Closing the loop with iron as a sustainable and recyclable energy carrier for a decarbonised future
Ahmed Aboalhamayie is a PhD Researcher in the School of Mechanical, Aerospace and Civil Engineering specialising in making iron the go-to material for creating a zero carbon future.
Ahmed's research challenge
Establishing iron as a sustainable, recyclable energy carrier.
The Top results
The results focus on solving critical barriers to making iron a viable zero-carbon fuel:
- Demonstrated circular regeneration via FAST: The research successfully utilises Field Assisted Sintering Technology (FAST) to rapidly recycle iron oxide (rust) back into pure iron. This process closes the "circular energy loop," proving that iron can function as a repeatable, sustainable energy carrier.
- Developed passivation and storage protocols: The study identifies specific slurry formulations, such as ethanol and kerosene suspensions, that protect iron particles from premature oxidation. This ensures the fuel remains stable and high-density during storage and handling until it is ready for combustion.
- Optimised combustion through bimetallic thermites: The research provides experimental evidence on how bimetallic additives and particle size (micron vs. nano) affect burning efficiency. These insights allow for the creation of more spherical particles, which improves the consistency, safety, and overall performance of the fuel.
Additionally, the project established a framework for quantitative high-speed imaging, providing robust, repeatable data on micro-explosions and burning characteristics that can be used by the wider scientific community.
Behind the scenes
Iron is a promising high-energy-density, recyclable energy carrier, oxidising to release carbon-free heat that can be regenerated and reused in a closed loop. Realising this requires two opposing strategies: suppressing oxidation during storage whilst promoting it during energy release. This research, a collaboration between the University of Sheffield, Wilkes University (USA), Sheffield Hallam University, the King Abdulaziz Military Academy (Saudi Arabia), and the Center of Nanotechnology, addresses both.
The project focuses on the combustion and regeneration cycle, where iron oxide byproducts are "recharged" back into pure metal using Field Assisted Sintering Technology (FAST). Key challenges addressed include improving burning efficiency through bimetallic thermites and preventing premature oxidation during storage using specialised slurry formulations. By employing high-speed imaging, the study provides quantitative data to ensure the fuel remains stable and high-performing for industrial use.
Who benefits from this work?
The primary beneficiaries are UK energy policymakers seeking carbon-neutral fuel alternatives, industrial manufacturers requiring stable and recyclable energy carriers, and the global scientific community who can utilise Ahmed's open-access datasets to accelerate development in metal-fuel combustion and material passivisation.
Research by Ahmed Aboalhamayie
Establishing iron as a sustainable, recyclable energy carrier
In Ahmed’s words
My research establishes iron as a sustainable, recyclable energy carrier to support the global transition to carbon-neutral fuels. By utilising the FAST system for rapid circular regeneration and optimising bimetallic fuel particles, I bridge the gap between advanced materials processing and high-efficiency combustion performance. Finally, my use of quantitative high-speed imaging provides the robust, repeatable data necessary to ensure these zero-carbon energy solutions are safe, consistent, and scalable.
Ahmed Aboalhamayie
PhD Researcher
Ahmed has contributed two high-impact journal articles in FirePhysChem (2026) and had a proceedings paper at the International Conference of Fluid Flow, Heat and Mass Transfer (FFHMT) in 2025.
FirePhysChem (2026):
- Experimental investigation of size dependent combustion in ethanol slurries and bimetallic thermite
FFHMT 2025:
- An of Colloidal Suspension of Carbon-Rich Fly Ash Microparticles and Diamond-Nano Powder (DNP) in Jet-A Fuel
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