Novelis Advances Sustainable Aluminium Production with Hydrogen Fuel in Recycling Furnaces

Novelis Tests Hydrogen Fuel in Aluminium Recycling

Novelis Inc., a frontrunner in sustainable aluminum solutions and a key player in aluminum recycling, has made a significant stride towards carbon-neutral production. The company announced the successful testing of hydrogen as a fuel source in its recycling furnace, located at its UK plant in Latchford, Warrington. This initiative takes part in the UK government's decarbonization efforts and demonstrates Novelis's commitment to reducing its carbon footprint in the aluminum industry.

The tests were carried out in partnership with Progressive Energy, an independent UK energy firm. To adapt the recycling furnace for hydrogen use, Novelis installed new burners, regenerators, and furnace lining materials. The shift from natural gas to hydrogen fuel could potentially decrease CO2e emissions by as much as 90%. This transition aligns with Novelis's 3x30 vision, which aims to position aluminum as a leader in sustainable materials and circular economies.

Emilio Braghi, Executive Vice President and President of Novelis Europe, stated, “Exploring renewable energy, like hydrogen, is crucial for achieving a sustainable aluminum production process. Our Latchford site is transforming into a prototype for decarbonized aluminum manufacturing with high recycled content.”

Safety was a top priority during the hydrogen pilot project, leading to multiple test phases that blended varying percentages of hydrogen (30%-100%) with natural gas. These tests evaluated the compatibility of existing infrastructure and equipment. Throughout the trial, hundreds of tonnes of 3000 series scrap aluminum alloy were melted and cast into sheet ingots. Comprehensive measurements were taken to analyze potential impacts on product quality, process efficiency, operating environments, and emissions.

The successful outcomes of this pilot project are set to influence future hydrogen use in Novelis's global recycling operations. Allan Sweeney, Plant Manager for Novelis Latchford, expressed pride in being among the pioneers testing hydrogen at an industrial scale, emphasizing the excitement about the project's results and their implications for future energy alternatives in aluminum recycling.

The demonstration project is part of the UK government’s Industrial Fuel Switching Competition, receiving support through a £4.6 million grant from the Net Zero Innovation Portfolio, which aims to assist industries in switching to low-carbon hydrogen solutions. The region's HyNet project plays a vital role, working to decarbonize industries in the Northwest and North Wales through low-carbon hydrogen production and carbon capture solutions. Novelis has been engaged in this project since 2017.

Further investments are underway at the Latchford facility, where an estimated $90 million will double its recycling capacity for used beverage cans (UBCs), enhancing annual capacity by 85 kilotonnes and significantly cutting CO2e emissions. Novelis aims to complete the commissioning of this project by December 2026.

Moreover, Novelis has set ambitious sustainability goals under its new 3x30 vision, targeting a 75% increase in recycled content by 2030, cutting carbon emissions to below 3 tonnes CO2e per tonne of aluminum shipped, and progressing towards becoming carbon neutral by 2050 or earlier. By enhancing the use of recycled materials and reducing carbon emissions through advanced energy sources, Novelis is pursuing a path towards sustainable aluminum production.

About Novelis

Novelis Inc. aims to reshape the future with sustainable practices. As the world's largest aluminum recycler and a leader in producing innovative aluminum solutions, Novelis strives to achieve a fully circular economy by collaborating with partners in various industries including aerospace, automotive, and beverage cans across multiple continents.

For more information, visit novelis.com.

About Novelis Latchford

The Latchford plant in Warrington is among Europe's largest recycling facilities for aluminum beverage cans and a key player in automotive aluminum recycling, processing up to 195,000 tonnes annually. The facility not only recycles all the aluminum beverage cans sold within the UK but also works closely with Jaguar Land Rover to promote a closed-loop system in Europe. Novelis's operations across Europe benefit from the region's efficient and interconnected supply chains, enhancing its capacity to deliver low-carbon, sustainable aluminum products.

Forward-Looking Statements

This announcement may contain forward-looking statements regarding Novelis's prospects and goals. These statements involve risks and uncertainties and the company does not intend to update them should circumstances change.