / cm²). 2 Magnesium is obtained and recycled for powder production. The support layer is washed and dried before being reused in the next coating cycle.

[0207] Example 2: Aluminum fuel pellet winding, filling, hydrolysis, hydrogen supply, and sales replacement

[0208] Following the method in step 1, 10-50μm aluminum powder is selected and coated onto a carbon fiber cloth support layer (single layer, 0.2mm thick) using a roller. The coating is then dried and sintered (nitrogen, 640℃, 1.5 hours) to obtain aluminum fuel flakes. The fuel flakes are wound and packed, with gaps formed by protrusions pressed onto the surface of the fuel flakes. An aqueous solution containing 2% magnesium chloride is introduced, and the water temperature is controlled at 45℃. The reaction is carried out for 40 minutes, achieving a hydrogen conversion rate of 94%. The aluminum hydroxide slurry discharged after the reaction is filtered, washed, and dried to obtain high-purity aluminum hydroxide powder (99.3% purity), which is sold as a flame retardant. The proceeds from the sale are used to purchase new aluminum powder for reuse. The support layer is cleaned and reused.

[0209] Example 3: Hydrogen supply via hydrolysis of magnesium hydride fuel cells (water self-sustaining mode)

[0210] Magnesium fuel pellets prepared according to the method in Example 1 were hydrogenated at 380°C and 2.5 MPa hydrogen pressure for 4 hours according to step 2 to obtain hydrogenated magnesium fuel pellets. These were then loaded into a reactor, and a small amount of tap water (approximately 20% of the total mass of the fuel pellets) was injected during startup. After the reaction started, the generated hydrogen was used to generate electricity via the fuel cell, and the fuel cell tailwater was returned to the reactor, achieving water self-sufficiency.

Claims

1. A closed loop system for storage and transportation of metal fuel and hydrogen production by hydrolysis, characterized in that, include: -Porous metal fuel sheet preparation unit, used to make standardized porous metal fuel sheets from metal powder; - A hydrogen hydrolysis device, the input end of which is connected to the output end of the porous metal fuel preparation unit, is used to accommodate the porous metal fuel and controllably introduce water to carry out a hydrolysis reaction to generate hydrogen and metal hydroxide; the hydrogen hydrolysis device includes a reaction control unit, which controls the hydrolysis reaction rate by adjusting one or more of the following: water flow rate, water temperature, and catalyst concentration. - A metal hydroxide recovery unit, the input end of which is connected to the slag discharge port of the hydrolysis hydrogen supply device, is used to collect the metal hydroxide; - A metal regeneration unit, whose input end is connected to the output end of the metal hydroxide recovery unit, is used to convert the collected metal hydroxide into metal powder and send it back to the porous metal fuel pellet preparation unit, or to purify the metal hydroxide and sell it as raw material and use the proceeds to purchase new metal powder to replace it and send it back to the preparation unit.

2. The system of claim 1, wherein, The porous metal fuel sheet includes at least one conductive support layer and a metal powder layer attached to at least one side of the conductive support layer; the conductive support layer is a porous conductive material that forms a composite structure with the metal powder layer after sintering; wherein, the selection of the conductive support layer should meet the requirements of corrosion resistance, conductivity and bonding strength with the metal powder layer; as an example, the conductive support layer can be selected from graphite felt, carbon fiber cloth, stainless steel mesh or nickel mesh.

3. The system of claim 1, wherein, The porous metal fuel sheets are stacked or wound into a hydrogen supply device for hydrolysis, with spacers between adjacent fuel sheets to form gaps through which water flows. The width of the gaps should ensure that the water flows evenly across the surface of the fuel sheets and carries away the reaction products in a timely manner, while avoiding excessive reduction in the system's volumetric energy density. For example, the width of the gaps can be 0.05-0.5 mm.

4. The system of claim 3, wherein, The spacer element can be implemented in any of the following forms: protrusions on the surface of the fuel pellet, sandwiched wire mesh, corrugated structure, or independent support ribs; wherein, the selection of the spacer element should meet the requirements of corrosion resistance, non-contamination of the reaction system, and compatibility with the fuel pellet filling process.

5. The system of claim 1, wherein, The metal powder is magnesium powder, and the metal hydroxide is magnesium hydroxide; optionally, the metal powder may also be aluminum powder, and the metal hydroxide may be aluminum hydroxide; the porous metal fuel sheet includes two forms: metal powder paper and hydrogenated metal powder paper, wherein the hydrogenated metal powder paper is obtained by hydrogenation treatment of metal powder paper; optionally, it also includes a hydrogenation unit for hydrogenating the porous metal fuel sheet.

6. The system of claim 1, wherein, The porous metal fuel sheet contains a catalyst to accelerate the hydrolysis reaction; the catalyst should be selected to meet the requirement of being able to destroy the passivation layer on the metal surface or reduce the activation energy of the hydrolysis reaction; as an example, the catalyst includes one or more of aluminum chloride, magnesium chloride, and carbon-based catalysts.

7. The system of claim 1, wherein, The hydrogen electrolysis device includes a water supply unit, a reactor, a reaction control unit, a catalyst addition unit, a hydrogen purification unit, and an optional water recovery unit. The water recovery unit is used to return the wastewater generated by the fuel cell power generation to the water supply unit when using hydrogenated metal fuel cells, thereby achieving water self-sufficiency.

8. The system of claim 1, wherein, The hydrogen hydrolysis supply device also includes one or more of the following safety protection measures: an electrical isolation unit to prevent accidental connection of external power; a metal depletion detection unit to automatically stop the reaction when the metal fuel is depleted; an overpressure protection unit to automatically release pressure when the pressure inside the reactor exceeds a set value; and a hydrogen leakage detection unit to cut off the water supply and sound an alarm when a hydrogen leakage is detected.

9. The system of claim 1, wherein, The metal regeneration unit uses one or more of the following methods to convert metal hydroxides into metal powder: electrolysis, thermal reduction, and plasma method; wherein, the thermal reduction method can be the Pidgeon process or the aluminothermic process; the selection of the regeneration method should comprehensively consider energy consumption, product purity, scale-up costs and market conditions.

10. The system of claim 1, wherein, The hydrogen produced by the hydrolysis hydrogen supply device is used in hydrogen supply terminals, which include fuel cells, hydrogen internal combustion engines, chemical synthesis devices, or combustion equipment.

11. The system of claim 1, wherein, The porous metal fuel pellets adopt a unified standard specification, and the metal hydroxide recovery unit adopts a unified interface to achieve standardized docking between the hydrolysis hydrogen supply device and the metal regeneration unit.

12. A closed-loop method for metal fuel storage, transportation, and hydrogen supply via hydrolysis using the system described in any one of claims 1-11, characterized in that, Includes the following steps: (a) At a centralized preparation center, metal powder is prepared into standardized porous metal fuel sheets; (b) The standardized porous metal fuel sheets are delivered to hydrogen-using terminals; (c) In a hydrolysis hydrogen supply device, the porous metal fuel sheets are loaded into the hydrolysis hydrogen supply device, and water is controlled to carry out the hydrolysis reaction to generate hydrogen for terminal use; (d) The metal hydroxide generated by the hydrolysis reaction is collected; (e) The collected metal hydroxide is transported to a metal regeneration unit to be converted into metal powder, or purified and sold as raw material, with the proceeds used to purchase new metal powder to replace it; (f) The converted metal powder or the newly purchased metal powder is returned to step (a) to realize the recycling of metal resources.

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