Novelis tests industrial scale use of hydrogen in a recycling furnace

The tests were carried out as part of a UK government decarbonisation programme in collaboration with Progressive Energy, an independent UK energy company, and required the installation of new burners, regenerators, and furnace lining material. Using hydrogen instead of the same amount of natural gas when operating a melting furnace can reduce CO₂ emissions by up to 90%.

“Exploring renewable energy sources, such as hydrogen, making first mover investments, and reducing energy intensity are part of our 3 x 30 vision to advance aluminium as the material of choice with circular solutions”, said Emilio Braghi, Executive Vice President, Novelis Inc., and President, Novelis Europe. “With the significant expansion of our local recycling capacity, we are transforming the Latchford site into a prototype for high-recycled content and decarbonised aluminium production.”

With safety as the top priority of the hydrogen pilot project, several series of tests were conducted by blending different percentages of hydrogen with natural gas (30 - 100%) to evaluate the impact on existing infrastructure and equipment compatibility.

During the trial campaign, several hundred tons of 3000 series scrap aluminium alloy were remelted and cast into sheet ingots. In addition, all relevant parameters were measured to assess any impact on the product, process, operating environment, and environmental emissions.

Further downstream processing, including rolling and finishing, will be completed at other Novelis plants in Europe to establish the real ‘end-to-end’ parameters of a hydrogen-based, recycled alloy production process. Following the full post-trial evaluation and assessments, a report will be released as part of the UK government's Industrial Fuel Switching programme later in 2025.

“The use of hydrogen is not common in the aluminium industry 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,” added Allan Sweeney, Plant Manager, Novelis Latchford. “The results from Latchford will drive further research into the potential deployment of hydrogen in our recycling operations worldwide.”

The demonstration project at Latchford is part of the UK government's Industrial Fuel Switching Competition programme. Supported with a grant of £4.6 million, as part of the £1 billion Net Zero Innovation Portfolio and the wider regional HyNet project. The programme is designed to support the industry to decarbonise operations through a switch from natural gas to low carbon hydrogen. As the UK’s leading industrial decarbonisation cluster, HyNet will decarbonise the industry across the North West and North Wales through the production, transportation, and storage of low carbon hydrogen, as well as through capturing industry’s CO₂ emissions through Carbon Capture Solutions. Novelis has been a partner in the HyNet project since 2017 and supports the development of the regional infrastructure project.

Novelis has also conducted its own technical feasibility studies into the use of hydrogen as a direct replacement for natural gas. More broadly, Novelis research and development teams worldwide continue to investigate the possibility of using plasma and electricity to supply energy to its production plants.

As announced in July 2024, Novelis is investing approximately £90 million to double the recycling capacity for used beverage cans (UBCs) at its plant in Latchford. The project will increase the facility’s UBC recycling capacity by 85 000 tpy and decrease Novelis Europe’s CO₂ emissions by more than 350 000 tpy. The project is expected to begin commissioning in December 2026.

Furthermore, as part of its new Novelis 3 x 30 vision, the company has set new ambitious sustainability targets to achieve by the end of 2030, including increasing recycled content from 63% to 75%, reducing carbon emissions to less than 3 t CO₂ emissions per ton aluminium shipped, and continue to lead the industry to circularity through first-mover investments. These are in addition to the company’s goal to be carbon neutral by 2050 or sooner. Along with using higher amounts of recycled content, decarbonisation of the company’s melting processes and energy sources are important levers to delivering lower carbon, highly sustainable aluminium solutions.

Read the article online at: https://www.hydrocarbonengineering.com/the-environment/21022025/novelis-tests-industrial-scale-use-of-hydrogen-in-a-recycling-furnace/