UK-based Novelis has “successfully” tested the use of hydrogen to power an aluminium recycling furnace at its Warrington plant.
Several series of tests were conducted by blending different percentages of hydrogen with natural gas, ranging from 30-100%, to evaluate the impact on existing infrastructure and equipment compatibility.
Several hundred tonnes of 3000 series scrap aluminium alloy were remelted and cast into sheet ingots. Additionally, all relevant parameters were measured to assess any impact on the product, process, operating environment and emissions.
Trial results will inform a full post-trial evaluation report, which is expected later in 2025.
H2 View understands that further downstream processing will be conducted at Novelis’ other European plants to establish the feasibility of end-to-end hydrogen-powered aluminium recycling.
“The use of hydrogen is not common in the aluminium industry today, and we are very proud to be one of the pioneers to have tested this new fuel at an industrial scale and in a real-world environment,” explained Allan Sweeney, Plant Manager at Novelis Latchford.
“The results will drive further research into the potential deployment of hydrogen in our recycling operations worldwide.”
The trial received £4.6m in funding from the UK Government’s £1bn Net Zero Innovation Portfolio and the wider regional HyNet project.
It was also part of the Industrial Fuel Switching Programme initiated in collaboration with Progressive Energy.
Furthermore, the Warrington plant will be backed by $90m in investment to double its used beverage can (UBC) recycling capacity by 85 kilo tonnes per year, which is anticipated to decrease Novelis Europe’s CO2e by more than 350,000 tonnes annually.
Hydrogen’s aluminium opportunity
From cans, foil and kitchen utensils to beer kegs and aeroplane parts, aluminium is among the world’s most widely used metals. Produced en masse globally, the metal accounted for around 3% of the world’s direct industrial carbon dioxide (CO2)emissions in 20221.
Produced through extremely energy-intensive processes, aluminium’s carbon footprint is primarily attributed to the smelting stage which sees aluminium oxide reduced to the usable material.
However, its primary production has been declining. Today, it is one of the most recycled materials, with approximately 75% of aluminium still in circulation2 (secondary). Recycling rates for aluminium in the automotive and building industrial markets exceed 90%. Through recycling aluminium, 95% of the energy needed to manufacture new material is saved.
Heads within the industry are now turning towards renewable sources to produce aluminium, with hydrogen included.
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