aluminum foil

News release: Hydro Produces First-Ever Recycled Aluminum From Green Hydrogen

Hydro has produced the world’s first successful batch of aluminum using green hydrogen as an energy source. The test is another step towards carbon-free aluminum.

Carbon-free green hydrogen replaced natural gas as fuel for the recycling of aluminum during the test. The test was carried out at a casthouse in Hydro’s extrusion plant in Navarra, Spain.

“We are excited to be conducting this test and it demonstrates Hydro’s commitment to decarbonization. By removing the carbon emissions from the energy source, we will be able to produce carbon-free aluminum from recycling post-consumer scrap,” says Paul Warton, Executive Vice President for Hydro Extrusions.

The test was conducted and led by hydrogen experts from Hydro Havrand, Hydro’s green hydrogen company, in partnership with Fives, an industrial engineering group with expertise in hydrogen burner technology and solutions for the aluminum industry. Fives has contributed with design, and supplying of key components and controls needed to operate safely and effectively. 

“This test is part of developing commercial fuel switch solutions and to demonstrate that hydrogen can be used in aluminum production. Green hydrogen can remove hard to abate emissions from fossil fuels, in processes where electricity is not an alternative, both in the aluminum industry and in other heavy industries,” says Per Christian Eriksen, Head of Hydro Havrand.

Green hydrogen is one of the most promising emission free fuels to address the hard to abate industry emissions. In the aluminum industry, green hydrogen can replace fossil fuel used for high temperature heating processes. Hydrogen has previously been used in lab scale tests. The test in Navarra is the world’s first known successful industrial scale test of using hydrogen as an energy source in aluminum production. The aluminum produced in the test will be used in Hydro Extrusions’ Navarra facility to make the world’s first extruded profiles using hydrogen.

The test is providing new insights on fuel switch from natural gas to hydrogen and its effects on metal quality. Hydrogen behaves differently and burns at a different temperature than natural gas. The test is investigating how these differences affect the aluminum melting process and the aluminum quality. This is a necessary step on the path to maturing the fuel switch solutions of hydrogen in aluminum. The results from this test can also be relevant for using hydrogen in primary aluminum casthouses and in other high temperature processes, like glass or cement.

Hydro and Fives are analyzing the test results, and a final report from the test is expected to be ready in the fall. Hydro Havrand will continue with building capabilities in the fuel switch to hydrogen, aiming to be the leading provider of industrial fuel switch solutions in green hydrogen.

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