Diesel generators remain pervasive in backup power, especially in data centers and remote operations, due to their low cost and energy density. However, they suffer from severe environmental impacts, high maintenance, noise, permitting issues, and poor power quality. Richard Wang of Voya Energy presents a transformative alternative: an electrochemical generator powered by aluminum. Aluminum offers significantly higher energy density than diesel, is non-flammable, and eliminates NOx emissions, air permits, and fire hazards. The system uses safe, compact pellets that can be refueled continuously and operates silently with instant start-up, delivering superior power quality and reliability. Voya’s fuel strategy leverages abundant, low-cost scrap aluminum—particularly low-grade, contaminated scrap—making it cost-competitive with diesel in the U.S. and more affordable globally. Crucially, the technology is compatible with impurities in scrap, which unexpectedly enhances electrolyte stability. In the long term, Voya plans to close the fuel loop by recycling aluminum hydroxide byproducts into new aluminum, creating an infinitely recyclable, ultra-low-cost energy fuel. This could revolutionize global energy access, especially in energy-importing island nations, by enabling secure, clean, and scalable power delivery from solar- and wind-rich regions. The innovation is enabled by the maturation of battery and fuel cell technologies and a unique U.S. metallurgical gap, making now the ideal time for commercial deployment.
I'm Shail Khan. I invest in early-stage companies and energy impact partners. Welcome to Catalyst.
So, a few years ago, I, along with Greg Thiel, who you've heard before on this podcast,
developed kind of an obsession with metal fuels. You'd be forgiven if this is the first you've
ever heard of the concept. It certainly was for me. But the promise is tantalizing. Specifically,
the idea is to leverage certain metals, which are widely abundant, readily available,
shelf-stable, inert, extremely high energy density, as a better replacement for things
like diesel for power generation. No green premium, just better. Ask any user of a diesel
generator, and they'll tell you all the reasons these things need replacing. They're dirty,
they break, they're extremely hard to permit. Even if you get them permitted, your runtime
is highly limited. Maintenance is hard. The fuel fouls if you're not careful.
The fuel itself is flammable and dangerous. You have permitting requirements that make you space
it out so your footprint area density is even worse, and on and on. It's not a hard sell to
replace it. But diesel as a fuel and the engines that run on that fuel have some unique characteristics
that have made them incredibly sticky and hard to displace, which is why we still have 170 gigawatts
of these things, 170 gigawatts in the United States alone. And we're adding more every day,
particularly when we're talking about diesel. So, we're adding more every day, particularly
when we're talking about diesel. So, we're adding more every day, particularly when we're
with the rise of data centers. For example, to wit, there are more than 10,000 diesel generators
in Northern Virginia alone. So, they're ubiquitous and, in my opinion, terrible. But no more. Greg and
my obsession turned into a partnership with Richard Wang, who you're about to hear from. Richard is
the co-founder and CEO of Voya Energy, which is building a new kind of power generator, one that
runs on aluminum, and will put an end once and for all to diesel for power generation. This is
a great partnership. So, we're adding more every day. And we're adding more every day. But no more. Richard is
the co-founder and CEO of Voya Energy, which is building a new kind of power generator, one that will
for flexible energy management. GridBeyond's advanced DERMS and VPP platform is tailored to what data
centers care about most, maximizing reliability, intelligently meeting curtailment obligations,
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at energyhub.com. Richard, welcome. Thank you. It's great to be here,
Shale. All right. I want to start by talking about diesel generators. Talk to me about the
market for diesel generators. Yeah, the market for diesel generators is surprisingly large.
It's this sort of invisible entity that backs up the whole globe's energy system. So we're looking
at, if you combine generator markets as well as the diesel fuel that is burned by the diesel
generators, something like $30 to $40 billion a year globally. And a lot of the fuel is for
off-grid applications, things like mining and construction and oil and gas, where you don't
have grid access. But most of the hardware sales is coming from backup generators, where they're
for a grocery store or data center or something else. Okay. And so let's, I think we should start
by giving diesel generators their flowers. There's a reason why we use them everywhere all over the
world. So we should talk about what's good and uniquely good about them. And then we can talk
about what's bad, which in my opinion is a longer list. But first, like what is good about diesel
generators? Why are they fit for purpose for these applications? Yeah, there is a very good reason
that they are so prevalent and nothing has been able to displace them so far, because it's a very
unique combination of the two. It's a very unique combination of the two. It's a very unique combination
of capabilities. So number one, a diesel generator is essentially a highly convenient microgrid in a
box. When you have the generator, you need nothing else to provide electricity wherever you are if
the grid is down or if the grid's not available. It's also incredibly low cost. Diesel generators
are on the order of hardware alone, $500 to $800 per kilowatt. Even the more expensive
emissions-controlled ones are about $1,000 per kilowatt. You're talking about an incredibly
low cost compared to a gas turbine or a lubricating engine or a fuel cell or any
other, most other kinds of technologies. And then fundamentally, it's also about the fuel itself.
When you think about what diesel is as a liquid fuel, it's a way to store energy incredibly
compactly, ultra high energy density. It's reasonably stable. It won't just catch on fire
on its own spontaneously. It doesn't leak out. You don't need specialized tanks like you do with
natural gas or other gaseous fuels like hydrogen. So it's a very simple fuel, easy to store on site,
a simple plastic tank. You can store 48 hours of fuel or a
96 hours of fuel. What people in the battery world consider very long durations is basically
trivial to store with a diesel generator. So that ability to be fully off-grid with fuel on site,
providing energy whenever you need, is fundamentally a really useful capability
and something that has not been replicated by any alternative technology.
Yeah. And it's also, as I think you sort of alluded to, but just to put a finer point on it,
the footprint area density of a diesel generator plus fuel storage, plus on-site fuel storage,
is pretty small. And it's way smaller than any alternative. If you're trying to get the same
amount of power and same amount of on-site storage, you know, you basically can't do it
in the same footprint. Absolutely. Like any kind of battery configuration with the same kind of
duration, you're talking about more than 10 times the footprint, whether lithium-ion or otherwise.
And similarly with gaseous fuels, unless you have, you know, compressed gas on site,
and even then you're not competitive with diesel in terms of energy density. Right. Okay. So for all those
reasons, we have so, so much diesel being used to generate power. Let's talk about why that's
a problem. What's bad about diesel generators? Well, I think the challenge is most obvious when
you look at who these days uses diesel generators at the most enormous scale. And that's where the
problems are most acute. And that is particularly with data centers. And so data centers, typically
almost all of them will have a giant fleet of diesel generators backing up a majority or even
a hundred percent of the load. They even have extra generators behind that to back the generators
themselves for extra redundancy to ensure their five nines reliability. So you have these enormous
data center fleets. Of course, many data centers are built close to urban corridors like Northern
Virginia in particular is where we've seen a lot of the most acute challenges with the diesel
generator fleets there. And what you see when you read the news publications is incredible community
opposition to the diesel generators. Even though these are not typically running most of the year,
they might only run a hundred hours per year for maintenance and emergency operations. The reality
is when they do, they're not going to be able to run a hundred hours per year for maintenance and
emergency operations. So they're not going to be able to run a hundred hours per year for maintenance and emergency operations. So
they do run, they are number one, incredibly noisy and the vibrations basically can shake up the
whole community. And then on top of that, it's really the air emissions, specifically the NOx
emissions that come out of the generators that are incredibly polluting. They have substantial local
health impacts, you know, millions or tens of million dollars of sort of negative health impacts
coming out of diesel generator fleets at data centers, which really has these days, a lot of
communities up in arms because of this. Yeah. And I would say those are the primary
reasons diesel generators suck, but there are, there's a set of secondary reasons too, which is
more that actually they're just not as easy to operate and maintain as one might think, given
that they are being used as backup generators. That's right. They're not great products in their
own right. And we've lived with them out of necessity. But if you think about some of the
additional challenge that they have for a data center, for instance, especially, or any other
demanding customer. So number one, the power quality coming out of a diesel generator tends
to be very dirty in terms of the voltage waveforms for your AC.
Um, and if you have spiky loads, it does tends not to respond very well. So you have a lot of
voltage sag or overvoltage. Um, so all of that is very challenging. You're trying to power a GPU or
any other sensitive electronic requires additional buffering systems, batteries, capacitor banks,
and so forth, which just add to system complexity. Um, and then on top of that, uh, diesel generators
as well require a lot of maintenance. And so the diesel fuel itself, you know, it's reasonably
stable, but in fact, every few months you have to go in and polish the fuel. Basically,
because the fuel will attract moisture from the atmosphere. It can start growing algae,
it can go bad. And so you have to constantly be swapping out this fuel every few months,
which is a big pain and overhead. Uh, and then the generators themselves, you have to run every
few months, typically once or twice, um, a quarter to ensure that the generators are working and
maintained. So all this adds a lot of overhead for a system that's only used very intermittently.
Um, and it's a, it's a big operational pain for users.
Right. Yeah. And so I think, you know, universally, if you go talk to somebody who owns an
operate.
or uses a diesel generator,
like they're not in love with the product.
It's quite the opposite.
But as you said,
we've sort of lived with them out of necessity.
I think we should spend a minute talking about
why there hasn't been a great replacement.
Like there are, you know,
I think intuitively you might think,
okay, well, we have natural gas generators,
reciprocating engines or whatever.
Why is that not a universal solution
to the diesel generator problem?
Yeah, we can look at a few
of the plausible alternatives.
And there are companies that are looking
to replace diesel generator fleets
with natural gas-based systems,
especially reciprocating engines.
And it partially works.
But I think if you talk to a lot
of the demanding users of diesel,
what they'll tell you is that
your natural gas systems are dependent
on the security of your gas pipeline network.
And the gas pipelines typically undergo stress
at exactly the same times
when your overall electric grid is overstressed.
And so if there's a big winter storm
that's rolling through
that's leading to a regional blackout,
there's a pretty decent chance
at a correlated risk
that your gas pipeline is also at risk.
And so that external dependency
means that you have this common mode failure,
which means that your natural gas systems
can never be as provably reliable
as truly having fuel on site
or totally independent
without any kind of external intervention.
You can operate for 48 or 96 hours continuously
because you have your fuel stored on site.
And so fundamentally,
natural gas is a fuel
that should be delivered
just in time through pipelines
rather than stored on site.
It's much more,
much more pain just to try to store a gaseous fuel.
Right.
Also, you have, to a lesser extent,
you have air permitting issues
with natural gas generators as well.
This is why,
part of why fuel cells suddenly
are an interesting thing,
again, is, you know,
because they're easier to permit
than a natural gas generator.
And we can talk about fuel cells separately,
but that is,
it's not as big an issue
as it is with diesel generators.
In some places, though,
it's a significant issue.
You know, you and I are in California.
It's hard to permit a new
backup natural gas generator,
let alone a diesel generator.
Absolutely, absolutely.
And you still have the same issues
with power quality,
with anything that's spinning
and with combustion.
So you have to buffer it with batteries.
Yeah, and so,
and they also tend to be
quite a bit more expensive.
And honestly,
CapEx is the most important
cost metric
when it comes to backup systems
because they're not used very often.
You don't care that the fuel
is more expensive.
It's really about
how cheap is your generator.
And diesel is by far
the cheapest solution out there.
Putting a gas turbine
is like incredible over-engineering
for something that
you're using 50 hours a year.
Right.
Okay, so speaking of
high CapEx then,
another alternative that
one could imagine
would be batteries.
Talk about why batteries
haven't really taken over
this market.
Yeah, batteries play
a pretty important role
because they have,
of course, many benefits.
They have excellent power quality,
basically instant cold start.
So when you need power,
you instantly get it
in milliseconds.
But the fundamental challenge
with batteries
is one of duration.
If you actually wanted
to have a battery
that could last for 48 hours,
which is a pretty typical
minimum duration
for a,
a backup generator,
you would need
an incredible fleet of batteries
that would be,
number one,
take up an enormous amount
of space.
Number two,
it would be so many batteries
that communities typically
are getting quite finicky
around lithium-ion in particular
because of local
flammability concerns
when you have so many batteries
all at once.
And ultimately,
the cost of those batteries
is cost prohibitive.
Even though batteries
have gotten so much cheaper,
typically we're sizing batteries
for typically four-hour durations,
maybe up to six or eight hours.
Nothing,
remotely close to 48 hours.
It just is not
the right chemistry
or the right approach
for something
that's so long-duration.
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Okay, so diesel generators,
they're everywhere.
They suck.
We haven't had a great replacement.
Let's talk about aluminum as fuel.
Talk to me about, first of all,
just give the fundamentals here.
Like, why could aluminum be a fuel?
Why can a metal be a fuel?
Yeah, it's a very non-obvious concept.
Most people have never heard
of metal fuels or aluminum
as a source of energy,
but in fact,
it is a remarkably efficient way
to think about storing
and transporting
and delivering electricity
at enormous scale,
independent of the electric grid.
And so how it works is,
when you think about
how aluminum exists
in the Earth's crust,
it in fact is found in bauxite,
which is an ore
that contains,
uh, aluminum bonded with oxygen.
That's its natural state
in the Earth.
Uh, and then what we do
when we think about producing
aluminum as a metal
for structural applications,
beverage cans,
cars, and things like this,
is that you take that mining ore,
you dissolve it down
with sodium hydroxide,
and then you get out
aluminum hydroxide
in a pure form as a chemical.
That's then dried out
into aluminum oxide,
and then the key process,
aluminum smelting,
is splitting apart
aluminum from oxygen
by using electricity
to dry it out
and drive an electrochemical process.
Uh, and that form of electrolysis
splits that bond,
and then you get molten aluminum
that then gets cast out
and produced into
whatever products you need.
And then typically at that point,
we forget about
the energy side of the equation.
You just have this great metal,
it's structural,
it's stable,
it doesn't corrode,
it's great for all sorts of uses,
and then sort of
that's the end of the story.
But, you know,
the reality is,
when you look at it
from a chemical perspective,
that aluminum in fact
has all that embodied energy
held inside,
and what it really wants to do
is to react
again back with oxygen
to go back into
its most stable state,
and that reaction actually
would then release
a ton of energy,
whether in the form of heat
or in the form of electricity.
Um, and so metal fuels
are basically a concept
of how do you take
aluminum in its metallic form,
react it with oxygen,
whether through combustion
or through electrochemical means,
to ultimately get out that energy
in usable form.
Okay, and so
what version of that
are you doing?
Uh, we are taking
the electrochemical approach.
Um, so, so originally
Voya went through
a fairly deep, uh, incubation,
looked at many different
metals technologies
and different pathways
for getting out, uh,
electricity or energy
from the metal.
Uh, first of all,
we decided that we really
wanted to get electricity
out of metal fuels,
not heat and not hydrogen,
because electricity fundamentally
is the most critical need,
uh, facing our energy
landscape, uh, today.
And then number two,
uh, you can imagine
trying to burn
a metal powder.
For example,
fine metal powders
are known to be highly flammable.
Uh, but if you burn it,
you then have
super high, uh,
great heat,
but then you have to pass it
through a steam turbine.
All of a sudden,
you're talking about
a very expensive
and challenging system
that's hard to scale
and, and, uh, very costly.
And so we decided
to really pursue
the electrochemical pathway,
which we believe
has, uh, incredible potential,
uh, because electrochemistry,
fundamentally,
what we're doing at Voya
leverages the fundamental
investments and breakthroughs
that have happened
in the battery
and fuel cell industries
over the last, uh,
couple decades.
And these days,
with the maturity
of, uh, electrochemical
technologies,
with the sort of capability
of the workforce
and talent base
that's out there,
you can really design
electrochemical systems
that are incredibly
cost-effective and, uh,
capable and ultimately
able to convert
that energy
from its raw
thermodynamic form
in aluminum
out to electricity
with far higher efficiency
than combustion
without any of the
NOx emissions
that you might otherwise
still get if you're
combusting at high temperatures.
You just get a very
clean, pure,
responsive electrical signal
out of that chemical reaction.
Okay, so maybe
to put a finer point on it,
like, walk me through
what happens inside
a Voya generator.
Yeah, so a Voya generator
is really a very novel,
uh, electrochemical
cell architecture
where we're essentially
taking, uh,
pellets of aluminum.
You can imagine
a few millimeter,
almost like a BB gun
pellet size,
so not a powder,
but actually
substantial-sized pellets,
and they're flowed
into electrochemical cells.
And then what's happening
inside that cell
is what's called
a metal-air reaction.
And so it's a little bit
akin to a hydrogen field
feel so. You want to think about it that way. The cathode side of the equation
equation, the positive side is basically a normal air cathode that comes from the fuel cell industry.
Our version of it doesn't have platinum or any other rare earths. It's a very low-cost,
commonly available air cathode. But what happens at the cathode is you have oxygen coming in from
ambient air. It reacts electrochemically with the electrolyte, alkaline electrolyte,
to turn into hydroxide ions inside this water-based electrolyte. And then that electrolyte
will then react preferentially with your aluminum pellets and dissolve them away. And as they get
dissolved away and bond up the hydroxide, you're basically touching an external circuit, a current
collector or a wire, that essentially conducts the electrons out from the aluminum, passes it
through an external load to power whatever you need, and then completes the circuit by going to
the cathode. And then ultimately, all that dissolved aluminum that gets flowed out of our
electrochemical cells, and then we have a separate subsystem to treat the electrolyte and extract out
the. byproduct in solid form. And so with this, you can basically continuously refuel the cell
as frequently as you need. So if you need to run continuously for 100 hours or 1,000 hours,
you could do that with this design because it's a continuously refuelable system. But then when
we're on standby and you're using it for a backup application and nothing's happening, we don't need
to feed in any fuel inside the cell. So the cell by itself is perfectly stable when the aluminum's
not inside. There's no chemical reactions. There's no degradation either. And so it's a very novel
architecture that combines all of that. And so it's a very novel architecture that combines all of
a lot of core concepts from the battery and fuel cell worlds. But we've really re-architected a lot of
these common components into a very novel design to achieve these capabilities.
We'll come back to the Voyager generator in one second. I realize one thing we didn't actually
make a clear point of, I think, in talking about aluminum as fuel is its energy density. I mean,
you said it sort of got all this embodied energy, chemical energy from the aluminum smelting. Just
how dense is it? Yeah. So aluminum has a whole bunch of great properties as a fuel. Most critically,
I would say, is the energy density. And if you want to compare it to diesel, which is sort of the
gold standard in terms of fossil fuel energy density. I mean, diesel is far more energy dense
than natural gas, for example. In fact, it is, from a volume basis, about twice as energy dense
as diesel on an as-converted basis. So come at the amount of electricity you're getting out per
liter or per gallon of fuel. And then even on a weight basis, you are a little bit better than
diesel in terms of energy per weight.
Moderately to significantly better than diesel and dramatically better than every other solution
out there. And then you combine this with the fact that it is a safe solid aluminum, of course. It
doesn't burn. It doesn't rust or corrode. Basically, you can stockpile this for years on end
and not lose any of the material to oxidation or side reactions. And because it's such a safe,
simple, stable solid, it transports extremely efficiently through existing logistics chains,
whether it's bulk carriers, the way that we move ores or grains or coal,
some of the lowest cost logistics options globally are available to aluminum as well.
You can put it on rail cars. You can put it on trucks. You don't need any special training or
permitting to haul this around. So in fact, logistically, far simpler than typical gaseous
or liquid fuels that are fossil fuel based. Right. Okay. So that's what got us excited
about aluminum as a fuel in the first place. Back to the generator then. So we started this
conversation by talking about diesel generators, which is sort of the initial market that you're
targeting and trying to take down.
Just give me an apples to apples comparison then. A Voya generator next to a diesel generator
on all the key metrics we care about, cost and efficiency and footprint and
all the performance, all those kinds of things. Just give me a head to head.
Absolutely. And we'll do the head to head comparison. And then we'll also probably
extend the point that our generator is fundamentally a different energy solution
from diesel. It can do every single thing that diesel can do better, but it has additional
benefits that actually make it far more valuable. So I'm going to give you a head to head comparison
of what a Voya generator can do better than a classical diesel generator. So we'll get into
that in a bit, but in terms of just head to head competition, as mentioned, the fuel is incredibly
energy dense, twice as energy dense as diesel, but even more significantly is if you're trying
to deploy a large fleet of diesel generators on a site. If you have like a hundred megawatts or
several hundred megawatts of diesel with 48 or 96 hours of fuel, like you have at any data center,
it becomes a fairly significant fire hazard from a local fire safety and fire marshal permitting
perspective. And so there are strict codes on basically how you can deploy a large fleet of
diesel and how far the generators have to be from each other. And also critically how you store
your fuel. Often with that quantity of fuel, you have to bury it underground in big tanks and even
between tanks, you need pretty substantial segregation. So there, you see a ton of empty
space on a typical diesel generator install. It's basically for fire safety. And so when we look at
what we're doing with our generators and fuel, every single thing is non-flammable. The generator
is non-flammable. It's a water-based system. The fuel is fundamentally non-flammable. The byproduct,
aluminum hydroxide.
is also inert, non-toxic, non-flammable compound. So there's no, none of these fire permitting
concerns on storing large amounts of fuel. So you can really stack this very, very densely together.
And what that means is per, in terms of megawatts per acre, the power density, how much power you
can pack in per acre, we are approximately a hundred megawatts per acre in our high density
configuration, which is about four times higher than a diesel generator installation. And so for
any sort of application where you're constrained on land, it's just incredibly more
compact compared to diesel. Of course, you also don't have any air quality permitting required.
There's no NOX, there's no SOX, there's no CO2, anything else coming out. So exempt from air quality
permits. There's no runtime constraints. You can run this as often as you'd like. You're not limited
by the state or by the EPA. Also in terms of, as mentioned, fire safety, just very simple permit on
that side as well. Very quiet. And then power quality as well is substantially better. So basically
instant cold start, just like a battery.
Whereas a diesel generator often will take five to 10 seconds to get to full power from a cold start.
So great for even superior for backup applications. And then critically for those spiky loads,
we're not going to destroy our turbines or our engines because of spiky loads. It can respond to
fluctuating loads very, very efficiently. So those are a lot of those basically key reasons why we
think it's superior to diesel. And also cost-wise as well, highly competitive with diesel. Again,
leveraging a lot of the lower-end batteries and the low-end batteries. So those are a lot of the
basically key reasons why we think it's superior to diesel. Again, leveraging a lot of the lower-end batteries and the low-end batteries
on costs that have come from batteries and fuel cells. So incredibly cost-competitive compared to
diesel.
Okay. So that's the direct head-to-head Voya versus diesel comparison. But then you alluded to,
like, there's things a Voya generator can do that a diesel generator can't. So what were you
referring to there?
Yeah. And so when you think about what a diesel generator is, it's actually not only great for
on-site backup. It's fundamentally a very valuable tool that can be used by the electric grid.
Whenever the grid is overstressed and you're running out of peak capacity, that entire installed base of
diesel theoretically would be super attractive as a grid resource. Now, you know, why don't we
typically use it as a grid resource? It's because there are strict air quality constraints on run
times when it comes to the emissions coming out. And local communities are going to be up in arms
if you're running these things hundreds of hours a year, even, because of all the pollution that's
coming out of the diesel generators. Even despite that, if you look at the Department of Energy,
they're trying to basically have these emergency rulings to allow diesel generators to run when
the grid is stressed to buffer the grid. So, you know, I think that's a really good point.
The opportunity is there, but diesel is fundamentally restricted because of the local pollution that it
causes from being a useful grid asset. With Voya, what we can do is twofold. Number one, Voya can
serve as a pretty idealized grid asset because you have basically instant start capability. Whenever
the grid needs to call upon this, you can run for tens or hundreds of hours in duration, even riding
out the most severe winter storms. It's a highly reliable grid asset. And so a super valuable tool
for utilities to call upon is the Voya. And so, you know, I think that's a really good point.
Where all this capacity that's already been paid for by the data centers or other commercial users
now can also serve as a highly flexible grid asset. And then it essentially is also like a
super battery on site. Like these days, a lot of hyperscalers are actually having to install
large Tesla megapacks to provide power quality. So all those spiking loads don't
throw crazy harmonic distortions across the grid and across their on-site fleet.
And what Voya can do as well, because we're an electrochemical system, just like a battery,
is respond every bit as well as a battery, which means that we don't need a big battery buffer
next to a Voya generator fleet the way you need with diesel. And so now this two-in-one solution
of serving all the capabilities of an on-site lithium-ion battery stack, as well as your
diesel generator stack, in a footprint that is multiple times smaller than either of those on
their own, it's just a dramatic cost and land savings, which is very attractive for large-scale
data center campuses. We haven't really talked about the remote applications,
or defense applications, which is another place where they're pretty heavily utilized.
But talk to me about what you're seeing there in the off-grid remote defense conglomerate of markets.
Absolutely. Off-grid power is an increasing need as well. Certainly when you look at
classical commercial uses like mining or construction or oil and gas,
all of these don't have grid access and are dependent on diesel generators. And where we see
we have a significant right to win. But I think in defense in particular, the value proposition is
not strongest when it comes to off-grid. And the reason is the military is an unusually demanding
user of diesel generators. And the key things they struggle with are number one, the generator,
and number two, the fuel. So all of it, essentially. So with the generator, the core problems they have
are the diesel generators are incredibly inefficient in terms of burning fuel,
especially for military uses where they're idling a lot of the time. It's very intermittent. It's
not operating near peak efficiency. They're often maybe down even like 25% efficiency. So super
inefficient, very heavy maintenance lows because they're not operating in their sweet spot.
And then they're very noisy and they run very hot.
which for something that's especially forward-deployed,
we're using a diesel generator for a military base
or for like a drone charging station
or for forward-deployed manufacturing.
That diesel generator we've heard in Ukraine
is like a giant hobing beacon for drones.
With an IR camera, you can spot that diesel generator
from miles away and know where the sensitive operations are.
So all of this makes it problematic for the military.
And then the fuel itself is challenging as well
because liquid fuels go bad.
So you have to ship them basically almost just in time
to get the fuel out in the field.
And they are heavy and take up a lot of space.
So the fuel logistics as well is challenging.
So with Voya, we are a sort of step change improvement
in all these fronts.
We have a generator that is compact, super quiet,
minimal heat signature.
So it's a very, very stealthy generator,
which is highly attractive, we found.
And then in terms of fuel logistics,
especially for the military use cases
where they're using the fuel so inefficiently,
we have a substantial energy density benefit,
about 20 to 30% less mass
and about 70% less volume.
So it's a lot of volume shipped to the front lines
for a typical military diesel generator
compared to Voya's aluminum generator.
So that logistics footprint as well is critical
in terms of military exposure to risk and attacks and so forth.
So we've seen a lot of traction for different use cases there
and are excited to see this pick up more momentum.
Okay, you and I have now both spent a couple of years
quietly obsessing over this
and talking to people about it selectively.
And I would say that, let me ask you,
there are two areas,
there's skepticism,
the two questions that I get most often.
The first one is like, why now?
You know, you didn't invent metal fuels,
we didn't invent metal fuels,
you're not the first person to think of using aluminum as a fuel even.
What is it that makes this possible now
where it wasn't before?
Like, why hasn't this already happened?
Yep.
If it's so great.
Yes, yes, perfect.
I think every single investor has asked me that question.
So very, very fair.
And I like to give sort of a nested series of responses,
starting from sort of simple and obvious macro trends,
which are important,
but are, I think, clear to everyone,
to things very specific to Voya itself.
So the most obvious is that the energy markets
are screaming for a solution like this.
Diesel, the pain points associated with diesel
have not been so acute
until only even the last couple of years or so.
And so the sort of time to go build a business commercially
has never been as attractive as it is today.
Number two, you know, as mentioned,
the maturation of the battery and fuel cell industries
is critical to this.
Things like just basic breakthroughs in power electronics
with Tesla,
and with battery energy systems,
all driving power electronics and inverters
to record low cost levels,
now makes a system like this very affordable,
whereas 10 years ago,
it would have been much more expensive than a diesel generator
and not attractive of a proposition.
Same thing with the workforce.
You have incredible electrochemical talent
from the billions that have been invested
in battery and fuel cell companies.
And all those people are now coming out
and looking for something new to do beyond batteries.
So you have an excellent workforce to go and design
and mature a system such as this that's so novel.
So those, I think,
are all things that we sort of get for free,
but they are important to the timing of this.
Then what's more specific to Voya
is the reality that the U.S. in particular
has completely ceded its entire metallurgical knowledge base
and industry, principally to China,
over the last 40 or 50 years.
And in the U.S. in particular,
almost every single aluminum smelter has shut down.
There's, I think, maybe only one left operational
in the U.S. these days.
And so along with that entire industry leaving the U.S.,
is also all the universities and all the grant agencies
stopping all R&D, basically, in aluminum smelting.
What that means is that the sort of basic knowledge base
you need to innovate and think creatively
around what can you do with metal fuels
is relatively lacking
when you specifically look at the details
of aluminum-based technologies.
And so when we did this deep incubation with EIP
around Voya Energy,
we really dug very deep into old industrial literature,
patent literature,
talked to experts, the remaining experts,
especially in Canada that still know aluminum smelting
and how it works and what's going on,
to really figure out what actually is the lay of the land,
first of all,
and then really to figure out
what are the sort of the nuggets of wisdom
and unique insights that we have to pull together
to come up with a pretty unique thesis as we have in Voya.
And so what we are actually doing at Voya,
if you look at the details,
is actually really quite unique
compared to any other metal fuels approach
that's been tried historically.
And it's because we spent the time
to really figure out what's going on
on the lay of the land in detail
and find a much more compelling technology hypothesis
to actually go make this work.
So we're pretty excited to having united
some of the best minds in metallurgy
as well as electrochemistry
and electrolyte designs from the battery worlds
to go attack this problem in a pretty unique fashion.
Okay, second area of skepticism
gets into aluminum as a fuel.
You know, I think the question is,
so aluminum is strategically valuable.
You know, you don't want to divert too much of it.
We need it for structural applications.
It's also pretty expensive
if you're buying primary aluminum.
So this gets into your fuel strategy.
Why does it make sense?
And in what conditions does it make sense
to actually use aluminum as a fuel?
And like, what are you going to do?
How are you going to get fuel?
Yes, so our fuel strategy is twofold.
So our primary strategy,
the first, let's say,
quite a few five plus years of the business
is based on scrap aluminum.
And what is,
what's attractive about the scrap aluminum industry
is it's an industry
with many, many different grades of scrap
that are available
at a moderate to substantial discount
versus primary aluminum
depending on the quality of that scrap.
And certainly if you think about scrap aluminum
and aluminum recycling,
there's the notion that aluminum
is infinitely recyclable.
And that is true of certain grades of scrap.
If we think about beverage cans,
they recycle very, very cleanly in a closed loop.
We don't want to touch any of those streams
because not only are they expensive,
at the end of the day,
they are serving a value
and a valuable purpose
by diverting the need to use more primary aluminum.
So we're not going to touch those kinds of scrap.
But you also have other forms of scrap,
especially things like shredded end-of-life cars
that are intrinsically mixed alloys,
they're contaminated with iron
and other impurities
that really impact their ability to be recycled
for any kind of high-strength structural application.
And because of that,
they are much more discounted versus primary aluminum.
It's not really a direct replacement for primary aluminum.
The prices are much more discounted
or decoupled.
Even if primary gets expensive,
low-grade scrap doesn't get that much more expensive.
And in fact, because it's not so useful inside the U.S.,
we don't tend to do the kinds of low-end manufacturing
that might even use the low-grade aluminum.
A lot of it is just either landfilled and wasted
or often exported to Asia for cents on the dollar
to be sort of put into other low-end applications.
And so that kind of scrap we think is highly attractive
because there isn't a lot of value,
it's fairly cheap,
and it's also a very mature industry
where it's well-distributed across the whole country.
Every major population center has scrapyards,
has recycling centers
that are already processing all the scrap.
And instead of shipping all that stuff over to Asia
or other countries,
we can harvest that
and convert it from a waste resource
to an incredibly valuable energy resource.
And I'll just add,
you can use low-grade scrap.
That's like a key point, right?
Like you don't need to go upgrade it first.
Yes, that was a key point of our thesis,
and we have been able to prove that out
in terms of our cell design,
and our chemical compatibility.
It is compatible with all the common grades of scrap
that are out there,
including the low-end grades.
We just had a nice breakthrough a couple of days ago,
I don't think you've heard about this yet,
where some of the common impurities
found in the lowest grades of scrap
actually have a significant beneficial impact
on the stability of our electrolyte.
So that was, I think, not planned for,
but a nice surprise that's come out.
But yes, the compatibility with low-end scrap
is a unique aspect of our technology approach
and key to unlocking that as a resource.
Okay, so that's part one of the fuel strategy
is leverage this existing broad liquid supply chain
for scrap, particularly low-grade scrap.
What's part two?
Well, on part one, I'll maybe just wrap up
and say that ultimately,
when you look at the net cost of the fuel,
we believe even in early days,
even with scrap in the U.S.
being more expensive than other countries,
with U.S. scrap, you're already at diesel parity
when it comes to fuel costs,
which is a critical thing for us.
We're not commanding a Greenpeace
premium or any other sort of premium.
Direct cost parity with diesel
for fully delivered costs,
including all the processing,
all the logistics steps and so forth.
So I wanted to lay that out there clearly.
Like from the beginning,
we're on cost parity with diesel in the U.S.
In other countries,
we'd actually be far cheaper than diesel,
where aluminum is cheaper
and diesel is more expensive,
like in Europe or in Asia, for example.
So very cost competitive, even early days.
But then long-term,
we believe the vision for metal fuels
goes far beyond using scrap as a fuel resource.
And ultimately, if you want to really
drive aluminum fuels
into a foundational new technology
for the global energy system,
you need to drive incredible volumes of fuel
on the scale of fossil fuels,
when you think about oil drilling
and oil refineries and so forth.
And you also need very cost competitive,
something ideally that's far cheaper than diesel
and can really compete for grid power
with things like liquefied natural gas
or nuclear or other forms of prime power.
And so long-term, the vision is to take that byproduct
that comes out of our general industry
generator, the aluminum hydroxide,
and instead of selling it off as a commodity chemical,
as we plan to do early days,
that aluminum hydroxide is the exact same feedstock material
that goes into all aluminum smelting today.
And so Voya is working on a longer-term set of technologies,
really exciting breakthroughs around aluminum smelting.
We've seen some real exciting things happening
in the industry that we think we can leverage
in a unique way for metal fuels production.
And what that allows us to do
is to build these highly cost-efficient
aluminum smelters to ultimately close
the loop.
recycle that byproduct, and then recreate the metal fuel. And then it becomes an infinitely
recyclable fuel, far, far lower cost than diesel, infinitely scalable, and allows you to build these
smelters wherever in the world globally you have abundant energy resources, places like the Western
Sahara with solar and wind, or Australia, or the Middle East, and capture all that ultra-low-cost
one cent per kilowatt-hour energy into the form of the metals, and then very elegantly ship them
across the globe for wherever you have an energy shortage, especially in places like
island economies, the Japans of the world, Hawaii. All these are huge net energy importers,
and having a fundamentally secure and diversified and clean ability to import energy at large
global scale, we think will completely change the energy landscape. All right, Richard, I'm glad we
were finally able to do this publicly. Thank you for your time. It was a pleasure. Thank you, Shale.
Richard Wang is the co-founder and CEO of
Oya Energy. This show is a production of Latitude Media. You can head over to
latitudemedia.com for links to today's topics. This episode is produced by Max Savage-Levinson,
mixing and theme song by Sean Marquand. Anne Bailey edits the video version of the show.
Stephen Lacey is our executive editor. All of our episodes are now on YouTube.
You can subscribe to Latitude Media for episodes of this show and Open Circuit.
You can also find the audio version of the show anywhere you get your podcasts.
I'm Shale Kahn, and this is Catalyst.
I'm Shale Kahn, and this is Catalyst.
Podcast Summary
Key Points:
Diesel generators are widely used for backup power due to their low cost, high energy density, and ability to operate off-grid, but they face severe environmental, health, and operational challenges.
Aluminum fuel offers a superior alternative by providing higher energy density than diesel, being non-flammable, safe, and transportable without complex logistics or permitting.
Voya Energy’s electrochemical generator uses aluminum pellets in a metal-air reaction to produce clean, responsive electricity without emissions, noise, or runtime limitations.
Compared to diesel, Voya generators deliver better power quality, compact footprint, zero air emissions, and instant cold start, while being cost-competitive and scalable for data centers and remote operations.
The technology leverages existing scrap aluminum supply chains, especially low-grade scrap, and is designed to be compatible with impurities, turning waste into a valuable energy resource.
Long-term, Voya aims to close the loop by recycling aluminum hydroxide byproducts into new aluminum fuel, enabling a circular, scalable, and ultra-cheap energy system globally.
Aluminum fuel addresses critical pain points in defense, mining, and off-grid applications where fuel efficiency, stealth, and logistics are paramount.
The rise of battery and fuel cell industry maturity, combined with a U.S. metallurgical knowledge gap, has created a unique window for metal fuel innovation to emerge now.
Summary:
Diesel generators remain pervasive in backup power, especially in data centers and remote operations, due to their low cost and energy density. However, they suffer from severe environmental impacts, high maintenance, noise, permitting issues, and poor power quality. Richard Wang of Voya Energy presents a transformative alternative: an electrochemical generator powered by aluminum.
Aluminum offers significantly higher energy density than diesel, is non-flammable, and eliminates NOx emissions, air permits, and fire hazards. The system uses safe, compact pellets that can be refueled continuously and operates silently with instant start-up, delivering superior power quality and reliability. S.
and more affordable globally. Crucially, the technology is compatible with impurities in scrap, which unexpectedly enhances electrolyte stability. In the long term, Voya plans to close the fuel loop by recycling aluminum hydroxide byproducts into new aluminum, creating an infinitely recyclable, ultra-low-cost energy fuel.
This could revolutionize global energy access, especially in energy-importing island nations, by enabling secure, clean, and scalable power delivery from solar- and wind-rich regions. S. metallurgical gap, making now the ideal time for commercial deployment.
FAQs
Diesel generators are noisy, emit harmful pollutants like NOx, require frequent maintenance, and have poor power quality. They also pose fire and safety risks, face strict permitting due to emissions, and take time to start, making them unsuitable for sensitive loads.
Aluminum has a significantly higher energy density than diesel—up to twice as much per unit volume and slightly better per unit weight—making it a more efficient and compact fuel option for energy storage.
Aluminum is non-flammable, inert, and stable, unlike diesel which is flammable and can ignite easily. The byproduct, aluminum hydroxide, is non-toxic and non-reactive, eliminating fire and environmental risks during storage and use.
Voya’s generator is electrochemical, not combustion-based, producing clean electricity with no emissions, instant cold start, superior power quality, and no runtime or air quality permitting constraints.
Yes, aluminum fuel is ideal for remote and military use due to its compact size, quiet operation, low logistical footprint, and resistance to degradation, offering significant advantages over diesel in these environments.
Voya primarily uses low-grade scrap aluminum, which is abundant, cheap, and widely available. This scrap is processed locally, avoiding the need for expensive primary aluminum and enabling cost parity with diesel.
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