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• Wisconsin has fewer remaining lead water pipelines than previous estimates, suggesting officials may be able to eliminate them faster and at lower cost than expected.
• New inventory requirements have given regulators and utilities their clearest picture yet of where lead pipes remain and where more investigation is needed.
• Federal regulators now require water systems to replace all lead service lines by the end of 2037 because no level of lead exposure is considered safe, especially for children.
• More than 181,000 Wisconsin service lines (12% statewide) are still classified as unknown because many communities lack complete records and must verify pipe materials through inspections and outreach.
• Federal infrastructure funding has provided major support for lead line replacement projects across Wisconsin, but officials expect available funding to decrease in the coming years.

Wisconsin may be closer than previously thought to eliminating lead water pipes. About 164,000 municipal and community lead water service lines still need replacement with safer materials, according to a Wisconsin Watch analysis of water system data reported in April. That’s roughly one of every 10 municipal and community water lines statewide. 

The estimate includes confirmed lead lines — roughly 146,000 across 137 municipal and community water systems — and an estimated share of service lines with unknown materials that are statistically likely to contain lead, based on EPA methodology.

Some data gaps remain, including some water systems that did not file a report on time.

Still, the total is far below previous government estimates as more complete inventories more clearly show where lead pipes remain, part of a nationwide effort to reduce exposure to the toxic metal linked to serious health risks.

The U.S. Environmental Protection Agency estimated in 2025 — before many water systems completed or updated their inventories — that nearly 180,000 water lines in Wisconsin were made of lead, a sharp drop from its 2023 estimate of over 256,000.

“We may be able to remove all (lead service lines) faster, fully, and forever – sooner and at a lower price tag than expected,” Erica Galante-Johnson, senior lead service line replacement policy analyst at Environmental Policy Innovation Center, wrote in a report comparing the lead service line estimate before and after new inventory data became available. 

Why replace lead service lines?

Once a popular material for water service lines, lead was banned by regulators for such purposes in Wisconsin and nationwide beginning in the 1980s due to concerns about potential lead exposure. 

“There is no safe level of exposure to lead,” the EPA’s website says. 

Children are especially vulnerable to lead, since even low levels of exposure can lead to behavioral and learning problems. High levels of lead in blood can cause seizures, coma or death. Adults exposed to lead are more susceptible to cardiovascular and kidney problems.

Water systems limit risk by treating pipes with chemicals that reduce corrosion, but failures such as Flint, Michigan’s crisis a decade ago show how those safeguards can break down, exposing residents to lead. 

That’s why federal regulators now require aggressive replacement timelines. 

Municipal and community water systems must replace all lead or galvanized pipes before the end of 2037. Some Wisconsin cities, like Madison and Stoughton, have already replaced all lead pipes. Many others, including Eau Claire, Milwaukee and Wausau, have projects underway to replace them at no or low cost to homeowners.

At least 29 municipalities in Wisconsin have received more than $159 million through 2025 to replace lead service lines through the 2021 Bipartisan Infrastructure Law, signed by then-President Joe Biden.

The EPA in May announced an additional $94.3 million Wisconsin allocation under the 2021 law. 

Biden’s EPA revised its Lead and Copper Rule, tightening monitoring requirements and establishing  timelines for replacing lead pipes. 

The first step: requiring water systems to document what’s underground.

More complete information helps identify where lead lines are concentrated, said Ann Hirekatur, the Wisconsin Department of Natural Resources’ lead and copper section manager.

The inventories are more than a bureaucratic exercise. Federal rules now tie them directly to replacement requirements.

Wisconsin water systems previously needed only to report estimates of their lead service lines to the state Public Service Commission.

Biden’s EPA changed that. Water systems were required to submit an initial inventory by October 2024, listing the best available information about each water line. That gave DNR officials line-by-line records for the first time, Hirekatur said.

By Nov. 1, 2027, water systems must improve those records by trying to identify service lines of currently unknown material and documenting connector materials. After that deadline, any service lines with an unknown material will be treated as lead, and water systems must start replacing at least 10% of lead lines under their control each year. 

The new regulations require digging through historical documents — or even digging up pipelines one by one — to confirm the material and location. 

The more rigorous process revealed more lead service lines in some communities than previously thought. That includes Whitefish Bay, which documented more than 56% of service lines as lead during the first draft of its inventory.

Locating pipelines can be challenging

Despite the new inventories, regulators still have yet to identify the materials in more than 181,000 Wisconsin service lines, or 12% of all statewide.

As of April, 312 of 610 Wisconsin municipal water systems identified materials in every service line. About 60% of systems recorded 5% or fewer pipelines as unknown material. 

Meanwhile, 102 municipal water systems reported more than half of their lines as unknown, with 12 yet to submit inventories. 

“Some systems kept good records, and some systems don’t have any records at all,” Hirekatur said.

Water system managers must show their work in documenting the makeup of service lines. 

The best evidence is a “tap card” that describes the pipe’s primary features and installation history.

But many communities never preserved those records because they were not required to do so.

The city of Lancaster illustrates that challenge. Water system officials started looking for lead pipes in the 1990s, and they initially found only two and about 50 others whose material was unknown. But the DNR initially marked more than 1,700 out of the city’s 1,845 lines as unknown because the verification documentation fell short of standards.

The utility didn’t save old paper inspection records, said John Hauth and Jamie McCartney, the retiring and incoming directors of public works, respectively.

Calling DNR representatives “very helpful,” Hauth said his inventory is now getting into “pretty good shape.” 

“We send it to them, they will highlight areas and send it back and say, ‘OK, well, you know you need to explain this better, or you need to match this up,’” Hauth said.

Gathering evidence

At the DNR’s suggestion, Hauth and McCartney used construction records to rule out neighborhoods built after lead was banned from new pipeline construction and found water meter replacement records to fill in some blanks.  

The managers submitted a revised draft, still under DNR review, that labeled fewer than 400 service lines as unknown. The city plans to verify the remaining resident-owned lines through door-to-door visits and use hydro-excavation equipment to check city-owned lines.

“We’ve only got the few that we know of,” Hauth said. “I think it’s gonna be manageable.” 

Josh Hyndman, Mount Horeb’s former water system manager, also has experience with thin documentation. The village started replacing lead pipes in 2011 and compiled its inventory as early as 2021 to apply for a DNR lead line replacement grant.

“We went down into our basement and started pulling out all the old records,” Hyndman said. “ I found a construction date that was from January of ’78, and it spelled out that everything would be three-quarter-inch copper for all businesses.”

That helped Hyndman determine that all service lines installed after 1978 were copper, reducing the number his team had to inspect or excavate.

In 2024, Hyndman left Mount Horeb for a job in Whitewater. Mount Horeb now has just one lead service line remaining, beneath a vacant lot. He said the inventory process was much easier in Whitewater because the city maintains comprehensive records for each line. As of April, Whitewater had 16 lead service lines and plans to replace all but one serving an abandoned water tower by the end of 2027.

Most unknown service lines are located on the private side of the water system, Cathy Wunderlich said. She is project manager and principal technologist with the engineering firm Jacobs, which the DNR contracted through 2028 to help local water systems finish their inventories. The service is free, with the costs covered by a federal grant.

Lead and copper are rarely used for water lines over two inches in diameter, so they’re more commonly used in private-side pipes instead of the public side, Wunderlich explained. 

Although municipal water systems do not own the private side of service lines, they must document them. That requires permission and access from property owners. 

A more cost-effective approach encourages residents to submit evidence, said Shawn Kerachsky, CEO of Community Infrastructure Partners, which used federal grants to contract with Wausau and Racine to inventory and replace the lead lines.

“This is not an engineering and construction problem,” Kerachsky said. “It’s a public health issue that happens to be solved through very simple engineering and construction, but world-class communication outreach and logistical planning.”

His company promoted the “Equiflow” campaign when helping Wausau complete its inventory — partnering with local organizations to encourage residents to identify their water lines by uploading photos or allowing technicians to inspect them. The approach helped Wausau reduce its share of unknown service lines to about 30%. 

The DNR also offers grants to help water systems educate residents about inventory and replacement projects.

What’s next?

Water systems will ultimately use the data to apply for federal grants and loans to fund lead service line replacements. 

“We encourage water systems to replace them as soon as possible, because it’s in the best interest of public health,” Hirekatur said. “Right now, there’s more money available through the Bipartisan Infrastructure Law funding, and once that gets used up, there’ll be a lot less funding available.”

The DNR will announce which projects it will select for federal pipeline replacement funds by year’s end. The program offers loans with a 0.25% interest rate, far below market rates, and principal forgiveness. The department expects to have some funding available in 2028, but much less than previous years.

Wisconsin’s lead pipe count is falling. But the search isn’t over. is a post from Wisconsin Watch, a non-profit investigative news site covering Wisconsin since 2009. Please consider making a contribution to support our journalism.

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Mississippi River conservation groups are among a broad coalition urging the federal government to take action against nitrate contamination in drinking water, which they say has reached “crisis levels” and is a public health emergency.

Nitrate, which forms when nitrogen-rich sources combine with oxygen, has long been found in the country’s surface waters and groundwater, where it can end up in people’s drinking water. Consuming water with elevated levels of nitrate is linked to birth defects, thyroid problems and some cancers.

Agricultural fertilizer and manure are the most common sources of nitrogen to groundwater, with septic systems and lawn fertilizers also contributing. An April analysis from the Environmental Working Group found that about 18% of the U.S. population from 2021 to 2023 used drinking water from community systems with 3 milligrams per liter (mg/L) or more of nitrate, the threshold at which the Environmental Protection Agency says indicates contamination.

Advocates say nitrate contamination has struggled to capture public attention but is costly and hazardous to those it affects. 

A May 5 letter to the Department of Health and Human Services and the EPA was signed by 80-plus groups, about a third of which are located in or focused on the Mississippi River basin. It calls on the agencies to “immediately identify and eliminate sources of nitrate pollution in drinking water and provide funds to communities to reduce nitrate to safe levels.”

The letter cites a recent report from the Iowa Environmental Council and the Harkin Institute at Drake University in Des Moines that found high nitrate levels in drinking water, as well as the presence of pesticides and forever chemicals, are linked to rising cancer rates in Iowa. Intensive farming across the state, including corn, soy and hogs, is the dominant source of nitrate pollution, the report notes.

“We understand these are long-term problems,” said Tyler Lobdell, senior attorney at Food & Water Watch, which spearheaded the letter. “The longer we wait to address root causes, the more difficult, and more expensive (it is), and the more harm is caused in the long run.”

The Department of Health and Human Services did not respond to a request for comment on the letter. A spokesperson for the EPA said it is beginning the next round of review of national drinking water regulations, last published in 2024.

Too much nitrogen taints drinking water, hurts river ecosystem

Nitrate contamination is a widespread problem across the country, especially in the Corn Belt, but actions to address it have been slow-going.

Groups in multiple states, including Wisconsin, Minnesota and Iowa, have previously petitioned the EPA to take emergency action on nitrate problems in specific regions. Lobdell said the agency has either ignored or given an insufficient response to those petitions, dating back several years and multiple presidential administrations.

Under former President Joe Biden, the EPA restarted an assessment — which had been suspended during the first Trump administration — of the impacts of nitrate on human health. Environmental advocates had hoped that it could lead to an adjustment of the national standard for nitrate in drinking water, which currently sits at 10 mg/L, because some research shows impacts to human health below that level. Little progress has been made on the assessment.

Beyond human health impacts, too much nitrogen in surface water can drive excessive algae growth, causing harm to fish and other aquatic life. It’s one culprit, in addition to phosphorus, in the creation of the Gulf of Mexico’s “dead zone,” an area of low oxygen that spans thousands of square miles from the mouth of the Mississippi River.

Kelly McGinnis, executive director of the environmental advocacy organization One Mississippi, a signatory on the letter, said that humans aren’t separate from the environment and that addressing nitrate contamination would have positive impacts on both.

She said she hopes the letter catches the attention of Health and Human Services Secretary Robert F. Kennedy Jr., who has pledged to “Make America Healthy Again” and has shown interest in reducing toxins in people’s diets.

“We felt the urgency right now to take advantage of the new research (from Iowa) to say, ‘Hey, this is something you guys need to be addressing,'” McGinnis said.

The spokesperson for the EPA said the agency is “committed to Making America Healthy Again by taking real, tangible steps to evaluate risks of nitrates in drinking water while following the law and gold standard science.”

This story is a product of the Mississippi River Basin Ag & Water Desk, an independent reporting network based at the University of Missouriin partnership with Report for America, with major funding from the Walton Family Foundation.

Wisconsin Watch is a member of the Ag & Water Desk network. Sign up for our newsletters to get our news straight to your inbox.

Mississippi River groups tell feds to act on nitrate contamination is a post from Wisconsin Watch, a non-profit investigative news site covering Wisconsin since 2009. Please consider making a contribution to support our journalism.

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An attorney read from a laptop propped atop a snowplow.

To his left was a Caterpillar street grader, and to his right, a dusty workbench. A disheveled American flag hung next to a red toolbox in the center of the impromptu stage.

Dozens of southwest Wisconsin residents recently forsook part of the local high school’s track-and-field meet so they could cast their votes inside the town of Cassville’s garage. The attorney had been retained by the town’s elected leaders to read the soon-to-be-newest regulation.

The unanimous outcome — 44 ballots in favor of banning data centers, none against — reflected a hostile backlash to unwelcome big tech incursions into rural spaces.

Residents instructed their town board to put a stop to the billion-dollar proposal by an anonymous developer after learning their community was on the short list.

Even promises of 50 jobs and more than $5.5 million in annual property tax revenue weren’t enough to make up for the loss of about 500 acres of Wisconsin’s Driftless area.

The pastoral landscape — known for rolling bluffs that straddle the locks and dams of the nation’s upper Mississippi River — possesses a bountiful aquifer, a temperate climate and few land regulations.

The latest move against data centers

Cassville’s ordinance is the latest move by a Midwestern community seeking to protect the qualities that make life so appealing to people — and data centers. 

Pushback over the power-hungry facilities that make the cloud run are occurring across the country, as companies expand in states like Mississippi and Tennessee.

Residents in Port Washington, Wisconsin, were the first in the nation to pass a referendum that would prevent their city from offering generous tax incentives without first obtaining voter approval.

Wisconsin lawmakers — some of whom previously supported a state sales tax exemption for new data centers — sponsored bills that would prevent developers from using confidential nondisclosure agreements when prospecting for new sites.

And in Clayton County, Iowa, directly across the river from Cassville, officials are considering zoning, setback and size restrictions.

Cassville residents fear data centers will devalue their properties, contaminate their wells and increase their electric bills.

“This is the Driftless area for Christ’s sakes,” said John Hawn, who retired to the area several years ago. “I suppose they didn’t expect any problems coming into a small town.”

‘There’s no information’

The Cassville project has been shrouded in secrecy. That includes the proposed location and what company will use it, leaving residents to fill in the vacuum with a frenzy of social media engagement.

“I don’t know really what to think about it because there’s no information,” town Supervisor Scott Riedl said. 

Ron Brisbois, executive director of the Grant County Economic Development Corp., has met with a developer but to date declined to identify the company that is scouting for locations so as not to jeopardize the project.

In an interview after Cassville’s vote, he said the town’s appeal is its proximity to electricity, specifically the high-voltage Cardinal-Hickory Creek transmission line that entered service in September 2024.

Brisbois estimated the data center would require 400 to 500 megawatts of power — a lot, even by the new transmission line’s standards.

But the town’s attorney, Eric Hagen, said if Cassville can make it inconvenient, the data center developer may look elsewhere. The company also is considering sites in Indiana and North Dakota.

“My read of the situation right now: They’re looking for the lowest-hanging fruit with the least amount of regulations,” Hagen said.

Cassville’s new ordinance prohibits data centers in the town for up to two years and prevents land use changes, such as constructing a residence on a farm field, without the town board’s approval. And the county cannot preempt local zoning authority in the town’s case, Hagen said.

“We can beat them to the punch.”

Data centers raise ire

Days after the town’s vote, Brisbois fielded questions from a concerned public at J&J’s Sandbar, a Cassville restaurant, over chicken and ham, mashed potatoes with gravy and macaroni salad.

He wonders whether the objections reflect data centers’ tarnished image more than concerns over actual water and power use. If a battery or farm equipment manufacturer were to move in and consume more of each, would residents even notice?

Brisbois said the developer has remained quiet for the past month, which he attributes to the lack of local tax incentives for the project rather than community unease.

“I’m looking forward to a bit quieter days,” he said, “where all I have to worry about with townships is housing and maybe an ag or a farm expansion.”

In rural Wisconsin, a town rejects a plan to build a massive data center is a post from Wisconsin Watch, a non-profit investigative news site covering Wisconsin since 2009. Please consider making a contribution to support our journalism.

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April 22, 1970, was no ordinary day in the bustling city of St. Louis. On this first Earth Day, streets filled with rallies, and lecture halls were packed with attendees. Most famously, rows of students marched through the streets wearing gas masks, protesting air pollution.

Around that time, John E. Franz was brewing up something dark in the depths of Monsanto’s St. Louis lab: glyphosate, an herbicide since linked to widespread environmental harm, cancer concerns and more than 100,000 lawsuits. 

While other countries have regulated or limited glyphosate production, the U.S. has largely ignored the problem. In February, President Donald Trump issued Executive Order 14387 to promote the production of glyphosate and security for its producers.

The U.S. is increasingly dependent on glyphosate, and its overuse is becoming a serious concern. Amid the many environmental issues competing for attention, glyphosate deserves a prominent place this Earth Day, especially in Wisconsin.

Why Wisconsin? Glyphosate levels in groundwater aren’t being consistently monitored in the state’s highest-risk areas — its CAFO counties.

From fields to faucets 

Wisconsin farmers apply millions of pounds of glyphosate each year, primarily to fields growing soybeans and corn — the state’s two biggest crops. Those crops are used to feed animals at Wisconsin’s 293 concentrated animal feeding operations, or CAFOs. 

After animals eat glyphosate-treated crops, the chemical can reemerge in their manure. This is a problem, considering that mismanagement of CAFO waste frequently leads to groundwater contamination. 

Seems like something that should be setting off red flags, right?

Monitoring falls short in Wisconsin

The Wisconsin Department of Agriculture, Trade and Consumer Protection (DATCP) oversees groundwater and surface water testing for agrichemicals. The agency monitors pesticides and agricultural runoff through a private well sampling program, a field-edge monitoring program and random well sampling conducted every five to 10 years.

However effective these programs may appear, a closer look at where Wisconsin’s CAFOs are located compared with where monitoring occurs reveals a stark mismatch.

The three counties with the most CAFOs — Manitowoc (25), Brown (22), Kewaunee (19) — are all located in the Northeast Lakeshore region, where none of DATCP’s 22 field-edge monitoring wells are located, according to a 2023 report, the most recent available. The state’s monitoring system misses areas at highest risk for aquifer contamination.

Unfortunately it gets worse. DATCP’s Targeted Sampling Program also does not cover the entire Northeast Lakeshore Watershed, and these sampling panels do not test for glyphosate or its byproducts, the agency’s most recent program report shows.

The solution? Advocacy

Glyphosate usage has increased 15-fold since the 1990s. It will continue to go unchecked if more research and monitoring aren’t conducted to track where this chemical ends up.

What can citizens do? Write, speak and act.

1. Monitor the DNR’s hearing and meetings calendar for groundwater-related meetings you can attend.
   
2. If you’re a private landowner with a well, write to DATCP and volunteer to have your well sampled.
   
3. Universities such as University of Wisconsin-Oshkosh and UW-Green Bay also play a role. DATCP already partners with both on research. Contact leaders of their water-related programs.

Why glyphosate still matters

To be sure, glyphosate is not the only problematic agrichemical. But it is by far the most widely used herbicide in U.S. agriculture, and its scale alone warrants closer monitoring of its spread in aquifers.

Still not convinced? Consider the many other contaminants that can leach into groundwater from CAFO manure — including other agrichemicals, pharmaceuticals, heavy metals and bacteria. Glyphosate is just one of many reasons stronger groundwater monitoring is needed in this region.

We’re not asking for much.

Glyphosate well testing is relatively inexpensive and should not strain government resources. Progress will depend on public pressure: Concerned citizens must keep pushing until stronger monitoring is in place across all at-risk areas of this beautiful state we call home.

Allison Gilmeister is a graduate student at Yale University studying religion and ecology. She grew up in Appleton. 

Opinion: In Wisconsin’s CAFO counties, glyphosate monitoring gaps threaten groundwater is a post from Wisconsin Watch, a non-profit investigative news site covering Wisconsin since 2009. Please consider making a contribution to support our journalism.

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Beavers have been in the news these past few months in a variety of ways. The latest Pixar movie, “Hoppers,” features an animal lover who “seizes an opportunity to use a new technology to ‘hop’ her consciousness into a lifelike robotic beaver and communicate directly with animals.”

The filmmakers worked with a University of Minnesota ecohydrologist, Dr. Emily Fairfax, as a science expert, even naming a key character for her (Dr. Sam — for Samantha Emily Fairfax), per Minnesota Public Radio. She visited the studio several times and led a research trip to Colorado to help the team learn more about beavers and their habitat.

In that MPR story, Fairfax said Pixar did a good job showing how beavers can improve ecosystems with their dams.

“When you lose that beaver, you also lose the homes for the other animals, and I think that’s a message that not everybody really understands,” she told MPR. “If you trap a beaver out, if you remove its dam, you will take away a lot more than just the beaver from that ecosystem, whether you meant to or not.”

She also spoke to the question of beavers as a nuisance or pest, a topic I’ve been reporting on for a few years now and interviewed her about for a recent story.

Researchers have identified Wisconsin as being among the top 10 states for biodiversity loss, largely due to climate change and animal overexploitation. But a vocal minority serving on a beaver advisory committee that is drafting recommendations for the state’s Department of Natural Resources believes it’s time for a change: Beavers should cease to be framed as a nuisance species and instead as an ecosystem engineer that creates wetlands. That can help reduce some of the worst effects of climate change: droughts, floods and fire.

The U.S. Department of Agriculture’s wildlife services program lethally removes beavers in Wisconsin and other states throughout the Midwest. In Wisconsin, wildlife services staff trapped about 2,200 beavers in 2025 and removed more than 800 dams.

The majority of beaver committee members — mostly composed of state and federal employees and interest groups — support the status quo. Those who do not have criticized the committee as stacking the deck against people who would advocate for substantive changes in policy. This makes, they say, the outcome a seemingly foregone conclusion. Some committee members have said a survey released to gauge the public’s tolerance of the critters frames beavers as pests and fails to mention the effectiveness of coexistence methods.

As Wisconsin Watch previously reported, the state has an arduous and often expensive permitting process to install flow control devices that can lower water levels in beaver ponds or prevent the blockage of culverts. That can usher landowners toward lethal solutions, the use of which Wisconsin law liberally allows.

People may hunt or trap beavers and remove their dams on their property without obtaining a license or reporting their catch. In fact, there are risks to ignoring one’s beavers.

People who own or lease beaver-occupied land and don’t allow their neighbors to remove them are liable for damages. Additionally, if a beaver dam causes damage to a neighboring property, the injured party may enter the property where the dam lies and remove it without being charged with trespassing.

Committee members petitioned to have Fairfax address the group. She stressed beavers’ role as a “keystone” species, on whom many plants and animals depend.

“It is harder to coexist,” she said. “But in many cases, it is worth it.”

Pest or nuisance? The role of beavers in ‘Hoppers’ and the real world is a post from Wisconsin Watch, a non-profit investigative news site covering Wisconsin since 2009. Please consider making a contribution to support our journalism.

Hydrogen has the potential to be a climate-friendly fuel since it doesn’t release carbon dioxide when used as an energy source. Currently, however, most methods for producing hydrogen involve fossil fuels, making hydrogen less of a “green” fuel over its entire life cycle.

A new process developed by MIT engineers could significantly shrink the carbon footprint associated with making hydrogen.

Last year, the team reported that they could produce hydrogen gas by combining seawater, recycled soda cans, and caffeine. The question then was whether the benchtop process could be applied at an industrial scale, and at what environmental cost.

Now, the researchers have carried out a “cradle-to-grave” life cycle assessment, taking into account every step in the process at an industrial scale. For instance, the team calculated the carbon emissions associated with acquiring and processing aluminum, reacting it with seawater to produce hydrogen, and transporting the fuel to gas stations, where drivers could tap into hydrogen tanks to power engines or fuel cell cars. They found that, from end to end, the new process could generate a fraction of the carbon emissions that is associated with conventional hydrogen production.

In a study appearing today in Cell Reports Sustainability, the team reports that for every kilogram of hydrogen produced, the process would generate 1.45 kilograms of carbon dioxide over its entire life cycle. In comparison, fossil-fuel-based processes emit 11 kilograms of carbon dioxide per kilogram of hydrogen generated.

The low-carbon footprint is on par with other proposed “green hydrogen” technologies, such as those powered by solar and wind energy.

“We’re in the ballpark of green hydrogen,” says lead author Aly Kombargi PhD ’25, who graduated this spring from MIT with a doctorate in mechanical engineering. “This work highlights aluminum’s potential as a clean energy source and offers a scalable pathway for low-emission hydrogen deployment in transportation and remote energy systems.”

The study’s MIT co-authors are Brooke Bao, Enoch Ellis, and professor of mechanical engineering Douglas Hart.

Gas bubble

Dropping an aluminum can in water won’t normally cause much of a chemical reaction. That’s because when aluminum is exposed to oxygen, it instantly forms a shield-like layer. Without this layer, aluminum exists in its pure form and can readily react when mixed with water. The reaction that occurs involves aluminum atoms that efficiently break up molecules of water, producing aluminum oxide and pure hydrogen. And it doesn’t take much of the metal to bubble up a significant amount of the gas.

“One of the main benefits of using aluminum is the energy density per unit volume,” Kombargi says. “With a very small amount of aluminum fuel, you can conceivably supply much of the power for a hydrogen-fueled vehicle.”

Last year, he and Hart developed a recipe for aluminum-based hydrogen production. They found they could puncture aluminum’s natural shield by treating it with a small amount of gallium-indium, which is a rare-metal alloy that effectively scrubs aluminum into its pure form. The researchers then mixed pellets of pure aluminum with seawater and observed that the reaction produced pure hydrogen. What’s more, the salt in the water helped to precipitate gallium-indium, which the team could subsequently recover and reuse to generate more hydrogen, in a cost-saving, sustainable cycle.

“We were explaining the science of this process in conferences, and the questions we would get were, ‘How much does this cost?’ and, ‘What’s its carbon footprint?’” Kombargi says. “So we wanted to look at the process in a comprehensive way.”

A sustainable cycle

For their new study, Kombargi and his colleagues carried out a life cycle assessment to estimate the environmental impact of aluminum-based hydrogen production, at every step of the process, from sourcing the aluminum to transporting the hydrogen after production. They set out to calculate the amount of carbon associated with generating 1 kilogram of hydrogen — an amount that they chose as a practical, consumer-level illustration.

“With a hydrogen fuel cell car using 1 kilogram of hydrogen, you can go between 60 to 100 kilometers, depending on the efficiency of the fuel cell,” Kombargi notes.

They performed the analysis using Earthster — an online life cycle assessment tool that draws data from a large repository of products and processes and their associated carbon emissions. The team considered a number of scenarios to produce hydrogen using aluminum, from starting with “primary” aluminum mined from the Earth, versus “secondary” aluminum that is recycled from soda cans and other products, and using various methods to transport the aluminum and hydrogen.

After running life cycle assessments for about a dozen scenarios, the team identified one scenario with the lowest carbon footprint. This scenario centers on recycled aluminum — a source that saves a significant amount of emissions compared with mining aluminum — and seawater — a natural resource that also saves money by recovering gallium-indium. They found that this scenario, from start to finish, would generate about 1.45 kilograms of carbon dioxide for every kilogram of hydrogen produced. The cost of the fuel produced, they calculated, would be about $9 per kilogram, which is comparable to the price of hydrogen that would be generated with other green technologies such as wind and solar energy.

The researchers envision that if the low-carbon process were ramped up to a commercial scale, it would look something like this: The production chain would start with scrap aluminum sourced from a recycling center. The aluminum would be shredded into pellets and treated with gallium-indium. Then, drivers could transport the pretreated pellets as aluminum “fuel,” rather than directly transporting hydrogen, which is potentially volatile. The pellets would be transported to a fuel station that ideally would be situated near a source of seawater, which could then be mixed with the aluminum, on demand, to produce hydrogen. A consumer could then directly pump the gas into a car with either an internal combustion engine or a fuel cell.

The entire process does produce an aluminum-based byproduct, boehmite, which is a mineral that is commonly used in fabricating semiconductors, electronic elements, and a number of industrial products. Kombargi says that if this byproduct were recovered after hydrogen production, it could be sold to manufacturers, further bringing down the cost of the process as a whole.

“There are a lot of things to consider,” Kombargi says. “But the process works, which is the most exciting part. And we show that it can be environmentally sustainable.”

The group is continuing to develop the process. They recently designed a small reactor, about the size of a water bottle, that takes in aluminum pellets and seawater to generate hydrogen, enough to power an electric bike for several hours. They previously demonstrated that the process can produce enough hydrogen to fuel a small car. The team is also exploring underwater applications, and are designing a hydrogen reactor that would take in surrounding seawater to power a small boat or underwater vehicle.

This research was supported, in part, by the MIT Portugal Program.

© Credit: Courtesy of the researchers

At a time when clean water is increasingly becoming a precious resource, Chicago Water Week spotlighted the technologies, strategies, and start-ups shaping the...

The post Great Lakes, Greater Innovation: The Midwest’s Water Tech Momentum appeared first on Cleantech Group.

On April 10th, Cleantech Group hosted the panel “Every Drop Counts: Navigating Water Challenges in Manufacturing and Data Centers,” in Palo Alto, California....

The post Every Drop Counts: Navigating Water Challenges in Manufacturing and Data Centers appeared first on Cleantech Group.

New Poll: American Voters Support Federal Investments in Electric Vehicles Broad, Bipartisan Support for EV Investments and Incentives that Lower Costs, Expand Access, and Help the U.S. Beat China in the Race for Auto Manufacturing WASHINGTON, D.C. – A new bipartisan national poll conducted by Meeting Street Insights and Hart Research finds broad public support …

The post Support for Electric Vehicles appeared first on Alternative Energy HQ.