The future of manufacturing takes shape as hydrogen powered aluminum recycling reduces emissions by 90%.
A major breakthrough in hydrogen powered aluminum recycling could help reduce the carbon footprint of everyday items like soda cans and car parts. Novelis, the world’s largest aluminum recycling company, has successfully tested hydrogen fuel to power its recycling furnace in the UK.
The company’s plant in Latchford, Warrington, replaced natural gas with hydrogen in its melting furnace. This switch could cut greenhouse gas emissions by up to 90% compared to using natural gas. Industry experts estimate that aluminum production accounts for about 2% of global carbon emissions.
The test wasn’t just a small experiment. Workers melted several hundred tons of aluminum scrap during the trial, turning it into sheet metal that will be used to make new products. The success of the hydrogen powered aluminum recycling test marks a significant step toward cleaner manufacturing processes.
Global Context and Competition
Similar hydrogen initiatives are underway in several countries as aluminum manufacturers race to reduce their carbon footprint. Germany’s Trimet Aluminum is testing hydrogen powered aluminum recycling in its smelting operations at their Essen plant, where they’ve invested over €100 million in hydrogen-compatible furnaces and infrastructure. The company aims to convert 30% of its smelting operations to hydrogen by 2026.
Meanwhile, Norway’s Hydro is developing hydrogen powered aluminum recycling solutions for its aluminum plants, leveraging the country’s abundant hydroelectric power to produce green hydrogen for their operations. Their pilot program at the Karmøy facility has already demonstrated a 15% reduction in energy consumption compared to traditional methods.
China, the world’s largest aluminum producer, responsible for about 60% of global production, has announced plans to explore hydrogen powered aluminum recycling technology in its manufacturing sector. The Chinese government’s latest five-year plan includes specific targets for hydrogen adoption in aluminum production, with pilot projects planned in Shandong and Yunnan provinces.
These initiatives are particularly significant given that China’s aluminum industry currently accounts for approximately 4% of the country’s total carbon emissions. Industry experts estimate that if all these international hydrogen projects prove successful, global aluminum production could reduce its carbon emissions by up to 40% by 2035.
Economic Implications
The shift to hydrogen powered aluminum recycling comes with significant cost considerations. Current hydrogen prices range from $5-8 per kilogram, compared to natural gas prices of $3-4 per million BTU. However, experts predict hydrogen costs will decrease as production scales up and infrastructure improves.
Safety came first in the testing process. The team started by mixing different amounts of hydrogen with natural gas, beginning at 30% hydrogen and gradually increasing to 100%. This careful approach helped them check if their equipment could handle the change.
The UK government supported this project with a £4.6 million grant ($5.8 million). It’s part of a larger £1 billion program to help British industries cut their carbon emissions.
What This Means for Consumers
When companies reduce their carbon footprint, the products we buy become more environmentally friendly. Aluminum is everywhere in our daily lives – from beverage cans to car bodies and building materials.
Novelis already uses a lot of recycled material in its products. Currently, 63% of their aluminum comes from recycled sources. They plan to increase this to 75% by 2030.
The company is also expanding its recycling operation in Latchford. A $90 million investment will double the plant’s capacity to recycle used beverage cans by December 2026. This expansion alone will reduce carbon emissions by 350,000 tons each year – equivalent to taking 76,000 cars off the road.
The Bigger Picture
Hydrogen powered aluminum recycling isn’t common in the industry yet. Novelis is one of the first companies to test it at an industrial scale. The results from this trial could influence how aluminum is recycled worldwide.
The Latchford plant plays a crucial role in European recycling. It can process up to 195,000 tons of aluminum annually – enough capacity to recycle every beverage can sold in the UK.
Beyond hydrogen, Novelis is exploring other ways to make aluminum production cleaner. Their research teams are studying how plasma and electricity could replace natural gas in their factories.
See also: How Is Green Hydrogen Made?
The Road Ahead
Novelis has laid out an ambitious roadmap to eliminate its carbon emissions completely by 2050 or sooner, with significant milestones planned for 2030. Currently, the company’s aluminum products contain 63% recycled content, but they aim to increase this to 75% within the next six years. This 12% increase would reduce their need for raw aluminum production, which is typically more energy-intensive and environmentally damaging.
The company has also committed to cutting its carbon emissions to less than 3 tons of CO2 per ton of aluminum produced – a significant reduction from current industry standards that typically generate 5-6 tons of CO2 per ton of aluminum. Beyond these specific targets, Novelis is positioning itself to lead the aluminum industry toward a circular economy model, where materials are continuously reused rather than discarded.
This new approach aligns with their existing closed-loop recycling systems, like their partnership with Jaguar Land Rover, where automotive aluminum scrap is recycled directly back into new car parts. The company’s recent hydrogen powered aluminum recycling furnace trial at Latchford demonstrates its commitment to these goals, as the technology could potentially reduce CO2 emissions by up to 90% compared to traditional natural gas furnaces.
This initiative is part of HyNet, a larger project to help industries in Northwest England and North Wales switch to hydrogen power. The project includes building infrastructure to produce and transport hydrogen and capture carbon dioxide emissions.
Industry analysts predict that successful implementation of hydrogen powered aluminum recycling could spark similar transitions across other manufacturing sectors, potentially reshaping industrial energy use in the coming decades.
