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Aluminium International Today (USO No; 022-344) is published bi-monthly by Quartz Business Ltd and distributed in the US by DSW, 75 Aberdeen Road, Emigsville, PA 17318-0437. Periodicals
The aluminium industry, as well as the globe, is going through a period of change. With global uncertainties and disruptions, innovation and adaptations; it is my opinion that the industry has also come to a point where change is necessary.
I glance back to 2021 and remember the buzz around the industry’s prospects. Since then, the world has felt a range of fluctuating emotions, many being negative. And it is those emotions that have, somewhat, dampened the buzz.
But one aspect of our industry keeps me positive.“Aluminium is infinitely recyclable”.
2024 has been a year of challenges. But ‘challenge’ is a word that thrives on context; whether a challenge is positive or negative is up to its surroundings.
Each time I travel to industry events, I challenge myself to visit an area of cultural significance.
At ALUMINIUM, Germany, I found myself roaming ‘Little Japan’ and admiring my bar of chocolate that was wrapped in plastic coated foil. In Ohio, USA, for the FNA show, I found myself counting Tesla’s whilst walking to the Blue Jackets Stadium.
And after ICSOBA, France, I stumbled across a zoo. It housed giraffes, a baby monkey and an abandoned bear cage; I thought about the new projects and investments in the industry, and in their shadow, the effects of deindustrialisation.
I am no expert in the fields of packaging, sustainability, or deindustrialisation, but you will find articles written by experts on these topics in this issue. Taking on the role as Editor is a privilege. I’ve come to realise that change requires radical devotion, meaning reflection upon my day-to-day activities. I look forward to walking this journey with you as we navigate the industry through positive and negative challenges.
zahraawan@quartzltd.com
Alba Announces Partnership with Ma’aden
Aluminium Bahrain B.S.C. (Alba) approved for Alba to enter into a non-binding agreement with Saudi Arabian Mining Company (Ma’aden) to commence due diligence towards a potential business combination involving segments of Ma’aden’s aluminium strategic business unit.
This partnership aims to create a larger, vertically integrated global champion with significant synergies offering advantages such as expanded production capacity; enhanced global presence; improved ESG performance; greater energy security; and significant shareholder value creation.
Alba’s Chairman of the Board, HE Khalid Al Rumaihi, stated: “The potential partnership accelerates Alba’s growth strategy, creating a global champion and cementing our position as the largest regional aluminium producer. This combi-
nation will allow both companies to scale-up production, extend our global presence and explore new opportunities in clean energy. Our partnership will not only deepen the strong ties between Bahrain and Saudi Arabia, but also contribute to Bahrain’s economic diversification and job creation.”
Adding further, Ma’aden Chief Executive Officer, Bob Wilt, said: “Harnessing the combined scale and expertise of both businesses
MQP Partners with BCAST
MQP has extended its contract with the UK’s top metals research centre Brunel Centre for Advanced Solidification Technology (BCAST), to support the drive to make casthouses more efficient.
MQP and BCAST at Brunel University London have been working together for four years to unlock the technology to increase grain refiner
efficiency and consistently improve melt quality, resulting in the development of the super-efficient Optifine 5:1 125.
The partnership will now continue for another year, with BCAST technicians focusing on testing customers’ own grain refiners against Optifine to see if they can improve melt quality and bring down waste and carbon
to forge a new global champion will not only advance Ma’aden’s ambitions for aluminum but also significantly boost the economic ties between Bahrain and Saudi Arabia. By bringing together two of the region’s most experienced players in the sector, we are setting the stage for stronger economic growth, enhanced job creation, and increased aluminum production capacity.”
emissions, as well as reduce plants’ overall manufacturing costs.
MQP chairman said it was fantastic to continue working with BCAST, moving from a solely research-led project using state-of-the-art High Resolution Transmission Electron Microscopy (HRTEM) to collaborating with a focus on customer service.
Aluminium Duffel: New Milling Installation
Aluminium Duffel announce the launch of its new logo and the commissioning of their new milling installation.
The new milling installation is an investment worth €26 million.
The milling installation has a capacity of no less than 400,000 tonnes of aluminium per year.
A installation provides the top and bottom of an aluminium rolling block with a cleaner surface by removing or milling a layer. This is necessary to continue the rolling process. Until now, an amount of the slabs were milled in the former sister company in Koblenz.
“Our widest slabs, which are essential for our customers in the automotive sector, are now milled in-house, which gives us more independence. Thanks to the high-
tech properties of the installation, we can make the milling process more sustainable, an important step towards our environmental goals. In short, in this way we continue to invest in a sustainable future for our company, for our people and for our environment,” says Koen Libbrecht, General Manager at Aluminium Duffel.
Aluminium Duffel started the construction of a new 2500m²
production hall in December 2022. Subsequently, the construction of the milling installation was started, which took about a year.
The first slab was milled on the installation on the 25th of September.
The new logo, which is shaped into a heraldic shield, aims to reflect the company’s core values: Change & Courage, People & Power, and Excellence & Teamwork.
Novelis and TSR: Strategic Partnership to Advance Circularity
Novelis has entered into a strategic 3-year agreement with TSR Recycling GmbH & Co. KG. The contract strengthens the partnership between Novelis and TSR, ensuring a reliable supply of raw materials made from presorted and processed end-of-life aluminium products of approximately 75,000 tonnes to be fed into Novelis’ production of low-carbon aluminium sheet for the automotive sector.
“We are very proud to publicly demonstrate our strong partnership with TSR, and to sustainably drive the circularity of our industry through this long-term commitment,” said Emilio Braghi, Exec-
utive Vice President, Novelis Inc., and President, Novelis Europe.
“This is an important alliance to secure the supply of high-quality processed raw materials to meet our customers’ sustainability targets, as well as advancing on our own 2030 journey toward 75% recycled content across our products.”
“At TSR, we are excited to deepen our collaboration with Novelis based on our joint purpose to maximise circularity and decrease carbon emissions, conserve natural resources and reduce energy of the material industries,” commented Denis Reuter, COO TSR
Hydro Opens New Recycling Plant in Hungary
Hydro have stated that the new aluminium recycling plant in Szekesfehervar, Hungary, will have an annual capacity of 90,000 tonnes, mainly serving the automotive market.
The recycling plant will initially process 15,000 tonnes of post-consumer scrap annually, increasing over the years to come in line with the growing customer demand for recycled, post-con-
The Women With Metal Awards
The ‘Women With Metal - the ALUMINIUM Awards’ were presented for the first time at ALUMINIUM 2024 on 9 October. In collaboration with Women With Metal, the UK Aluminium Federation (ALFED) and Aluminium International Today, the show organiser, RX Germany, launched the awards to recognise the achievements of women in the industry and promote equality and diversity. It also recognised the efforts of male colleagues.
Women remain underrepresented in many industries, including the metals sector, which
Group. “Ensuring that valuable resources are reused and repurposed benefits both our businesses and the planet. By working together, we can lead the transition toward a circular economy for the automotive sector and beyond...”
sumer aluminium.
“Our most ambitious customers in key industries like the automotive industry are pushing demand for low-carbon and recycled aluminium upwards... This plant will strengthen Hydro’s capacity to provide our customers with advanced components in recycled aluminium,” says President and CEO Eivind Kallevik.
“Our customers are not only asking for recycled and low-carbon aluminium. They also need us to recycle their process scrap, so we can create closed loops. With our new and modern recycling facility in Hungary, we are now able to offer that,” says Paul Warton, Executive Vice President of Hydro Extrusions.
- Unsung Shero: Gerd Aalborg Aas (Norsk Hydro).
encompasses the aluminium industry. The awards recognised exceptional individuals across five categories:
- Role Model: Negisti Gebreegziabher Gared (N A Y S Aluminium Engineering PLC).
- Young Leader: Pia Reuß (Speira).
- Sustainable & Innovative Leader: Ramona Tosone (AMAG Austria Metall AG)
- Male Ally: Carlos André Valim (Alcoa)
Starts
The R$1.3 billion investment to replace fuel oil with natural gas and will reduce the refinery’s carbon emissions by 30 percent. When fully completed, six steam generation boilers and all the refinery’s calciners will operate on natural gas.
Novelis Announces Sierre Plant’s Recovery and Restart of Main Assets
Novelis announce the recovery and restart of its Sierre plant, Switzerland, which was severely impacted by a devastating flood at the end of June. Following the flood, the plant faced significant challenges that impacted the company’s ability to serve its customers from the Sierre plant. “I am incredibly proud of the speed and flexibility our company has shown, and the resilience and determination of our workforce to overcome adversity and get our assets back up and running in record time.” said Emilio Braghi, Executive Vice President, Novelis and President, Novelis Europe.
Poll: Britons Want Labour to Push Ahead with DRS
In a poll commissioned by Alupro, 73 percent of Britons called for the new Labour government to press ahead with a deposit return scheme for all drinks containers including aluminium cans, glass bottles, and plastic bottles. The poll of 2,000 UK adults was conducted by Yonder between 30th August to 1st September 2024. Tom Giddings, Alupro Executive Director, said: “The Great British public could not be clearer. They want Labour to get on and deliver for the environment.”
Alunorte
Alumina Production Using Natural Gas
Global Aluminium Leaders Unite on Decarbonisation Ambitions
Aluminium industry leaders convened at Climate Week NYC to discuss accelerating the decarbonisation of the aluminium value chain through visible innovation, integrated procurement strategies, and cross-sector collaboration, while addressing regional disparities in recycling, energy access, and regulatory frameworks.
In a panel hosted by the Interna-
tional Aluminium Institute (IAI), the executives called on each other to demonstrate the leadership needed to push ambition and demonstrate an economically viable transformation pathway for the sector.
The panel explored how collaboration between aluminium producers, manufacturers, consumer brands, and policymakers can
help overcome these challenges and drive sustainable demand for low-carbon materials.
“The aluminium industry has made strong progress, but to meet the growing demand for low-carbon materials, we must work together across the value chain and with our peers, not just our supply chains” said Marlen Bertram, Director of Scenarios & Forecasts at the IAI.
Henan Yirui Issues New Aluminum Hot Rolling Mill from SMS Group
Henan Yirui New Materials Technology Co., Ltd., China, officially took over the new aluminum hot rolling mill from SMS group and put it into production. This final project milestone was sealed by issuing the FAC to SMS, after the new aluminum hot rolling mill was installed and commissioned, and started two months earlier than originally planned.
The new hot strip mill is the centerpiece of a strategic expansion project that Henan Yirui, a subsidiary of the Henan Mingtai group, implemented at its site near the city of Gongyi, Henan Province, China.
The new mill is a solution developed by SMS for refurbishing and integrating components from an existing hot rolling mill, consisting of a reversing roughing mill and a single-stand reversing finishing
mill, in a 1+4 tandem configuration. In addition to the reversing roughing mill, Henan Yirui now has a four-stand finishing mill at its disposal.
The new hot strip mill can produce trimmed strip up to 2,150 millimeters wide.
“Installation and commissioning times were significantly shortened thanks to the superior technology
and the outstanding efforts, dedication and commitment of Henan Yirui and SMS group. The seamless integration of the secondhand equipment into the process automation of a highly advanced four-stand tandem mill was a challenge. SMS group’s solution to incorporate the roughing mill smoothly into the X-Pact® Pass Schedule Calculation (PSC®) system supplied for the new finishing tandem mill was impressive.” Liu Jie, General Manager of Henan Mingtai Aluminium.
“Throughout the project it has always been a real pleasure to work with such highly motivated and dedicated project teams from both parties. The flat decision-making hierarchy on the customer side was also very helpful.”
Rüdiger Roger Wiechmann, Project Manager at SMS group.
Alba Renews Alumina Supply Contract with Alcoa
Aluminium Bahrain B.S.C. (Alba) has renewed its long-term agreement with Alcoa Corporation to secure a stable supply of alumina.
Under the terms of the agreement, Alcoa will supply up to 16.5 million tonnes of smelter grade alumina to Alba over a 10-year period, commencing in 2026.
Alba’s CEO, Ali Al Baqali, emphasised the significance of this contract extension, stating: “Our long-standing partnership with Alcoa is a testament to our shared commitment to sustainability and mutual growth. This agreement not only guarantees a steady sup-
NOVEMBER
20th - 21st
The 2nd European Green Aluminium Summit 2024
The 2nd European Green Aluminium Summit 2024 will take aluminium carbon reduction as the theme, unites key stakeholders from aluminium industry, policy regulators, major industry suppliers and technology providers to address hot topics aiming to gather best practices/insights in aluminium industry towards net zero. Held in Frankfurt, Germany www.ecv-events.com/ EuropeanGreenAluminum/ index.php
25th - 26th
Bureau of Middle East Recycling (BMR) 2024
The BMR was formed to represent all the suppliers/traders of the Middle East Recycling Industry and to bring them under one banner and platform with the unified thoughts of promoting the Metal Recycling Business of Middle East, protecting the environment and sharing market information.
Held in Dubai, UAE www.bmr.ae/home.html
28th November
ALFED Business Briefing
The Annual ALFED Business Briefing provides the perfect opportunity to meet with ALFED members and hear from a host of industry representatives, offering new insights on market updates, transformation, innovation, strategy, and sustainability in the current climate.
Held in Windsor, UK www.alfed.org.uk/event
MARCH
5th- 7th
ply of alumina for our operations but also reinforces our position as a key player in the global aluminium market.”
Adding further, Alcoa’s President & CEO, William Oplinger stated: “By securing this contract extension with Alba, Alcoa further strengthens its position as the premier global alumina supplier, while continuing to provide strategic support to one of the world’s largest aluminium producers.”
METEF
METEF represents in Italy the only reference point for the aluminium industrial supply chain. Join us at the International trade fair for the Aluminum Supply Chain.
Held in Bologna, Italy www.metef.com/en/
For a full listing visit www.aluminiumtoday.com/ events
Aluminium Industry in Germany Part Two
By Richard McDonough*
Aluminium is a major component of the industrial sector of the Federal Republic of Germany (Germany). The metal and products produced from it are important parts of this European nation’s economy as well as its trade with countries throughout the world. Pic 1
In each year from 2019 to 2023, Germany was ranked as the second largest country globally in exports of aluminium and articles thereof (hereafter noted as “aluminium and related products”), according to the International Trade Centre (ITC). Unless otherwise stated, statistics detailing imports and exports of aluminium and related products to and from Germany are approximate and are from the most recent reports issued by the ITC.
Only China was ranked higher for exports of these products during the five years from 2019 to 2023. Germany was ranked just ahead of Canada in 2021, and of the USA in 2019, 2020, 2022, and
2023.
Germany was also the second largest importer of aluminium and related products worldwide in each year from 2019 to 2023. Only the USA was ranked higher for imports of these products during those years. Germany was ranked just ahead of Japan in 2019; the country was ranked just ahead of China in each year from 2020 to 2023.
The amount of aluminium and related products exported from Germany was 8.2% of the total exports of these products from all nations in 2023. As for the level of imports, the amount of aluminium and related products imported into Germany represented 9.9% of the total imports of these products globally in 2023.
Businesses active in the aluminium industry in Germany include a number of German-headquartered companies as well as multinational corporations with operations in this European Union country. This news column details some
of the recent activities of several of these businesses, including EGA Leichtmetall, Hydro, Novelis, RONAL GROUP, and TRIMET Aluminium SE.
EGA Leichtmetall
Pic 2
Emirates Global Aluminium (EGA) completed the acquisition of Leichtmetall Aluminium Giesserei Hannover GmbH in the Spring of 2024. The German operation is now known as “EGA Leichtmetall.”
According to a news statement from EGA on 3 May 2024, EGA Leichtmetall “…is a European specialty foundry that uses renewable energy to produce up to 30,000 tonnes per year of billets, with secondary aluminium as some 80% of input material. Production at [EGA] Leichtmetall includes hard alloys and larger diameter billets up to 1,150 millimetres, with uses including manufacturing high load bearing extruded profiles and very large forged components.”
Pic 1. An aerial view of the Hydro Aluminium Gießerei in Rackwitz, Germany. (The photograph was provided courtesy of Hydro.)
EGA, headquartered in the United Arab Emirates, indicated that this acquisition added to its existing business in Europe. The company detailed that it was already exporting approximately 600,000 tonnes of primary aluminium to Europe annually and that it was a significant supplier of aluminium to several industries, including the automotive and construction sectors.
“I am pleased to welcome our new Leichtmetall colleagues in Hannover to EGA,” said Abdulnasser Bin Kalban, Chief Executive Officer of EGA in the news statement. “Becoming part of the biggest ‘premium aluminium’ producer in the world will give Leichtmetall new strength for its customers and to grow.”
He went on to note that the acquisition was “…an important early milestone in our drive to build an aluminium recycling business in Europe, where we are already a major primary aluminium supplier, and around the world.”
The news statement from EGA indicated
that “Market analysts expect global demand for recycled aluminium to double by 2040. Recycled aluminium is expected to account for around 60% of the growth in global aluminium supply between now and 2030, and around 70% of supply growth between 2030 and 2040.” Pic 3
Hydro
Pic 4
Norsk Hydro ASA (Hydro) has major operations in Germany. The company has four manufacturing plants in the Federal Republic in Bellenberg, Offenburg, Rackwitz, and Uphusen. According to the company, these plants produce extruded aluminium products and tubing solutions.
In addition, Hydro indicated that it has “…aluminium building systems activities in a number of locations, including Ulm,” as well as an “aluminium sorting plant in St. Peter, Dormagen [that] has been a part of Hydro since 2015. The plant sorts 36,000 tonnes of post-consumer
aluminium scrap annually before it’s sent to Hydro’s recycling network in Europe.”
Hydro, headquartered in Oslo, Norway, is working with Porsche AG (Porsche), with its headquarters in Stuttgart, Germany, to further utilise aluminium as the motor vehicle manufacturer seeks to continue to decarbonise its supply chain.
“Last year, the partners announced their co-operation with a Letter of Intent (LOI),” noted a news statement from Porsche on 10 July 2024. “They have now specified their delivery targets: for widespread use in its sports car production, Porsche and its suppliers will have access to carbonreduced aluminium with an ecological footprint of less than 4 kg of CO₂ per kg of aluminium. Renewable energy will be used in the production of this raw material.”
The news statement continued by detailing that “The two companies are not only aiming to further reduce these total emissions; they also want to increase
Pic 2. The EGA Leichtmetall plant in Germany. (The photograph was provided courtesy of EGA.)
Pic 3. The EGA Leichtmetall plant is located in Hannover, Germany. (The photograph was provided courtesy of EGA.)
Pic 5. Barbara Frenkel (second from left), Member of the Executive Board for Procurement at Porsche AG, and Eivind Kallevik (fourth from left), President and CEO of Norsk Hydro ASA, stand with project teams of the two companies. (The photograph was provided courtesy of Porsche AG.)
Pic 6. Novelis and TSR Recycling GmbH & Co. KG announced their partnership efforts to Advance Circularity in the Aluminium Industry at the Aluminium World Trade
their use of secondary materials from post-consumer scrap. These are materials disposed of by private households or commercial, industrial and institutional facilities after a product has been used. It is expected that by 2027/2028, Hydro will be supplying carbon-reduced aluminium with a recycled proportion of at least 75%. Porsche and Hydro are also testing the areas of the car in which aluminium with an even higher proportion of recycled material can be used.”
“The collaboration with Hydro is an important milestone for Porsche on our path to decarbonisation along the entire value chain,” stated Barbara Frenkel, Executive Board Member for Procurement at Porsche. “The partnership is also making a contribution to responsible procurement because Hydro’s aluminium supply chain is transparent.”
“Our collaboration with pioneers like Porsche supports Hydro’s ambition to change the game for sustainability in the
aluminium industry,” said Eivind Kallevik, President and CEO of Hydro. “Together, in this long-term strategic partnership, Hydro and Porsche will push forward innovative solutions and business models, aiming to drive decarbonisation and circularity in the automotive industry.”
According to the news statement, “As a lightweight material, aluminium is playing an increasingly important role for electric cars in particular. For example, it makes up around 30% of the total weight of the [Porsche] Taycan. Apart from the front and rear aprons, the entire shell of the electric sports car is made of aluminium.”
Pic 5
Novelis
Pic 6
“The aluminium industry in Germany is undergoing a transformative shift, driven by a growing demand for sustainable and low-carbon solutions,” said Nicole von der Ropp, Novelis Communications Europe. “At the forefront of this evolution is Novelis, a leader in aluminium rolling and recycling, committed to setting new benchmarks in environmental responsibility and innovation.”
She stated that “Novelis Europe is one of four operating regions of Novelis, the world’s largest recycler of aluminium and leading in the production of flatrolled aluminium products. Sustainability is at the core of Novelis’ operations. In Germany and beyond, Novelis supports various industries in expanding recycled content of the aluminium in use, thus significantly reducing the product’s carbon footprint and jointly boosting circularity.”
According to Emilio Braghi, Executive Vice President of Novelis and President, Novelis Europe, “The company has set ambitious targets to decrease its greenhouse gas emissions by 30% by 2026
and aims to achieve carbon neutrality by 2050. A cornerstone strategy to reach these goals is through the increased use of recycled aluminium, which saves up to 95% of the energy required to produce primary aluminium.”
Novelis operates the largest European recycling plant in Nachterstedt, SaxonyAnhalt in Germany, noted Ms. von der Ropp, “…utilizing up to 400,000 tonnes of aluminium scrap, which is crushed, sorted, thermally cleaned, melted, and returned to the production cycle.”
There is a strong commitment to sustainable aluminium solutions.
“In the automotive sector, for instance, Novelis supplies lightweight, highstrength alloys used to make full structural frames, as well as hoods, doors, fenders, and many other components,” stated Ms. von der Ropp. “Novelis is the world’s largest supplier of aluminium sheet to the automotive industry as well as the global leader in automotive closed-loop recycling, a process that allows the company and its customers to reuse production scrap
Pic 4. The scrap yard at Hydro’s St. Peter recycling plant in Dormagen, Germany. (The photograph was produced by Marius Motrøen and provided courtesy of Hydro, 24 March 2022.)
Show and Conference 2024.
(The photograph was provided courtesy of Novelis, 9 October 2024.)
Pic 7. A building at the Technical University of Applied Sciences Wildau in Wildau, Germany, is clad in perforated Novelis ff2® pre-painted aluminium panels. (The photograph was provided courtesy of Novelis.)
Pic 8. Novelis is active in volunteer activities in Germany. (The photograph was provided courtesy of Novelis.)
and recycle the aluminium into similar products.”
One of the sustainability efforts she cited is the Car2Car project led by the BMW Group and funded by the German Federal Ministry of Economic Affairs and Climate Action.
A news statement from the BMW Group, headquartered in Munich, Germany, in the Spring of 2023, explained that “…the Car2Car project focuses on the materials aluminium, steel, glass, copper and plastic. In [the] future, innovative dismantling and automated sorting methods should allow far greater quantities of the resources recovered from end-of-life vehicles to be made suitable for use in the production of new cars than has so far been the case. This project also includes an end-to-end evaluation of both the ecological and economic impacts of closed-loop recycling of the materials being investigated.”
Novelis is one of the businesses supporting the Car2Car project.
“The Car2Car project is another important step towards economically and ecologically sensible circularity in the automotive industry,” said Michael Hahne, Vice President, Automotive, Novelis Europe. “The intelligent, efficient reuse of post-consumer material preserves resources, significantly lowers environmental impact, and, at the same time, reduces dependency on raw material imports.”
Another sustainability project cited by Ms. von der Ropp is the Automotive Circularity Platform. These efforts are being done in partnership with thyssenkrupp Materials. The focus of this project, according to a statement from Novelis in the Summer of 2023, is “… to digitalise the market for secondary materials recovered from automobiles at the end of the consumer-use cycle and
increase its transparency by creating an ecosystem for the automotive end-of-life value chain.”
On 9 October 2024, Novelis announced that the company and TSR Recycling GmbH & Co. KG (TSR) have entered into a three-year agreement in which approximately 75,000 tonnes of presorted end-of-life material will be recycled at Novelis Nachterstedt and then fed into low-carbon aluminium sheet for the automotive industry. TSR, a company of the REMONDIS Group, is headquartered in Lünen, Germany.
“We are very proud to publicly demonstrate our strong partnership with TSR, and to sustainably drive the circularity of our industry through this long-term commitment,” said Mr. Braghi of Novelis. “This is an important alliance to secure
the supply of high-quality processed raw materials to meet our customers’ sustainability targets, as well as advancing on our own 2030 journey toward 75% recycled content across our products.”
“At TSR, we are excited to deepen our collaboration with Novelis based on our joint purpose to maximise circularity and decrease carbon emissions, conserve natural resources and reduce energy of the material industries,” stated Denis Reuter, Chief Operating Officer of TSR. “Ensuring that valuable resources are reused and repurposed benefits both our businesses and the planet.”
“By working together, we can lead the transition toward a circular economy for the automotive sector and beyond,” he continued. “We are proud that, thanks to our innovative Europe-wide processing lines, we can contribute to this effort.”
Sustainability efforts are also being taken by Novelis to further utilise recycled aluminium in the production of beverage can sheet.
“As part of the European Aluminium Packaging Group, Novelis is working with other European can sheet manufacturers to develop a new sustainability standard for the beverage can sheet market, with the ultimate goal of ensuring that aluminium beverage cans are made from up to 100% recycled material,” said Ms. von der Ropp. “Novelis is engaged in developing a beverage can using a single alloy. Today, the can body and ends are made from different alloys. However, by using a single alloy the overall recycled content could be increased to almost 99%.”
“We are keen to push the development of a standardised can end solution with an ultra-high recycled content, and significantly lower carbon emissions thus paving the way to a new industry-
Pic 9. The final wheels are being packed, palletised as specified by the customer, and made ready for dispatch at the RONAL GROUP plant in Landau, Germany. (The photograph was provided courtesy of RONAL GROUP.)
Pic 10. Flowforming technology at the RONAL GROUP plant in Landau, Germany.
(The photograph was provided courtesy of RONAL GROUP.)
Pic 11. Hump measurement being done at the RONAL GROUP plant in Landau, Germany. (The photograph was provided courtesy of RONAL GROUP.)
wide level of sustainability for aluminium beverage packaging,” stated Alexander Kuzan, Vice President, Beverage and Food Packaging, Novelis Europe.
In addition to producing aluminium for use in the automotive and beverage industries, Novelis also produces a variety of aluminium products for use in the building and construction sectors of the economy. These aluminium products include anodised and pre-painted aluminium.
The company is also active in producing rolled aluminium plates and sheets for the aircraft and space industry.
“Driving innovation in the aviation industry is a very lengthy process that involves many parties, stated Andreas Delis, Director, Sales and Marketing, Aerospace and Industrial Plate, Novelis Europe. “We are therefore proud to have developed this special fuselage demonstrator together with our long-standing partner Airbus, which not only has a positive impact on the manufacturing process, but also meets our and our customers’ sustainability requirements.”
Ms. von der Ropp detailed that Novelis is active in community programmes in locales where the firm has operations.
“The company actively supports initiatives that promote STEM and recycling education, environmental conservation, and social programmes,” she explained. “Through these efforts, Novelis aims to create a positive impact that extends beyond its immediate business operations.” Pic 7. Pic 8
RONAL GROUP
Pic 9
“RONAL GROUP is one of the world’s leading manufacturers and suppliers of light alloy wheels for passenger cars and commercial vehicles,” said Mirco
Herrmann, Executive Vice President of Group Sales Officer at RONAL GROUP. “Our wheels combine top-level design and technology – as well as enormous passion.”
The company is based in Härkingen, Switzerland, and has facilities in several locales in Germany.
“Every year, about 19,8 million wheels can be manufactured at 13 production sites across three continents,” Mr. Herrmann stated. “Our high standard of quality is a common theme in all areas, from technical development to production, based on the most innovative technologies, up to meticulous tests – top quality is a continuous process.”
“We produce aluminium wheels for OEM and under our own brand RONAL also for the aftermarket business,” he continued. “Our brand SPEEDLINE TRUCK produces forged light alloy wheels for trucks, buses, and trailers. We also manufacture aluminium wheels for specific motorsport sectors.”
According to Mr. Herrmann, “The direct customers are OEM and dealers. The end customer can buy our aftermarket products via the dealers.”
“Our OEM customers can be found worldwide,” he continued. “We have production sites in Europe, Mexico, and Taiwan. Our aftermarket business has been focused on Europe, but recently we have started with business activities in the USMCA [United States – Mexico – Canada] region as well. In general, dealers from all over the world can get in touch with us if they are interested to sell our RONAL aftermarket products.”
He stated that sustainability is critical in the operations for RONAL GROUP.
“For us as a manufacturer of light alloy wheels, aluminium is one of our most important resources,” said Mr. Herrmann.
“The production of primary aluminium is an energy-intensive process that has an impact on the environment: At around 72%, aluminium accounts for the most relevant share of our carbon footprint.”
“To do our part for the environment, we already source 100% of our aluminium from members of the Aluminium Steward Initiative (ASI),” he continued.
“In addition, 65% of our purchased aluminium is produced with certified renewable energy.”
Mr. Herrmann explained that “…RONAL GROUP has been a member of ASI as a Downstream Supporter since 2018, as an Industrial User since September 2020, and ASI Performance Standard certified since September 2022. ASI, the global nonprofit standards setting and certification organisation, brings together ethical, ecological and social aspects along the entire value chain.” Pic 10. Pic 11
Pic 12. The TRIMET production site in Essen, Germany. (The photograph was provided courtesy of TRIMET Aluminium SE.)
Pic 14. A pouring table at the TRIMET production site in Essen, Germany.
(The photograph was provided courtesy of TRIMET Aluminium SE.)
Pic 13. Philipp Schlüter, Chairman of the Board of Management at TRIMET Aluminium SE.
(The photograph was provided courtesy of TRIMET Aluminium SE.)
TRIMET Aluminium SE
Pic 12
“Aluminium is the metal of the future and provides the foundation for green transformation,” stated Philipp Schlüter, Chairman of the Board of Management at TRIMET Aluminium SE (TRIMET). “This makes it even more important to produce this material in such a way that vehicles, energy systems, packaging, and the other products in which it is used benefit from its ecological quality.”
“With the development of an emissionsfree cell technology, we are aligning our aluminium smelters and the flexibility of the production process towards the goal of climate-neutral aluminium production,” he added.
TRIMET is a family-owned business headquartered in Essen, Germany. According to a company spokesperson, the company “…specialises in the production, recycling, and distribution of aluminium and aluminium products, serving diverse industries such as automotive, aerospace, packaging, construction, and renewable energy. TRIMET is one of the largest aluminium producers in Europe with
approximately 2,400 employees and an annual production capacity of 540,000 tonnes of primary aluminium.”
“TRIMET operates five production sites in Germany and two production sites in France,” the company spokesperson continued. “The product range includes molten aluminium, wire rod, rolling and remelting ingots, extrusion billets, and sows. With its own research and development laboratories in Essen, the company is dedicated to developing new aluminium alloys and optimizing production processes to enhance material performance and sustainability.”
A key facet of operations at TRIMET is sustainability.
“The company emphasises energy efficiency and reducing CO2 emissions across all its operations,” noted the company spokesperson. “Recycling processes are designed to maximise the reuse of aluminium, significantly lowering the energy required compared to primary production. TRIMET annually processes over 270,000 tonnes of recycled aluminium in addition to primary production, contributing to a circular economy.”
“Together with partners from research and material development, TRIMET has developed an innovative process that does not release carbon dioxide during aluminium electrolysis, thus reducing direct CO2 emissions in metal production to almost zero,” the company spokesperson continued. “Following the successful completion of the pilot phase, TRIMET will test the technology under production conditions at its Essen site. This process uses so-called inert anodes and cathodes, which are made from a material that releases oxygen instead of carbon dioxide during the electrolysis process.”
Beyond these efforts, “The family business has also developed an innovative technology to align its aluminium smelters’ energy consumption with the fluctuating supply of renewable energy,” according to the company spokesperson. “This flexibility helps integrate green energy into the grid more effectively. The company’s goal is to achieve climate-neutral aluminium production by 2045.” �
Pic 13. Pic 14.
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A Resilient Performance
The European aluminium foil market: 2019-2024
The European aluminium foil market has faced a series of complex challenges over the past five years, including global trade tensions, the COVID-19 pandemic, and the energy crisis exacerbated by geopolitical conflicts. Despite these disruptions, the industry has shown remarkable resilience, adapting to evolving demand patterns and supply chain disruptions.
Key market developments in Europe between 2019 and 2024 are examined, focusing on the trends and shifts that have shaped the European aluminium foil industry. From the initial effects of global trade disputes in 2019, through the pandemic-induced changes of 2020 and record domestic growth in 2021, to the rising energy costs and geopolitical instability of 2022 and 2023, the analysis details how the sector has navigated these challenges.
Insights into the first half of 2024 show early signs of market recovery, suggesting potential for renewed stability. A comprehensive analysis of market performance is provided, covering shifts in domestic and export demand, the evolving role of thinner and thicker foils, and the industry’s response to economic and geopolitical pressures. Additionally, the future outlook for the sector is explored, particularly in light of emerging opportunities in sustainable packaging and the electric vehicle market.
2019: A moderate performance amid global trade tensions
2019 marked the beginning of a turbulent period for the European aluminium foil sector. Despite challenges, the overall market decline was moderate. Total deliveries reached 933,000 tonnes, a slight 1% decrease from the record highs of 2018. The trade dispute between China and the USA and stagnating domestic
demand led to a 3.1% drop in European deliveries, amounting to 781,300 tonnes. However, exports grew by 11.4% to 151,700 tonnes, though this momentum did not last into the final quarter, where demand fell by 16.7%.
Thin foil, used for flexible packaging and household applications, saw a decline of 2.6%, while thicker foil, typically employed in semi-rigid containers and technical applications, performed better, growing by 2%. Despite the emerging COVID-19 pandemic and ongoing trade tensions, the year ended with a relatively minor drop in demand.
2020: Solid performance in a difficult year
The COVID-19 pandemic brought unprecedented challenges in 2020, but the aluminium foil industry showed remarkable resilience. Total production reached 930,700 tonnes, a slight 0.2% decline from 2019, with European deliveries down 0.5% and exports up 0.8%.
The pandemic altered consumer behaviour, leading to increased demand for household and flexible packaging foils, which grew by 2.1%. Increased consumption of packaged food and food delivery contributed to this rise,
*Director Statistics & Market Analysis
By Anja Holthoff-Schlegel*
as more people had meal occasions at home. Products such as aluminium coffee capsules, household foil for leftovers, and semi-rigid containers for takeaway packaging experienced heightened demand.
This period also saw stockpiling at all levels of the value chain—from households to packaging converters—driven by both high demand and high aluminium prices during the second half of 2021 and early 2022. These price increases prompted companies to build up inventories ahead of further cost rises. Despite these factors, thicker foils used in industrial applications declined by 4.3%, reflecting the struggles of the automotive and construction sectors. A slight market recovery in Q4, with deliveries up 2.9%, underlined the sector’s resilience.
2021: Record growth driven by European demand 2021 marked a significant recovery for the European aluminium foil market. Deliveries surged to a record 967,000 tonnes, a 3.9% increase compared to 2020. Domestic demand played a crucial role in this recovery, surging by 7.5% over the year, driven by continued stockpiling across the value chain. Inventory build-up occurred in households, filler levels, and packaging converters, as high aluminium prices encouraged companies to secure raw materials during a volatile period.
The demand for thinner foils used in packaging increased by 3%, while thicker foils for semi-rigid containers and technical uses grew by 7%. Export markets, however, struggled, declining by nearly 15% due to ongoing supply chain disruptions and rising energy costs. As the pandemic subsided, destocking led to a reduction in orders from packaging converters. Nevertheless, strong European demand more than compensated for the decline in exports.
2022: Stability despite rising costs
In 2022, the market stabilised despite rising energy costs due to geopolitical tensions, particularly the war in Ukraine. Total production grew slightly by 0.4% to 971,300 tonnes, with European demand increasing by 0.8%. Exports showed signs of recovery in the second half of the year, reducing the annual decline to 1.9%.
Demand for thinner foils, particularly in flexible packaging and electric vehicle batteries, increased by 1.5%, while thicker foils, widely used in construction and automotive sectors, remained flat. The war also led to energy shortages and inflation, significantly reducing private consumption of packaged goods across Europe. This slowdown, combined with weak performance in the automotive and construction sectors, further dampened demand.
Global aluminium foil production in 2022 reached around 7,000 kilotons, with China continuing to dominate, producing approximately three-quarters of global output. Europe’s share of global production fell to 13%, down from 15% in 2021, reflecting the ongoing market challenges.
2023: A challenging year for European aluminium foil 2023 brought significant challenges, with total deliveries falling by 14.6% to 831,700 tonnes. The decline was driven by inflation, reduced purchasing power,
and the ongoing impact of geopolitical tensions. Domestic shipments dropped by 13%, and exports fell by 22%, with thinner foils used in flexible packaging seeing a 30% drop.
Thicker foils for semi-rigid containers and technical applications saw a 12% reduction. Despite these difficulties, European demand for converter foils in packaging grew by 5%, offering some relief. Global aluminium foil production contracted by 3%, reflecting weak demand in packaging and consumer goods sectors due to inflation. The market looked ahead to 2024 for potential recovery as economic conditions stabilised.
2024: Signs of recovery in Europe amid persistent challenges
The first half of 2024 began with continued weak demand, with Q1 shipments down by 6.2%, totalling 217,800 tonnes. Domestic demand fell by 3%, and exports plummeted by 26.6%, reflecting ongoing challenges in overseas markets. High interest rates and supply chain issues, particularly in the construction and automotive sectors, further weakened demand. Thinner foils used in flexible packaging dropped by 7.7%, while thicker foils fell by 3.6%.
However, the market rebounded in Q2 2024, with shipments increasing by 6.6% year-on-year to 227,000 tonnes. European sales, particularly for converter foils and semi-rigid containers, drove much of this
recovery, with thinner foils growing by over 8% and thicker foils rising by 4%. Exports remained weak, falling by 9%, but total shipments for the first half of 2024 reached 446,000 tonnes, a slight 0.2% increase.
July 2024 saw a further 18% increase in shipments compared to July 2023, signalling ongoing recovery. European sales grew by 3% in the first half of the year, and converter foil applications for flexible packaging and semi-rigid containers saw a 5% and 11% rise respectively. Despite weak export conditions, domestic demand is expected to continue growing throughout 2024.
Conclusion
The European aluminium foil market has undergone significant turbulence between 2019 and 2024, from trade disputes to pandemics and geopolitical crises. Yet, the industry has proven its resilience, maintaining a relatively stable output despite these obstacles. Strong domestic demand, particularly in packaging and technical applications, has helped cushion the impact of global disruptions. As 2024 unfolds, early signs of recovery provide hope for a more stable future, particularly with the growing demand for sustainable packaging and electric vehicle batteries. The aluminium foil sector is well-positioned to continue its growth trajectory, even amid ongoing global uncertainties. �
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Indonesia - Little China, Big Appetite
By Andy Farida*
Those that do not know Indonesia, the archipelago is a vast and diverse collection of over 17,000 islands. It sits on unique geological and tectonic conditions that mean it has various strategic minerals with rich veins, some tapped and untapped, that could power a circular economy.
Indonesia’s ambitious plan is to produce everything in-house, from bauxite to billet, and is a key element of the government’s broader electric vehicle (EV) strategy. It aims to produce 600,000 EVs by 2030 and will partner with four Chinese EV companies –Neta, Wuling, Chery and Sokon – to build an EV production and export hub in the country. Indonesia will not only benefit from technological advancement and provide highly skilled jobs, but will also be the perfect destination to tap on the growing middle class.
Fastmarkets Research forecasts that electric car sales will reach 17.5 million this year, with over one in five cars sold globally expected to be electric. That said, EV sales are mainly focused in China and the developed economies and there is still untapped potential in developing economies like Indonesia.
Aluminium’s light-weight appeal and increased usage among leading automotive producers, especially on the low-carbon aluminium front, has gained significant traction and looks set to grow
exponentially over the next decade.
The EV megatrend has long taken off and is picking up speed as consumers transition and embrace newer technologies and products that are much healthier for the environment. China wants to transform Indonesia into the next powerhouse to serve the Southeast Asia region on their future EV needs.
Nickel success, aluminium is next Look no further than the recent developments in nickel. China has successfully extracted and expanded its nickel operation in Indonesia. Investments are usually tied with knowledge-transfer, jobs and the developments of of key infrastructures. The same tactic has been applied on aluminium and alumina with China looking to tap into the country’s already rich bauxite production capability.
Still, success comes with costs and challenges. Worker unrest and the lack of environmental standards have repeatedly appeared though some progress has been made. Realising low-carbon end products will bring their own challenges, from extra funding for the installation of a renewable energy grid to disposing waste in an environmentally friendly way.
Most recently, the Indonesian government has pushed back on their renewable energy target for 2025, which
has further undermined their overall interest and capability to deliver what the world needs.
Indonesia bauxite export ban worked like a charm
Aluminium has an important role to play in the EV strategy. With its 1 billion tonne bauxite reserves, Indonesia is well placed to harness this opportunity.
Indonesia produced around 3.9 million tonnes of alumina in 2023, but Fastmarkets analysts forecast this could reach 10 million tonnes by 2025. Our research now shows that recently-opened PT Borneo International Aluminium (BAI) will bring 1 million tonnes alumina capacity alone by 2025.
Another seven alumina refineries are due to come online next year to bring an additional 9 million tonnes of alumina capacity online. Assuming all 11 alumina refineries open on schedule, total Indonesia alumina capacity could reach 16 million tonnes in the next 5 years.
PT Borneo smelter grade alumina refinery (SGAR) project makes this all the more feasible, with the refinery estimated to produce around 1 million tonnes of alumina. Most recently, Press Metal announced interest in building a $750 million alumina refinery in Indonesia though capacity and timeline remains
* Base Metals Research Analyst - Aluminium, Fastmarkets
unclear.
Indonesia alumina in high demand Fastmarkets calculated its daily benchmark alumina index, fob Australia at $540.92 per tonne on September 25, its highest level since September 2018.
Fastmarkets’ alumina pricing suite has recently expanded with the launch of inferred indices for Indonesia, Vietnam and India on September 2.
The launch of the inferred indices reflects a wider trend in the market, whereby origins ex-Australia are increasingly trading on the spot market amid ongoing expansion projects across the Pacific basin.
For example, concluded trades of Indonesia-origin material reported to Fastmarkets in the year to date have increased by 66% since 2019. Meanwhile, Australian liquidity reported to Fastmarkets has dropped by 46% over the same period.
As such, Indonesia is positioning itself to challenge Australia’s dominance over alumina supply in the region.
China primary aluminium capacity capped at 45 million tonnes It is undeniable that China needs an external source of primary aluminium.
The strict policy to cap primary aluminium production in China at 45 million tonnes per year, has been telegraphed for many years. As such, capacity ex-China is set to expand rapidly over the next decade. Foreign investments outside China can futureproof its growing aluminium needs and this template has been replicated in many other resource rich countries.
This has of course made China even more powerful, allowing it to retrain control over key critical minerals, which has unsurprisingly invited trade sanctions and forced its western counterparts to reduce reliance by re-establishing alternative sources of supply.
China alumina production growing strongly amid strong profit margins
China’s alumina and aluminium output continued to rise in August, according to the latest data from the country’s National Bureau of Statistics (NBS).
In August, alumina production was 7.34 million tonnes, up by 26,000 tonnes, or 3.67%, from 7.08 million tonnes a year ago and up by 13,000 tonnes, or 1.80%, from 7.21 million tonnes in July.
Over the first eight months of 2024, alumina output totalled around 55.88
million tonnes, up by 1.08 million tonnes, or 1.97%, from 54.80 million tonnes in the same period a year earlier.
Chinese domestic alumina prices kept moving higher, leading to refineries trying to produce more to benefit from the improved margins, sources said.
Fastmarkets’ weekly price assessment for alumina metallurgical grade, exw China was 3,910-3,970 yuan ($554-563) per tonne on Thursday August 29, up by 30 yuan per tonne from 3,880-3,940 yuan per tonne on August 1.
China transforming the Indonesian landscape China’s success in transforming Indonesia’s fortunes and landscape should bring prosperity to that region too. Future investments and other collaborative projects should yield higher alumina output, and it could potentially boost primary aluminium output too.
We remain optimistic about Indonesia’s key role in supplying the world with the much-needed minerals to achieve a greener future. With the right attitude and ambitious mindset, Indonesia looks set to be the next powerhouse in the aluminium space. Indonesia Bisa! �
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ALFED: The UK Industrial Strategy Green Paper
An Essential Opportunity for the Aluminium Industry.
With the UK Government’s release of its ambitious Invest 2035: The UK’s Modern Industrial Strategy, ALFED welcomes this significant development and recognises its critical role in shaping the sector’s future. This green paper serves as both a proposal and a roadmap to foster economic stability and growth across eight priority sectors, from advanced manufacturing to clean energy.
In this article, Nadine Bloxsome, CEO of ALFED highlights how the strategy’s objectives align closely with ALFED’s own UK Aluminium Manifesto. Yet, while ALFED remains optimistic about this strategy’s potential to deliver on these fronts, several questions remain unanswered, and areas require clarification for the aluminium sector to maximise its role in achieving the UK’s green and industrial ambitions.
Key Areas for ALFED’s Focus and Queries for the DBT
The Identification of Key Subsections
The Industrial Strategy seeks to prioritise subsectors within broader industry categories, such as clean energy and advanced manufacturing. For ALFED, it’s imperative that this prioritisation recognises aluminium’s versatility across sectors. As Nadine Bloxsome comments, “Aluminium’s lightweight and recyclable properties make it indispensable in both established and emerging technologies. For example, in electric vehicles and renewable energy systems, aluminium offers unparalleled efficiency and sustainability advantages. We urge the Department for Business and Trade (DBT) to ensure aluminium manufacturing and processing receive due focus as foundational components of these priority subsectors.”
ALFED’s consultation response stresses that while high-growth sectors are spotlighted, more granular analysis is necessary to fully capture the nuances of subsector contributions. ALFED proposes a collaborative approach where DBT actively engages with industry bodies to provide the insight needed for policy precision.
By Nadine Bloxsome*
Accounting for Emerging Technologies
In today’s fast-evolving market, the aluminium industry is continually innovating. Advanced alloy developments, for example, have revolutionised aluminium’s applicability across aerospace, automotive, and construction sectors. However, traditional data sources are insufficient to capture the impact of these emerging technologies accurately.
“We call on the government to implement a dynamic approach to subsector analysis, integrating flexible, forward-looking methodologies that adapt to rapid technological advancements,” Nadine asserts. ALFED’s proposal includes support for establishing an adaptive framework that encompasses innovations beyond conventional data measures, ensuring the aluminium industry can seamlessly integrate into future sectors.
Strengthening Foundational Sectors and Value Chains
As a material critical to the UK’s economic resilience, aluminium plays a fundamental role in the national value chain. It underpins multiple industries that are vital for the nation’s sustainability goals. The government’s approach to foundational sectors, such as those providing primary resources, must recognise aluminium’s pivotal role. ALFED has urged that the strategy’s emphasis on value chains extends beyond final products to encompass essential foundational materials.
“Our sector’s resilience is the resilience of UK manufacturing. Recognising aluminium within the value chain framework ensures the robustness of entire industrial ecosystems,” Nadine highlights.
Barriers to Competitive Industrial Activity and Increased Electrification
The Industrial Strategy acknowledges barriers to competitiveness, notably in energy costs and infrastructure limitations. These factors disproportionately affect aluminium manufacturers, whose
*CEO of ALFED
operations are energy intensive. ALFED has identified competitive energy pricing, particularly through Power Purchase Agreements (PPAs), as a crucial area where government intervention could enhance industry viability.
Nadine comments, “Adopting energy policies that enable stable, affordable access is vital. The aluminium industry’s contributions to net-zero targets are unfeasible without competitive energy solutions, and we urge the government to explore international best practices.” Drawing on case studies from Europe and North America, ALFED’s response recommends energy frameworks like targeted PPAs for industrial applications and enhanced grid connectivity support.
ALFED’s Ongoing Engagement and Call for Member Action ALFED’s response underscores our commitment to working collaboratively with the government to align on sectorspecific needs. The newly established Industrial Strategy Council, under the chairmanship of Clare Barclay, Microsoft UK CEO, will play a pivotal role in fostering an ongoing dialogue between public and private sectors. This Council’s establishment signals a governmental shift toward a stable, evidence-based industrial policy approach.
Nadine articulates, “As the consultation proceeds, ALFED will maintain active dialogue with DBT, ensuring that our industry’s voice is represented in every stage of policymaking.” ALFED encourages all members to submit their feedback directly to the consultation, strengthening the aluminium sector’s united voice.
ALFED’s comprehensive draft response is already paving the way for a more integrated, sustainable industrial framework for the UK. This response highlights aluminium’s transformative role across industries. ALFED is calling upon the government to build upon this collaborative effort, incorporating industry insights to achieve a competitive, resilient economy. �
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The Aluminium Smokescreen
By Christian Mabey*
How Russian Metal sneaks into UK markets amid sanctions
As the Russia-Ukraine conflict continues to evolve, its far-reaching effects are rippling through global supply chains, with the metals sector being hit particularly hard. The aluminium market, a crucial element for industries ranging from construction to aerospace, is at the heart of this geopolitical turmoil. Despite sanctions and import bans, there is growing concern within the industry that Russian aluminium is still entering the UK market through indirect routes.
The Current landscape of aluminium trade
Despite an import ban imposed by the London Metal Exchange, Russia remains a major force in the global aluminium market, accounting for a significant 5.6% of world exports. This notable market share has created a visible gap in the supply chain, forcing businesses across various sectors to seek alternative sources.
Responsible manufacturers and suppliers are responding by sourcing aluminium from countries not involved in geopolitical conflicts. At Optima Products, for example, we have formed a strategic partnership with Norwegian manufacturer Norsk Hydro, a company renowned for its commitment to sustainable practices and ethical production methods.
The back door dilemma:
A growing concern
It’s becoming increasingly evident that not all sectors are adhering to these ethical standards. Reports from industry
insiders suggest that Russian aluminium is entering the UK market through the back door, via third-party vendors operating in Eastern Europe, Eurasia, and the Far East. This clandestine influx raises serious moral questions and ethical concerns, as it potentially contributes to sustaining Russia’s military activities.
The crux of the problem lies in the intricate nature of aluminium supply chains. When procurement doesn’t occur directly from known and vetted manufacturers, tracing the origin of aluminium logs becomes a challenging task. The complexity is further compounded by the fact that aluminium, once processed, bears no easily discernible markers of its origin.
Furthermore, the risk of inadvertently acquiring Russian-sourced aluminium significantly increases when purchases are made from nations that haven’t implemented their own Russian import bans. This creates a loophole in the global trading system that unscrupulous actors can exploit.
The ripple effects on the UK aluminium industry
The influx of potentially sanctionbreaching aluminium doesn’t just pose ethical dilemmas but also has direct implications for the UK aluminium industry. Legitimate businesses committed to sanctions and ethical sourcing are placed at a competitive disadvantage, as the lower prices of this ‘grey market’ aluminium can undercut those prioritising transparency and responsible sourcing, creating an uneven playing field.
Moreover, the presence of this
aluminium of dubious origin in the market can lead to reputational risks for unsuspecting companies. In a time when consumers and businesses are increasingly mindful of supply chain ethics, the discovery of Russian-sourced aluminium in a company’s products could trigger significant backlash.
At this point, I could also bemoan the lack of correct carbon information that accompanies this ‘anonymous’ aluminium, but that’s for another article. I think in this instance, it’s about dealing with the main issue at hand - that we need to put a stop to this unacceptable situation now.
The need for concerted action
While the UK has made commendable strides in banning direct imports from Russia, these efforts fall short of addressing the complexities inherent in global trade networks. Many countries continue to engage with Russian aluminium suppliers, either knowingly or unknowingly, creating a web of intermediaries through which sanctioned materials can flow.
To effectively combat this issue, we need a multi-pronged approach that involves stakeholders at every level of the aluminium industry:
1. Increased awareness: Both the industry and government must spotlight the loopholes in trade agreements with
*Christian joined Optima in 2006. He oversees Optima’s manufacturing and design facilities in both the UK and Asia.
countries that haven’t restricted Russian aluminium. This includes educating businesses about the risks of sourcing from certain regions and the importance of supply chain due diligence.
2. Clear guidelines: Develop and disseminate comprehensive guidelines for aluminium purchasers. These should outline best practices for verifying the origin of aluminium and provide a framework for ethical sourcing decisions.
3. Enhanced due diligence: Implement rigorous checks and balances before finalising contracts or transactions. This could include requiring detailed documentation of the aluminium’s journey from smelter to supplier, and potentially even third-party audits of supply chains.
4. Collaborative effort: Engage with organisations such as ALFED (Aluminium Federation), CAB (Council for Aluminium in Building), and the IAI (International Aluminium Institute) to drive policy changes. These industry bodies can play a crucial role in setting standards and lobbying for more robust regulations.
A call to action for the aluminium industry
As stakeholders in the aluminium industry,
we find ourselves at a critical juncture. The choices we make now will shape the future of our industry and its reputation. We have a responsibility to ensure our supply chains are not only efficient and costeffective but also ethical and transparent.
By taking these steps, we can work towards halting the influx of Russian aluminium through both known and
unknown channels. This isn’t just about complying with sanctions; it’s about setting a new standard for ethical business practices in our industry.
This may seem like a daunting challenge, and it cannot be addressed overnight, but it represents a crucial step in our ongoing efforts to maintain the integrity of our industry and support global peace efforts. Billet Casting Technology for High quality billet production
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Data-Centric AI in Aluminium Manufacturing
By Denis Gontcharov*
Introduction to Data-Centric AI Data-Centric Artificial Intelligence (DCAI) focuses on improving the performance of Artificial Intelligence (AI) models by enhancing the quality of data used to train these models. Fig 1
It represents a shift away from the traditional Model-Centric AI (MCAI) approach that prioritises refining the model itself, i.e. the hyperparameters defined by the code. This paradigm shift is driven by two realisations. First, even the best AI models will falter if trained on poor-quality data. Second, many great AI models are readily available as opensource solutions. Tweaking these models further leads to diminishing returns. DCAI, therefore, seeks to maximise the effectiveness of AI through improved datasets rather than endlessly tweaking machine learning algorithms.
Why DCAI is relevant for aluminium manufacturers
One of the key challenges in the aluminium industry, as in most heavy industries, is the lack of high-quality labelled data. For AI systems in general, garbage in equals garbage out. Although, for example, primary aluminium production generates vast quantities of time series, much of this data is incomplete, noisy, or inconsistent. DCAI addresses these issues by focusing on enhancing data quality through systematic improvements such as better labelling, reducing noise, and handling data imbalances. Having accurate, labelled, and relevant data is crucial to building AI systems that can optimise production, reduce waste, and improve product quality.
Aluminium manufacturers usually don’t have large digital departments with several data scientists. Tweaking the model code is therefore not feasible.
However, an experienced process engineer or other domain expert is an ideal candidate to improve the data using DCAI techniques. After all, they understand the data like no one else. This way, aluminium manufacturers can start with DCAI without needing in-house AI capabilities.
Fig 1. Image source: Landing AI. (2023). Tips for a Data-Centric AI approach. Retrieved 14 October 2024, from https://landing.ai/blog/tips-for-a-data-centric-aiapproach
Fig 2. Image source: Landing AI. (2023). Tips for a Data-Centric AI approach. Retrieved 14 October 2024, from https://landing.ai/blog/tips-for-a-data-centric-ai-approach
Potential DCAI use cases for the aluminium industry
DCAI can provide significant benefits to various AI use cases in aluminium manufacturing. Below, some DCAI techniques are presented for common industrial AI use cases.
Predictive maintenance
DCAI enhances predictive maintenance by improving the quality of sensor data
* Data Engineering for AI startups in Manufacturing
used to monitor machinery conditions, such as temperature and vibration. One of the major challenges of predictive maintenance is data imbalance, as failures are rare, meaning there is much more data about normal operation than about failures. DCAI addresses this imbalance by generating synthetic, i.e. artificial, failure data, ensuring AI models have more examples of rare machine failures. DCAI also focuses on better labelling of historical events, helping AI models distinguish between normal fluctuations in the data and actual precursors to failure.
Quality control and defect detection
Quality control and defect detection often rely on machine vision, and therefore image data. DCAI improves defect detection by ensuring high-quality image data through preprocessing techniques such as noise reduction and lighting correction. Cleaner image data helps AI models detect defects more accurately with fewer images. DCAI also works to improve defect labelling, reducing inconsistencies that may confuse AI models. Lastly, as with predictive maintenance, DCAI can handle the challenge of rare defects by generating synthetic data to balance the dataset, allowing AI to learn patterns even when particular defects are infrequent. Fig 2 The following example from the pharmaceutical industry illustrates the concept of dataset reduction. The image above shows six images of pills. Some of these pills contain scratches (in white). However, three of the six images on the left are blurry: it’s hard to see if the pills are scratched. Following DCAI principles, removing them from the dataset will improve model performance. It’s worth noting that reducing the dataset size by 50% runs counter to the traditional argument that more data is always better.
Energy efficiency
DCAI improves energy efficiency in aluminium production by refining the quality of real-time energy consumption data. Real-time data is challenging because it’s often not subjected to proper data testing. DCAI addresses missing data by imputing gaps, for example using rolling averages, and removing statistical or physical outliers. This ensures that AI models are always fed with high-quality information, leading to more accurate energy predictions and optimised usage.
How aluminium manufacturers can get started without hiring experts
One of the advantages of DCAI, unlike MCAI, is that it doesn’t require hiring data scientists to build complex machine learning models from scratch. There are several strategies that manufacturers can employ that do not involve hiring:
1. Leverage Existing Data: Manufacturers can start by focusing on the data they already have. By improving the quality, consistency, and labelling of their existing datasets, they can lay the groundwork for successful AI applications. Many DCAI techniques, such as data
augmentation or noise reduction, can be applied without needing extensive machine learning expertise. Often, a trained process engineer or business analyst can do the job.
2. Use Off-the-Shelf AI Tools: There are numerous MLOps (machine learning operations) platforms and tools available that can help manufacturers apply DCAI methods without needing to develop these methods from scratch. An industrial example is [Landing AI](https://landing.ai/ blog/tips-for-a-data-centric-ai-approach). These platforms often come with builtin tools for data preprocessing, cleaning, and labelling, allowing manufacturers to focus on improving their data right off the bat.
3. Rely on Domain Experts: Instead of relying on AI experts, manufacturers can work with domain experts who have deep knowledge of aluminium production processes. These experts can help define what good data looks like, which can then be fed into AI systems to improve their effectiveness.
4. Start Small: Manufacturers can begin by applying DCAI techniques to a small part of their production process, such as a single machine or production
line. By focusing on improving the data in one area, they can demonstrate the value of DCAI before scaling up to the entire facility.
Conclusion and further resources
Data-Centric AI offers aluminium manufacturers a powerful way to harness the benefits of AI without needing to hire large teams of data scientists. By focusing on improving the quality of their data, manufacturers can develop more effective AI systems that can optimise production, reduce defects, and enhance energy efficiency. �
This article was based on the following industrial paper: A Review of Data-Centric Artificial Intelligence (DCAI) and its Impact on the Manufacturing Industry, presented at the 2024 IEEE Conference on Artificial Intelligence (CAI). The AI use cases are based on the writer’s professional experience, and the content provided by Landing AI. For more information regarding DCAI, the reader can contact the writer Denis Gontcharov at denis@gontcharov.eu.
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EGA: A Digital Future
Aluminium International Today spoke with Carlo Nizam* following his attendance at the Future Aluminium Forum. Carlo disused digital technologies and their application at Emirates Global Aluminium (EGA).
1. The video presented to delegates at the Future Aluminium Forum was very well-received. For those who were not in attendance, can you provide an overview of Emirates Global Aluminium’s new digital strategy and its objectives?
We are executing our digital transformation strategy with a dual track approach that simultaneously delivers tangible business impact through quarterly waves of uses cases and lays the digital foundations to enable sustainable digital transformation at scale. Our strategy will not only make us more operationally and financially competitive but also more agile, efficient and adaptable in an exponential age of technology that is accelerating at breakneck speeds. This is not something reserved for tech start-ups, it’s something that we as large industrial companies need to embrace whole heartedly to future-proof our businesses.
2. What specific digital technologies are being implemented as part of this strategy, and how are they expected to enhance operations within the aluminium industry?
We have identified ten digital capabilities to support a broad spectrum of use cases across both our physical operations and corporate activities globally and that collectively enable smarter, more agile, and data-driven decision-making processes. While these may evolve over time, they currently include cloud computing, data analytics and AI, Internet of Things, digital
3. You have shared information about EGA’s dual track approach within the digital factory. Can you share more detail around how Emirates Global Aluminium plans to leverage digitalisation to improve efficiency, productivity, and sustainability across its operations?
While the digital factory is delivering strong impact and change through waves of more than 200 use cases, this alone is not enough to sustain digital at scale across EGA. So far, we have executed more than 80 of 200 use cases identified, That is why we are simultaneously laying structural foundations to prepare EGA to scale digitally and go beyond just use cases. For example, we are defining top-down digital ambitions and value roadmaps for each of our business areas across EGA. These value roadmaps are used to identify priority use cases in line
process automation, to name a few, and many more.
We believe these capabilities will enable sector-wide digital transformation for the aluminium industry and drive operational excellence, improve sustainability, and create a more connected and resilient value chain.
with business priorities before they are executed by the digital factory.
Separately, our goal is to fully integrate industry 4.0 digital capabilities into the business. This requires upskilling our people, who have the real business domain expertise, with new digital skills so they can be more autonomous and productive. To achieve this, we have set up a digital academy that has so far upskilled more than 2,000 of our employees on effective use of analytics, AI applications and agile ways of working. Our employees are not only learning about the different digital capabilities but also how to leverage them using our digital technology platforms. This is crucial if we want to achieve a digital critical mass across the company.
The next foundation is all about technology but before we look at that, let’s take a moment to reflect on our metal value chain. In our industry, raw materials are refined to create an end product. Now
*Chief Digital Officer at Emirates Global Aluminium
at each step of the value chain, there is a digital footprint of data for everything that happens. This can also be refined as a resource to create additional value and herein lies a very big untapped opportunity.
To leverage this opportunity, we need a data refinery which we call a data platform, that ingests and structures data to make it easily accessible for our employees to analyse. We introduced our EGA data platform in early 2023 and it made a significant impact for our business, both commercially and technically.
But we also have other platforms that sit on top of the data platform for each of our 10 digital capabilities. These selfservice digital platforms are designed to be used by our upskilled employees without IT involvement. Simplifying the use, providing access and training to such platforms is key to scaling digital transformation across EGA.
4. Could you elaborate on any challenges or obstacles faced during the implementation of the digital technology strategy, and how were they addressed? Is there any advice you would offer to the rest of the sector?
Digital transformation is not just about leveraging new technology capabilities, but also about transforming ways of working, mindsets and ultimately culture. As the old saying goes, “culture eats strategy for breakfast”. It is crucial to understand the driving forces behind workplace culture and build a strong foundation of trust with a coalition of the willing.
Start with small initiatives and achieve quick wins is essential build momentum, confidence and trust, while also working on laying solid foundations that will support lasting impact and value. Technology is exciting but it is only a small part of the bigger picture – people are what drive meaningful change.
6. You mentioned at FAF 24 that “the speed of innovation is growing exponentially.”
How does Emirates Global Aluminium ensure the security and integrity of its digital infrastructure and data in the face of increasing cyber threats?
Ensuring the security and integrity of our digital infrastructure is paramount. We adhere to the highest standards of cybersecurity, continuously improving our defenses and making considerable investments to maintain robust cyber security measures. We are also leveraging our 10 digital capabilities particularly AI and advanced analytics, to foresee and counter cyber threats proactively.
7. Can you discuss any partnerships or collaborations that Emirates Global Aluminium has formed to support the implementation of its digital technology strategy?
We rely on an ecosystem of strong partners to support our digital transformation. This includes consulting services, software, hardware as well as private and government research institutions.
9. What measures are being taken to ensure that employees are adequately trained and equipped to effectively utilise the new digital technologies?
As I mentioned, we established a digital academy to strengthen enhance our employees’ digital literacy and capabilities. So far, we have upskilled more than 2,000 of our employees across multiple areas such as analytics, AI and agile ways of working. Our employees not only learn about the different digital capabilities but also how to leverage them using our digital technology platforms so they can contribute pro-actively to our ongoing and future digital transformation projects.
5.You stated that “As a digital lighthouse for our region, we democratise digital capabilities to ‘change the game’ and create inspiring experiences for ourselves, our customers, and our partners” - EGA’s digital ambition. In what ways do you anticipate that the new digital technology strategy will impact the company’s competitiveness within the global aluminium market?
It is already creating a tangible impact on our productivity and efficiency. So far, we have delivered over $100m of impact through over 80 use cases. Our agile way of working is helping emphasise a sense of urgency to accelerate how we work, which in turn reinforces a relentless focus on our customers.
8. How is Emirates Global Aluminium utilising data analytics and artificial intelligence to optimise decision-making processes and drive innovation?
EGA is utilising data analytics and AI in many ways. For example, our smart cranes employ machine vision technology and neural networks to ensure adherence to operational standards. This system automates compliance checks through visual inspections, enhancing process accuracy while reducing the need for manual interventions. AI-powered compliance monitoring ensures consistent quality control and safety performance across operations.
Another example is we use machine learning models to forecast potential pot failures. These predictive models analyse historical and real-time data to identify early warning signs of equipment issues. These capabilities minimise unplanned downtimes, enhance asset reliability, and extend the lifecycle of critical production equipment.
EGA is optimising its sales planning strategies through advanced analytics and predictive algorithms to optimise sales planning. This approach allows for dynamic demand forecasting, smarter inventory management, and improved supply chain visibility, which ultimately enable more accurate and profitable business decisions.
By embedding these AI-driven solutions into our core business functions, EGA is not only optimising current processes but also paving the way for new innovations that redefine industry standards. This data-centric approach empowers us to remain agile, improve our competitive edge, and create long-term value in a dynamically evolving market landscape.
10. Looking ahead, what are the future plans and aspirations for Emirates Global Aluminium’s digital technology strategy, and how do you envision it evolving in the coming years?
We will continue to push the boundaries of what is possible to achieve ambition of becoming a digital lighthouse for our region and industry. We see enormous potential to unlock additional value for our business through Industry 4.0, not only to fulfil our purpose of innovating aluminium to make modern life possible but also to leverage digital capabilities, products and services as potential new revenue streams.
Innovations in Aluminium Storage and Handling
As the aluminium industry strives to enhance operational efficiency, optimise storage space, and pursue sustainability goals, AMOVA, a subsidiary of the SMS group, is leading the way with its cuttingedge automated storage and handling solutions. AMOVA leverages decades of experience in heavy load handling to address the unique challenges of aluminium logistics. In an exclusive interview with Aluminium International Today during the ALUMINIUM Show in Düsseldorf, AMOVA’s CEO, Bernd Klein, shared insights into the company’s innovations, their impact on sustainability, and how AMOVA is shaping the future of aluminium logistics.
Addressing
Aluminium Storage Challenges with Advanced Automation
The aluminium industry faces distinctive challenges due to the material’s properties, which differ significantly from those of steel. Unlike steel, aluminium is softer and more susceptible to deformation, requiring customised storage solutions to maintain its quality. “It’s very important to store aluminium coils individually and not stack them on top of each other,” Klein explains. “This is why most of our high-bay storage systems are specifically designed for aluminium, ensuring that each coil remains undamaged during storage and handling.”
AMOVA’s high-bay storage systems, a core offering, are engineered to store large aluminium coils vertically, up to 10 coils high, minimising space requirements and preventing potential damage. “Fully automated processes eliminate the need for forklifts and manual handling, which often resulted in coil damage,” Klein noted. “With automation, our clients have seen significant improvements in coil quality, as well as reductions in workforce requirements, which translates to operational cost savings.”
Innovations in Digital and DataDriven Logistics
AMOVA’s advanced technology extends beyond mechanical solutions, incorporating digital tools that enable real-time tracking and inventory management. Klein highlighted the use of a warehouse management system that includes simulation software for plant planning. “Our clients can visualise their entire storage operation in 3D, much like a computer game. Operators can navigate the plant, click on any coil,
and access real-time data,” he explains. This enhances operational oversight and enables predictive maintenance, where system data is used to forecast and address potential issues before they disrupt operations.
AMOVA’s business intelligence (BI) systems collect data across the entire
operation, from equipment health to energy usage. “Our BI tools empower clients with actionable insights. They can monitor their operational data and perform predictive maintenance, which is critical for minimising downtime and extending equipment life,” adds Klein.
Commitment to Sustainability and Energy Efficiency
In an industry increasingly focused on reducing carbon footprints, AMOVA has made significant strides in creating sustainable logistics solutions. The company’s storage systems incorporate forced cooling techniques that significantly reduce the cooling time for aluminium coils between rolling stages. “Typically, natural cooling can take up to 31 hours, but with our forced cooling system, we can reduce that time to just 15 hours,” Klein explained. This innovation not only accelerates production but also reduces storage requirements.
AMOVA’s systems are also designed with energy recuperation capabilities, capturing energy generated during coil
lowering processes. This energy can be fed back into the system or used for other operations, promoting a more sustainable energy cycle. Additionally, AMOVA encourages clients to install solar panels atop their storage systems. “In many cases, these panels generate more power than the storage system needs, allowing our clients to offset some of their energy consumption with renewable sources,” Klein added.
A Focus on Client-Centric Solutions and Global Reach
AMOVA prides itself on working closely with clients to create customised solutions that address specific operational challenges. This client-centric approach has been key to their success, allowing them to cater to both new facilities and retrofit existing ones. “Many clients need to maximise the limited space they have, particularly in urban areas,” Klein said. “Our systems are designed to fit into Brownfield applications, where we integrate automation into existing facilities, improving efficiency and
reducing the need for additional space.”
One such client, Murat Mr. AKKAS, Investment Projects Manager at Assan Alüminyum, expressed their appreciation for AMOVA’s support. “We sincerely thank the AMOVA team for the dedication and professionalism demonstrated throughout our first and only High Bay Storage system project. The mutual efficiency of our partnership has made the project results even more meaningful. The deep knowledge, experience, and project management of AMOVA, combined with their contributions to the project, played a crucial role in our mutual success. We look forward to continuing this synergy in future collaborations to improve the effectiveness of our warehouse management, and we believe that many more successful projects will be held together.”
Enhancing Safety and Productivity with Digital Twins
To further support safety and productivity, AMOVA utilises digital twin technology, allowing them to create virtual replicas of their storage systems. These digital
twins enable clients to conduct preimplementation testing, reducing onsite commissioning time and enhancing system reliability. “With digital twins, we can simulate the entire operation, test all movements and automation sequences, and identify potential issues before they occur on-site,” Klein noted.
By simulating various scenarios, AMOVA can fine-tune systems to meet the specific demands of the aluminium sector, ensuring they are prepared to adapt to changes in market demands, supply chain challenges, and technological advancements.
Shaping the Future of Aluminium Logistics
Looking ahead, Klein envisions a future where aluminium logistics is even more automated, digitised, and sustainable.
“The aluminium industry is moving towards more resilient and adaptable storage solutions, and we’re focused on providing systems that not only meet current demands but also prepare our clients for future challenges,” he shared. AMOVA continues to explore partnerships and collaborations that could further enhance their systems and expand their
reach within the aluminium sector.
AMOVA’s innovations in aluminium storage and handling not only optimise operational efficiency but also contribute to industry-wide sustainability efforts. By integrating advanced automation, digitalisation, and sustainable practices,
the company is setting a new standard in aluminium logistics, helping its clients achieve their sustainability goals. As the industry evolves, AMOVA remains committed to pioneering solutions that align with the shifting priorities of the aluminium sector. �
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145 Years of Metallurgical Solutions
By Virginia Cesana, Marketing & Communication Coordinator, A.Cesana S.r.l.
Established in Milan - Italy in 1879, A.Cesana S.r.l. has a history that spans over 145 years. What started as a bronze foundry in Milan has transformed into a leading company that produces and distributes an extensive range of products to the non-ferrous metal foundries related to automotive, aerospace, packaging and home appliances industries.
A.Cesana’s product portfolio presents high-tech and tested solutions: from foundry consumables, release agents for aluminium die casting & extrusion, casting accessories, rotor degassing systems and melting & holding furnaces. The company provides the complete product range needed in modern cast houses and foundries.
The ability to share an extensive foundry knowledge, gained through A.Cesana’s long presence in the market, has earned it a reputation as a reliable and trusted partner. With a focus on optimisation and cost effectiveness, the team ensures that its products not only meet the current demands but also align with future advancements, offering optimal performance and sustainability worldwide.
Recent Projects: Degassing units for molten metal treatment
problems and find the best solution.
A comprehensive range of degassing products are available, including machines, rotors, and instruments to monitor metal density before and after the degassing process. The new DUAL SEF Model 2024, an advanced degassing unit equipped with flux dispenser, rotating anti- vortex fin, hygrometer - temperature sensor, data recorder, inverter technology, first-class PLC and remote control. This unit performs degassing using a durable silicon carbide rotor, ensuring efficient deoxidising of aluminium alloys by eliminating porosity, impurities, and oxides from the melt.
A.Cesana S.r.l. recently completed a series of high-profile projects, focusing on enhancing non-ferrous metal casting processes. Our team provided custom metallurgical treatments and advanced solutions to improve casting precision and efficiency. Throughout the development of the projects, we frequently visited and discussed with the clients, supporting requests and developing them further. Our commitment goes far beyond the outcome, we aim to establish long-lasting relationships with our clients, we are always ready to respond to
The portable DUAL 2 degassing unit, with its robust design and precise control mechanisms, offers flexible transport and efficiency for ladles & furnaces. It can be moved with a forklift or crane/lifter and the lid is equipped with an insulated structure to prevent heat loss and metal splashes risk. Fitted with a silicon carbide rotor and the addition of Gas Detector Unit offers support to high-quality casting processes by optimising degassing cycles.
The silicon carbide rotors are designed with a threaded end for easier installation, along with a special propeller. The shaft geometry is optimised to fit degassing devices used in furnaces and ladles containing liquid aluminium. These rotors can operate in temperatures ranging from 660°C to 820°C. They withstand oxidising conditions, high temperatures, flux erosion, and mechanical friction during treatments.
The GAS DETECTOR is easy to use and moves to different workstations. It is designed to verify the quantity of hydrogen gas contained in liquid aluminium alloys, allowing intervention with adequate degassing treatment before pouring.
A.Cesana’s Commitment to Quality and Industry Standards
A.Cesana’s success is intertwined with its commitment to quality and adherence to strict industry standards. A pivotal moment was in 1993, when the company achieved ISO 9001 certification. Being one of the first companies in Italy to receive the certification is a testament to its rigorous quality control and customer-centric approach.
A Timeline of Success: Key Milestones
Throughout its history, A.Cesana has remained a family-owned company, preserving its founding values of professionalism, respect, and dedication. After the death of Giovanni Cesana in 1946, his son Giorgio Cesana took over the company at the age of 18. Under his leadership, A.Cesana flourished and expanded its operations, including entering into international partnerships.
The 1980s saw the next generation of Cesana family members, Luca, Alberto, and Domitilla, join the company, ensuring the continuity of its values and business philosophy. Each member brought unique skills to the table, enhancing the company’s capacity to innovate and expand into new markets. The family commitment to the non-ferrous metal industry enabled the generations to pass on their knowledge and experience, making it possible to develop a unique and reliable relationship with long-term clients as well as new ones.
Looking to the Future
As A.Cesana celebrates 145 years in business, its vision for the
future remains clear: continuous improvement, innovation, and global expansion. The company aims to further strengthen its position in the metallurgical and foundry sectors while expanding its influence in international markets.
The company is already taking significant steps toward this future by leveraging new technologies and forging strategic partnerships with international players. This drive for innovation ensures that A.Cesana remains at the forefront of the metallurgical field, setting new standards in product quality and performance.
A.Cesana S.r.l.’s journey from a small bronze foundry in Milan to an international company leader in metal treatment solutions is a testament to its resilience, adaptability, and commitment to excellence. Through generations of dedicated leadership and a focus on innovation, the company has not only survived but thrived in an industry that demands constant evolution. �
New research into nucleation
Aluminium grain refiner specialist MQP has succeeded in further increasing the efficiency of its Optifine 5:1 125 product on the back of research with the UK’s top metals centre. By John Courtenay*
Optifine 5:1 125, which previously had a minimum 120% relative efficiency compared with Optifine 3:1, which in itself is three times more efficient than standard grain refiners on the market, has been consistently delivering a 130% efficiency since further experimentation using High Resolution Transmission Electron Microscopy (HRTEM) got underway this year.
Chaiman John Courtenay said the work with Brunel Centre for Advanced Solidification Technology (BCAST) at Brunel University London had revolutionised the effectiveness of grain refiner, which is added to aluminium in the production process to eliminate cracking, waste and poor quality material for everything from thin foils to high gloss automotive applications.
“To be able to deliver 130% relative efficiency is incredible, something we
couldn’t have imagined a decade ago,” he said. “At Aluminium 2024, we saw a clear uptick in casthouses’ commitment to taking action and trialling our Optifine grain refiners to improve their systems, processes and efficiency, and having to
add even less grain refiner to the melt is only going to be good news, equating to better quality together with meaningful cost savings.”
The partnership with BCAST, located at Brunel University London, began in 2020,
* Chairman, MQP
resulting in the launch of Optifine 5:1 125 in 2021. For over a decade, BCAST had been looking into the industry problem of inconsistency of aluminium quality on a global scale, which results in huge waste and substandard products across manufacturing. Joining forces with MQP set the scene for a research project to implement the science in an industrial setting.
Today, Optifine, which is made with low carbon, green aluminium, is used in the production of over five million tonnes of aluminium alloys annually in 45 major casthouses worldwide, its appeal being that casthouses only need to use a third of the amount of standard TiBAI grain refiners typically used. It can also bring costs down by half and means less coil changes and transportation around the casthouse and lower warehouse inventory.
For Steel and Aluminum Rolling Industries
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Better length accuracy in cut-to-length applications as a result of faster acquisition and tracking
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Accurate elongation and mass-flow control with improved signal processing and synchronization
Enhanced I/O for better integration with modern automation systems For details call +1-416-445-5850,
Qualification of Hydrogen as Fuel in Aluminium Casthouses
By Justin Dzik*
Aluminium production emits ~270 Mt CO2/year, according to the International Energy Agency, and is considered a key enabling material for the energy transition. Decarbonisation of aluminium production is therefore critical, not only for the aluminium sector, but also for sectors such as automotive, building and construction and energy.
Fives North American Combustion (Fives) has performed a series of experimental tests in their combustion laboratory in Cleveland, OH, United States, to confirm the use of hydrogen as a fuel. The tests focused on the use of hydrogen in a regenerative burner, one of the most common burners used in secondary aluminium applications. Emissions, energy efficiency and safety were all studied during the tests.
Introduction
Casthouses consist of several energy intensive and high temperature processes, relying heavily on fossil fuels. These are pre-heaters, de-lacquering furnaces, holding furnaces, melting furnaces and homogenisation furnaces.
The tests presented in this article involved both natural gas (NG) and hydrogen (H2) in the test furnace. The test furnace simulates an industrial process having similar geometry and construction to an industrial aluminium furnace, running at temperatures seen in secondary aluminium melters.
Burner
The most common burner platform used in secondary aluminium applications is regenerative burner technology. Fives’ North American TwinBed™ regenerative burners offer high velocity operation in addition to high energy efficiency. The burner assembly has two main operating modes. Conventional mode where fuel and air are injected through a nozzle mix burner (main burner) and LNI (low NO x injection) mode where only air is injected through the main burner and fuel is injected through a separate lance, see Fig 1. During the tests hydrogen was introduced in LNI mode only. The North American TwinBedTM (TM in exponent) II
regenerative burner is shown in Fig 2
LNI reduces thermal NO x production by allowing the air and fuel jets to entrain mostly inert furnace gases and through that create a more distributed combustion process with lower temperature peaks. An additional benefit is that the peak oxygen concentration during combustion is reduced. Together, these two phenomena lead to “flameless” oxidation where the combustion occurs as a low intensity cloud in the furnace.
Hydrogen Supply
Fives’ North American Combustion Laboratory is equipped with a hydrogen supply system. The supply is delivered by compressed gas on tube trailers. At maximum capacity, a maximum flow rate of approximately 62,000 scfh (1,700 Nm3/h) is achievable. The facility is located at the rear of the property (shown in Fig 3), connected to the laboratory by approximately 300 m of stainless-steel pipe. It is connected to all furnaces in the laboratory to facilitate burner and process testing.
Challenges of using Hydrogen compared to Natural gas
There are certain challenges hydrogen
poses as an industrial fuel compared to natural gas. Certain attributes of hydrogen combustion are well known such as higher flame temperatures and faster flame speeds. Others such as smaller molecule size and ease of ignition also pose challenges for industrial burner design. On average, the flame temperature is 200°C higher when burning hydrogen compared to natural gas. The flame speed is anywhere from four to ten times as fast with hydrogen, depending on the air fuel ratio. The autoignition temperature is lower (520°C hydrogen compared to 640°C with natural gas) and hydrogen needs approximately fifteen times less spark energy compared to natural gas. All of these challenges need to be considered when designing burners and associated control equipment. Factors such as flame temperature not only pose a material concern on the equipment but also pose a risk to the material being processed. However, hydrogen is nearly directly interchangeable with natural gas on a component and pipe sizing basis. This is based on the Wobbe index for natural gas (13.0 kWh/Nm³) and hydrogen (11.4 kWh/Nm³) being very close. Special consideration still needs to be given to materials for components and piping.
*Director of Innovation and Business Development, Fives North American Combustion, Inc.
Fig 1. Fives’ North American TwinBed™ burner modes of operation, from FNAC literature GRM56, Magna-Flame LNI
Operations and Burner Management System
Fives has integrated control and safety functions for the hydrogen operation to the existing burner management system, to ensure safe introduction of hydrogen. This includes standard control and safety functions similar to natural gas and additional permissive functions. Examples of these additional permissives include: preventing hydrogen supply when the furnace temperature drops below 760°C. This guarantees that hydrogen is introduced into an environment where combustion is ensured to happen.
Emissions
During testing in the Fives laboratory, the NO x emissions were measured with a chemiluminescent type of analyser. In these tests, the volumetric concentration (oxygen corrected ppmvol or mg/Nm3) of NO x when operating on hydrogen were about 17 % higher than when operating on natural gas. However, when the emissions were compared on a mass per unit energy basis (g/MJ) the hydrogen emissions were 14 % lower than those on natural gas. This swing in relative emission performance supports the need to have appropriate emissions regulations to support the fuel switching to hydrogen.
Conclusions & Way forward
For new or existing furnaces operating on natural gas, regenerative burners can provide the highest efficiency to minimise the amount of fuel consumed thus reducing the total carbon emissions. Also, low NOx technologies, such as LNI, can be utilised to minimise NO x with
regenerative technology. To reach future decarbonisation goals, installation of new equipment should be done with the thought that hydrogen may be in the future for industrial fuels. This means that consideration should be taken when choosing future components to be ready for new fuels. Also, regenerative systems will be applicable whenever hydrogen fuel becomes available. The cost of hydrogen will inevitably be higher compared to natural gas, so any means of reducing the amount used will be attractive.
The tests indicate that introducing hydrogen as fuel has minimal negative implications on safety performance, energy efficiency, and operability of the
test furnace Fig 4. NO x emissions are identified as a possible area for further study to ensure that changing the fuel to hydrogen does not have a negative impact on air emissions.
In addition to reduction in NO x emissions through technology development and process optimisation, work must be done on the regulatory side. Today, regulatory requirements are often expressed in concentration-based terms, but the industry needs regulatory requirements that are fuel agnostic and tie directly to the absolute amount of pollution being emitted into the atmosphere. This will give the industry flexibility to choose the optimal decarbonisation technology. �
Fig 2. Fives’ North American TwinBed™ II Regenerative Burner
Fig 3. Fives North American Hydrogen Infrastructure
Fig 4
ASAŞ: Leading the Future of Aluminium Flat Rolled Products
Based on its stable financial growth trend since its establishment in 1990, ASAŞ is one of the leading manufacturers in Europe and exports to more than 90 countries across 6 continents. With over 3000 employees, ASAŞ provides services for its clients at its aluminium extrusion profile, aluminium composite panel, aluminium flat rolled products, PVC profile and roller shutter production facilities which are located in a total of 1.300.000 m² area, of which 400.000 m² is enclosed, in Türkiye.
The aluminium flat rolled products production facility offers a wide variety of products including coil & sheet, foil, lacquered foil and pre-painted aluminium products. Equipped with state-of-the-art machinery, including continuous casting lines and rolling mills, ASAŞ upholds the highest quality standards while efficiently meeting customer demands. With its recent investments, company will double the production capacity of its aluminium flat products facility from 120,000 tons to 240,000 tons. The new lacquering and lamination lines can handle thicknesses from 7 to 350 microns, enabling simultaneous coating of both surfaces in one pass. Additionally, the launch of the second 6 Hi-Mill cold rolling investment in September 2023 positions ASAŞ as Turkey’s fastest mill, achieving an exit thickness of just 0.15 mm and a rolling speed of 1800 m/min. With these investments, ASAŞ aims to exceed customer expectations and strengthen its presence in the global market.
The company embraces the principles of continuous investment in sustainability, technology, integration, and innovation to better serve its customers and contribute to a better world for the future. In line with
“With our latest investments, ASAS is significantly expanding its production capabilities while maintaining our dedication to sustainability. These advancements allow us to better serve our global customers and strengthen our position in the market, all while upholding the highest environmental and operational standards.”
Derya Hatiboğlu
this commitment, the biodiversity action plan has been prepared in collaboration with expert scientists and biologists to guide investments in an environmentally friendly manner. Furthermore, ASAŞ proudly became the first facility in Türkiye to implement recycling systems for oils used in cold and foil rolling processes, preventing 1,200 tons of rolling oil from entering the environment each year. Additionally, the ASAŞ R&D team has developed an innovative method to recycle solvents used in its coil coating line, effectively reducing waste.
In its commitment to responsible practices, ASAŞ is actively pursuing Aluminium Stewardship Initiative (ASI) certification across 11 sustainability categories. This commitment to sustainability highlights the company’s dedication to sustainable sourcing and production. To further enhance its sustainability efforts, ASAŞ calculates its corporate carbon footprint and water footprint, developing projects to improve these processes. Furthermore, all electrical energy used in production is sourced from renewable energy, and the process is certified with the Renewable Energy Certificate (IREC). ASAŞ also prepares Environmental Product Declarations (EPDs) for 12 key product types, ensuring transparency and accountability in its operations.
To advance its sustainability goals, ASAŞ has established ASAŞ Energy, a new company dedicated to investing in clean energy sources, including wind, solar, biogas, biomass, and hydroelectricity. Furthermore, the company supports research and development in hydrogen energy and cultivates energy crops for biomass and biogas production. �
Our Challenges and Aspirations
By Zahra Awan*
As you walked into one of the six halls at the ALUMINIUM Dusseldorf show, the Hydro stand was not hard to miss. With its café, aluminium art installation, MercedesBenz AMG, and Brompton display, the stand is set up like a museum. Only unlike a museum, which often only reflects on the past, the stand has a bustling crowd discussing the future.
Anders Vindegg, Head of Media Relations, Hydro, navigates his way around the clusters and groups of people. Later I would be a part of one of these groups in conversation, only to turn around and begin another. We made our way to the stand’s meeting rooms which, I was warned, we may be thrown out of to make way for other meetings.
“I thought I could hear a familiar accent.”
Based in Wrexham, or as many around the world now know it - Ryan Reynolds Country, Wayne Clifton, Head of Recycling Europe, Hydro, sat over this laptop and was attempting to make the most of a rare quiet moment.
Anders and Wayne spoke with Aluminium International Today on the challenges and aspirations that Hydro has for its business, focusing on sustainability.
1. Could you update us on Hydro’s developments and investments the past two years, focusing on projects that have pushed the sustainability agenda.
Wayne Clifton (WC):
A big part of our 2050 net zero strategy is focused on recycling, as we see it as the fastest way to reduce our carbon footprint.
We have been taking some big steps over the past two years, getting ourselves ready for upstream positioning to support our downstream operations; when I refer to upstream for recycling, I am referring to the sorting and collection of scrap.
To give a brief update on our projects in Europe, we are building new recycling plants in Spain [1] and just opened a new plant in Hungary [2], adding capacities to our plants in France [3], and of course a
Anders Vindegg (AV): As Wayne said, recycling is the fastest to net zero, but there is no doubt that at the same time we need to take care of our primary aluminium products.
Even though the ideal would be that the global demand for aluminium would be fulfilled by recycling aluminium, we are not in a position where that is realistic. So, our primary aluminium production is still very important and will continue to be for many years to come.
To combat the carbon emissions from primary production, we have worked on a lot of technological developments. Since 2021, we have invested around €400 million in decarbonisation projects and upgrades at our Norwegian smelters. We are adding post-consumer scrap in the production at our primary aluminium smelters, we are investing in casthouse technology to reduce emissions, and we’re exploring the use of green hydrogen.
Another €200 million is invested in a fuel
project Wrexham [4]
We are making an investment to build a 30,000 metric ton sorting hub in Wrexham which will support our production of recycled low carbon aluminium in the UK. Then looking at future projects, we realise that there is a need for advancing the technology in these recycling plants themselves. We need furnaces and technology that is able to handle more challenging scrap types.
On the recycling side, we see this as our route to net zero, using more postconsumer scrap and digging deeper into the scrap pile taking advantage of more complex scrap.
switch decarbonisation project at our alumina refinery Alunorte in Brazil, cutting 700,000 metric tons of CO2 emissions anually. This is all part of our roadmap for how Hydro will achieve its commitment to achieving net-zero aluminium production by 2050 or earlier.
What’s really nice is that by developing both the primary and the recycling side, we are able to provide a good combination of products with low carbon footprints and varying degrees of recycled content both from primary and recycled aluminium. This is really beneficial to us as the market is still finding its feet, but the trend is clear: There is a pull from the market for low carbon aluminium, as our customers need to decarbonize their value chains in the face of growing consumer awareness and regulatory demand.
We understand that we need to be ready to move with the market and so this balance between the two gives us the ability to adapt and change.
Wayne Clifton, Head of Recycling Europe in Hydro Aluminium Metal
Anders Vindegg, Head of Media Relations in Hydro
Mercedes-Benz EQS displayed at Hydro’s stand at ALUMINIUM 2024 in Düsseldorf.
2.
Hydro has been investing in HalZero technology. Could you give a brief update on this?
AV: In 2023, we announced the decision to build a pilot at our research technology center in Porsgrunn, Norway [5], which is being built as we speak.
HalZero is a very promising technology, but we emphasise that it is still in development. Tests that have been done have been conducted at lab scale, with the aim to have the first industrial scale production of HalZero to take place by 2030.
In order for this to be achieved, we need further investments and continued research. Scaling up pilot testing will require significant investment and public-private partnerships. In 2023 the Norwegian state enterprise Enova granted NOK 141 million for the construction and operation of our test facility in Porsgrunn. The test facility will be up and running by 2025, and is an important step towards the goal to make the HalZero technology viable for implementation in new electrolysis capacity.
4.
3.
Let’s talk about legislation and addresses scrap. Keeping scrap within the UK is a huge challenge, let alone in Europe. Do you think something needs to be put in place on a wider scale, or local scale, to take responsibility for this scrap?
WC: Yes, we need the right policies and frameworks in place. I know that there is the recent adoption of the EU Waste Shipment Regulation but I don’t think that it will be a big enough barrier to stop the exportation of scrap out of Europe. At the same time, we also need the facilities and the capacity to process and utilise this scrap material in Europe. In Wrexham, we already have the cast house located where we will be building a new sorting facility. This will directly stop 30,000 metric tons of material being exported out of the UK, which when upgraded through our in-house LIBS technology will enter our greener and low carbon products.
Onshoring is important to us, and I know I say that from a UK perspective, but even from a European perspective onshoring is a bit of a buzzword. To keep that material local and be able to consume it locally is really important. I think that legislation is key, but we must also continue to progress our technology to be able to utilise that material. One dilemma that we do face as an industry is that there is not a harmonised view on pre- and post- consumer scrap.
Pre-Consumer Scrap: Material that never fulfilled its purpose as a product. This includes scraps, rejects, trimmings etc. that are often found on the factory floor
Post-Consumer Scrap: Material that had a life as a product and has been disposed of. This includes aluminium from packaging, vehicles, and construction etc.
Could you elaborate on the pre and post scrap dilemma?
WC: The debate essentially lies in whether you believe that the emissions in a material should be carried through when calculating footprint, or not.
At Hydro, we believe that pre-consumer scrap should have a carbon footprint. As it is material that never fulfilled its purpose as a product, the material should carry the carbon footprint of the original primary aluminium from which it was produced. In Europe you typically see 8 kilos of CO2e per kilo of aluminium in pre-consumer scrap, with an average of around 20% of the aluminium during a manufacturing process turning into scrap that will have to be remelted again.
That is why we consider post-consumer scrap as an essential part of our journey to net zero and this is also where the debate comes in. Some in the industry argue that the pre- and post-consumer scrap should have the same footprint, a zero-carbon footprint, but the process means that this is not the reality.
AV: The reality is that pre-consumer scrap is the byproduct of an inefficient production. In some ways you can actually argue that it should have a higher footprint than primary aluminium, as it has had additional processes applied to it, remelting, to ultimately give it life as a product.
We make sure to distinguish our definition of scrap. There is a clear difference between pre- and post-consumer scrap and it is our belief that post-consumer scrap is the fastest way to net zero, and to utilise that in the best way possible is essential to decabonising the industry.
The opening of the recycling facility in Székesfehérvár, Hungary in September 2024.
Aluminium scrap at Hydro’s recycling plant in Wrexham, UK.
5. Is the pre- and post- consumer scrap debate considered within Carbon Border Adjustment Mechanism (CBAM)?
WC: That’s a really good question, and where we still have some way to go. I think one of the questions you mentioned before this interview is “what change would you like to see in the industry”, and I think that CBAM is one of the main areas where we have high concerns and would like to see change. This is because the legislative view on CBAM currently has no differentiation between pre- and post-consumer scrap. That creates a big loophole and puts us in Europe at a disadvantage.
The intention of CBAM is to create a level playing field between EU producers and importers when it comes to carbon footprint. However, CBAM has a significant loophole as it assigns zero emissions to
6.What encourages you to make sustainable commitments despite the challenges you are presented with? Which industry has been most influential?
WC: What is encouraging is that we have forward-thinking customers. These companies are demanding sustainable, recycled material. We see that the market is being driven forward.
The building and construction industry has been our bread and butter for the last 20 plus years. But we see now that the automotive industry is really important. We have built partnerships with the automotive industry and are investing in increased capacity and capabilities to serve the automotive market.
One example of our commitment to the demand for more sustainable aluminium from key European industries such as transport and automotive, building and construction, renewable energy installations, and consumer durable market is our investment in Torija, Spain [6]. The plant will have 120,000 tonnes of annual capacity and aims to decarbonize European industries and ensure that scrap is kept in Europe.
AV: It is encouraging to see how the automotive companies have set concrete goals to lower the carbon footprint of their vehicles. And we have every reason to believe that other industries will also follow, and for sustainability to gain higher ranking on their agendas.
imports based on remelted process scrap, despite it having a carbon cost in the EU, thereby avoiding the CBAM levy. This loophole can be exploited at all stages of the value chain.
By failing to distinguish between pre- and post-consumer scrap, we run the risk that one could deliver a semifinished product from outside of Europe, registered as pre-consumer scrap (which has no footprint assigned to it), avoiding the CBAM.
AV: And this would undermine the very goals of CBAM, namely to prevent carbon leakage and to drive global decarbonisation. This is a challenge high on our agenda, as we work with decisionmakers to close this loophole.
This issue has not been only flagged by us, but by a growing body of industry, think tanks, NGOs and most recently, flagged in the Draghi Report on EU competitiveness. We will continue working with EU decision-makers to make sure that CBAM is fit for purpose.
WC: And that is one of our main goals, to educate. It is important for us to continue working with the decision-makers, but this also extends to our customers’ products and how they then pass down this engagement to their consumers.
Hydro has entered into several partnerships lately, for example with Mercedes and Brompton. These are just two examples of customers who are driving the sustainability agenda.
7.As the year is drawing to a close, what are your thoughts moving to 2025?
WC: We know we are in the squeeze period. The manufacturing indexes are quite low, but I think we are starting to see some of them approaching back to the baseline. Once this happens, and the general economy begins to turn, we expect to see an upturn. Focusing on our recycling side of the business, I think we’re doing a good job, and we are positioned in a way where we have a good balance with our customer scraps supply, and our investments in recycling facilities. We still believe in the long-term picture for recycling and I think we are in a good position to ride this storm. So, I’m not worried.
AV: Moving to our future with primary aluminium, I previously noted that primary aluminium is still important, and that it will continue to be important. We are working hard to reduce the footprint of our primary aluminium, and we are aware that we need to take new steps constantly.
I have spoken about our investments in new technology. Moving forward we aim to further increase the recycled content in primary production, further develop and mature projects related to biogas and green hydrogen to decarbonise our cast houses and more, including development of carbon capture for existing smelters and the new HalZero technology.
There are still a lot of steps that we can take, some of them small and some of them bigger. But to summerise, primary aluminium is still very high on the agenda and will definitely continue to be so, alongside recycling.
.Conclusion
WC: Aluminium is the perfect circularity product. As you know, aluminium can be recycled over and over and over again. We need to continue to work hard to decarbonise our entire value chain, from mine to component – and recycling. Recycling is an integral part of the aluminium industry, and as long as we have good arrangements to be able to recycle and sort the aluminium scrap, it can be turned into products again and again and again and again, for eternity, without losing its properties.
That’s why aluminium will play a big part in the circular world that we want to achieve.
Sustainability and Transparency, Consistently Brought Together
By Dr. Thomas Payer*
At Speira, we believe that sustainability and transparency are two sides of the same coin. Because we want to make it as easy as possible for our customers to decide for the lowest-carbon, most-circular aluminium. As well-informed decisions are the best decisions, that is why we are transparent and consistent about the research, decisions and convictions that guide our product design.
Names differentiate and create identities. This is exactly what we want to do with our products and, around two years ago, we replaced their numerical designations with truly descriptive names. These give our customers orientation and create recognisability. It quickly becomes clear which product it is, where it can be used and what properties it has. For example, the solutions from the AURA product family offer maximum design freedom in the body design, while the solutions from the SOUL product family support the vehicle body from the inside with properties such as lightness, safety and stability. The product groups for beverage cans (VERO), packaging (VELA) and battery systems (ION) are equally memorable.
ORBIS and RIVOS – our certified labels for sustainable solutions
But we have not left it at that. We are constantly working to redefine the limits of aluminium and produce each of our products with the highest possible recycled content. We want our customers to be able to rely on this ambition: Thirdparty certified and at least 75% external scrap use. We created a label for our most circular products that embody resource efficiency and reuse. With unwavering transparency, ORBIS champions a more sustainable future and paves the way to a closed loop. ORBIS is not just a label. It is a testament to our commitment to build a circular world that works!
With a clear focus on the carbon footprint and transparency, we are now taking the next step – again third-party certified and designed to make it as easy as possible for our customers to choose the most sustainable aluminium. By combining external scrap and lowcarbon primary metal, tailored to regional opportunities for sustainable energy use, we maximise resource efficiency and minimise the carbon footprint of our products. We call it RIVOS, bringing us
and our customers one step further to net zero.
Approaches from different ends
So, creating a circular world that works is not only about recycling. At Speira, we aim to be net zero by 2045. That is five years earlier than the Paris Agreement‘s goal. Our scope 1 emissions are expected to hit zero as early as 2040, and our scope 2 emissions even by 2035.
Fig 1
As is well known, the process of recycling aluminium is remarkably efficient, saving up to 95% of the energy compared to primary production. This substantial energy saving directly translates into a significant reduction in greenhouse gas (GHG) emissions, aligning with global efforts to combat climate change.
However, the benefits of recycling aluminium go beyond energy and emissions. Notably, the process requires considerably less water compared to primary production, thus contributing to water conservation. Moreover, by reducing the need for bauxite mining, aluminium recycling offers biodiversity advantages, preserving natural habitats
Always looking to redefine the limits of Aluminium- the recycling experts of team Speira (c) Speira
Mauritz Faenger-Montag**
Ecology Manager, Speira
of External Affairs, Speira
and ecosystems.
Navigating the value chain
The allocation of these benefits in a value chain that includes primary metal and multiple recycling is determined by value decisions and conventions along the value chain. Given that there is no universally accepted ‘best option’ that outperforms all others scientifically, our approach to recycling is driven by a combination of industry standards, environmental conventions, and our unique perspective on sustainability.
Typically, customers of rolled aluminium products place a high value on products with substantial recycled content. This preference is largely driven by the sustainability benefits associated with higher recycled content, which resonates with the environmental values of their own customer base.
Recycled content
As great as aluminium recycling is, the definition of what counts as recycled content in aluminium products is open to interpretation. ISO 14021 defines recycled content as “the proportion, by mass, of recycled material in a product or packaging. Only pre-consumer and postconsumer materials shall be considered as recycled content, consistent with the following usage of the terms:
Pre-consumer material: Material diverted from the waste stream during a manufacturing process. Excluded is reutilisation of materials such as rework, regrind or scrap generated in a process and capable of being reclaimed within the same process that generated it.
Post-consumer material: Material generated by households or by commercial, industrial, and institutional facilities in their role as end users of the product, which can no longer be used for its intended purpose. This includes returns of material from the distribution chain. For the purposes of the calculation, the term ‘product’ refers to the final product as delivered to the construction site and incorporated in the works.“
Not as clear as it seems
The challenge lies in the definition of pre-consumer material: What exactly is “the same process”? Where is the point of substitution? This leaves a lot of room for interpretation and opportunities for greenwashing. Different interpretations include the following:
� Casthouse: The composition is fixed, so every process after casting contributes to recycled content. This approach can make your numbers green but is not very honest.
� Production of intended product: Internal scrap from other product streams (e.g., foil production scrap in can sheet products) contributes to recycled content. Blurry lines of separation for better numbers.
This is how we do it
Instead of focusing only on the best numbers, Speira wants to stand for real commitment and genuine sustainability motives. That’s why our approach to the rather vague definition of recycled content is sharp, and we encourage all producers and supply chain partners to measure, and report recycled content the same way:
� Only external scrap is recycled content and directly contributes to recycled content.
� Internal scrap is composed of recycled content and primary metal (see
below).
We fully agree that other definitions are also applicable. As we are committed to transparency, we are willing to share information about our metal input mix and its composition.
Internal scrap
Not recycled content per default, but containing recycled content:
� For us, internal scrap does not contribute to recycled content.
� Speira‘s input mix of recycled content = Speira‘s output mix of recycled metal content.
� We do not “generate” additional recycled content within Speira.
� Internal scrap, however, is a mix of recycled aluminium and primary metal, depending on the plant’s metal input mix.
� Note that calculating internal scrap as recycled content would result in mandatory negative recycled content for prime-based products, which is difficult to calculate and leads to highly artificial figures.
Fig 2
Our view on environmental benefits Summing up: How does Speira allocate the benefits of aluminium recycling to the carbon footprint of an aluminium product, e.g., a sheet or a foil?
We follow the approach to track the physical reality of emissions as close as possible. Scrap from external sources outside Speira (including our value chain with our joint venture operations) is accounted for the emissions from the recycling process without accounting for emissions that occurred somewhere in the history of this metal. This typically results in emission levels of 0.5 kg CO2e per kg of recycled aluminium.
Internal scrap from our own processes (including our joint venture operations) carries the carbon footprint of the metal input into the process that generated this scrap. In addition, there are the emission from remelting and rerolling, resulting in total emissions slightly above the level of the original input into the plant. Internal
scrap has never been a product, or semifinished product, and for resource and energy efficiency reasons, all measures to reduce internal scrap help to save emissions.
We follow the rules of ISO 14040-44 and ISO 14064. By application of these rules, we differentiate between internal scrap that has been kept in our value chain for internal reprocessing and externally sourced scrap that has previously left our plants and that, with the recycling, starts its second (or third or fourth) life cycle without the historical footprint attached to it.
A call for consistency – for the benefit of partners, customers, and our planet
Ultimately, our primary goal is the reduction of carbon emissions. The methods we adopt, grounded in established standards, to quantify and convey the advantages of aluminium recycling are essential tools in our collective mission to lower carbon footprints.
It’s imperative that we unite to establish a widely accepted, standardised approach for assessing the recycled content in aluminium products. This collaborative effort in assessing, reporting, and promoting the substantial benefits of
aluminium recycling is vital. It is only by working together that our collective efforts to reduce carbon emissions will be fully recognised and appreciated.
As an industry, we’re moving in the right direction. Now let‘s make it count –the right way. �
Commitment to Sustainability: A Journey of Continuous Innovation
By Nicole von der Ropp*
THE Novelis plant in Latchford, a key player in aluminium recycling and processing in the UK, is driving significant sustainability initiatives. With a history of innovation dating back to 1991, the plant has continually evolved, integrating advanced technologies and practices. Recent projects include pioneering hydrogen use in recycling processes, an investment to double the capacity for recycling used beverage cans (UBC) as well as community initiatives. These efforts reflect Novelis’ commitment to reducing carbon emissions, accelerate sustainability and fostering circularity in the aluminium industry.
Heritage and Evolution
The Novelis Latchford plant in the UK has a rich history of innovation and commitment to sustainability, marking several significant milestones over the years. Originally established as a dedicated facility for recycling used beverage cans (UBCs) in 1991, the plant has evolved into a hub for advanced aluminium recycling and processing. This transformation reflects Novelis’s broader mission to lead the aluminium industry towards greater sustainability.
In 2005, the Latchford facility became part of Novelis UK Ltd. A pivotal development occurred in 2006 when Novelis was acquired by Hindalco
Industries, a flagship company of the Aditya Birla Group. This acquisition integrated Novelis into a global network of aluminium production and recycling expertise, enhancing its capacity for innovation and sustainability.
The plant further expanded its capabilities in 2013 with the commencement of the Automotive Casting Centre, which includes a closed-loop recycling system for Automotive. This system exemplifies Novelis’s commitment to circular economy principles by reprocessing aluminium scrap from automotive production back for new vehicles, thereby minimising waste and conserving resources.
In 2016 Novelis partnered with Jaguar Land Rover (JLR) to reduce the environmental impact of its vehicles by incorporating high-recycled content aluminium into their designs. This collaboration led to the creation of a new alloy [Novelis Advanz™ 5F-s5754 RC], containing at least 75% recycled content, and the establishment of a closed-loop recycling system. In collaboration with JLR and transport partners, Novelis established the first closed-loop system with a dedicated round-trip railway service to efficiently deliver material between Germany and the UK. These innovations not only lowered vehicle weight and improved fuel efficiency but also significantly cut CO2 emissions and
* Communications Novelis Europe, Novelis
production costs, earning both companies the prestigious European Aluminium Award.
Hydrogen Trials: Pioneering Sustainable Solutions
Exploring the use of hydrogen in its recycling processes is one initiative announced in June 2023. The first trial, in October 2024, aims to replace natural gas with hydrogen in one of the plant’s furnaces, a move that could significantly reduce Scope 1 carbon emissions, which are direct emissions from owned or controlled sources. Hydrogen, as a cleaner alternative to fossil fuels, holds the potential to reduce CO2eq emissions by up to 90% compared to traditional methods. Novelis joined the HyNet project in 2017, supporting the development of regional infrastructure for hydrogen use and conducting technical feasibility studies. The use of hydrogen in recycling is at the forefront of decarbonisation efforts within the aluminium recycling industry, with the potential to set new standards for sustainability.
Allan Sweeney, Plant Manager at Novelis Latchford, emphasised the significance of this trial: “We are proud to be pioneers in using hydrogen within the aluminium industry. These trials will advance research on integrating hydrogen power into our recycling operations globally, potentially
leading to near-zero emissions.” This technology could be adopted across other facilities, accelerating the industry’s transition to a low-carbon economy.
Boost in Recycling Capacity and Technological Advancements for UBC In July 2024, Novelis announced a major investment of approximately $90 million to double the recycling capacity for used beverage cans (UBC) at the Latchford plant. This expansion is a crucial step in Novelis’s sustainability journey, enabling the facility to recycle an additional 85 kilotonnes of UBCs annually. This increased capacity is expected to come online by December 2026, in time to handle 100% of UBCs collected under the anticipated UK deposit return scheme.
Emilio Braghi, executive vice president of Novelis and president of Novelis Europe, stated, “Of all the recycling players in the European market, Novelis has the highest ambition to maximise recycled content across our product range. This investment underscores our commitment to sustainability, driving the transformation of the aluminium industry towards full circularity.”
The project includes constructing new facilities and installing state-of-the-art
technologies, such as a new dross house and bag houses, along with advanced shredding, sorting, de-coating, and melting systems. These advancements will not only increase the plant’s capacity but also improve its energy efficiency. The new equipment for processing UBCs, will enable the site to operate more efficiently, further reducing its carbon footprint.
Allan Sweeney highlighted the strategic importance: “The investment in Latchford strengthens our position in the UK market as the largest recycler of aluminium. Thanks to technological developments, we can recycle all types of UBC scrap, fostering low-carbon and high-recycled content products that support our ambitious sustainability goals and those of our customers.” In addition to environmental advantages, the investment will also generate 25 new jobs at the Latchford plant, benefiting the local economy and community. Looking at the wider picture, the Latchford plant continues to support an impressive growth in the UK UBC recycling rate which stood at just 2% when the plant first opened (1991) and is now around 80%. Continued investment opens up the potential to move towards 100%.
Community Engagement:
Warrington Town Football Club Novelis is strongly committed to the communities in which it operates. As such, Novelis will be the main sponsor of Warrington Town Football Club and will provide kits for all teams for the 2024/25 season. Novelis and Warrington Town FC have pledged to work together to promote aluminium recycling in the community. The club’s home ground will serve as a platform to raise awareness of the importance of recycling and encourage fans to adopt sustainable practices.
Allan Sweeney, Latchford Plant Manager, expressed his enthusiasm about the partnership, saying that Novelis is thrilled to support Warrington Town Football Club and its community. He pointed out that sponsorship goes beyond football and should promote a culture of sustainability and environmental protection. By promoting aluminium recycling on the ground, Novelis aims to make a positive impact and set an example for other clubs and their supporters.
Novelis Latchford’s investments and initiatives are not just about improving production capacity, they are an integral part of the company’s ambitious vision towards a more sustainable and circular future. The company’s efforts align with global trends emphasising recycling and resource efficiency in modern manufacturing. As the demand for sustainable solutions continues to grow, Novelis’s initiatives at Latchford demonstrating the viability and benefits of integrating sustainable practices. �
Global Aluminium Producers on a Decarbonisation Pathway
By Dr. Subodh Das*
Net Zero is possible
The demand and production of aluminium are growing every year. According to a new report from The International Aluminium Institute (IAI) and CRU, global aluminium demand will increase by almost 40 %, or 33.3 Mt, from 86.2 Mt in 2020 to 119.5 Mt in 2030. It is also expected to increase by about 80% by 2050.
Despite its green credentials and endless possibilities, energy consumption, greenhouse gas (GHG) emission, and waste generation remain the three major concerns for the aluminium industry. Hence, rising aluminium production may result in CO2 levels reaching a dangerous level by 2100 if no substantial action is taken.
The net-zero goal is not an easy target for the global aluminium sector, emitting 8–15 tons of CO2 per ton of aluminium. Despite that, the industry has been working towards decarbonising its operations, taking baby steps towards reducing greenhouse gas (GHG) emissions.
The pathway
Thanks to consumers’ growing environmental consciousness, pressure from policymakers, and global climate goals, global aluminium producers and industry associations are joining hands to decarbonise the industry across its three stages of production.
The IAI acts as a common platform and representing body to bring together global aluminium majors and allied associations for a common goal. The IAI commits to tracking and reporting the member companies’ ambitions and progress in greenhouse gas emission reductions and reporting the aluminium industry’s total global greenhouse gas emissions annually. However, decarbonisation actions and investments are expected to take place at the company level based on the local availability of options and government policies.
GHG emission reduction targets Fig 1. Image: IAI
Major aluminium producers have already announced their long-term greenhouse gas emission reduction target, aiming for net zero by 2050 and an interim reduction milestone by 2030 or 2035. The targets mostly cover Scope 1 and 2 emissions, with a few aiming for Scope 3. Most of them utilise the IAI Aluminium Carbon Footprint as the calculation reference.
Similarly, the Aluminium Stewardship Initiative (ASI) is working towards setting a sustainable standard for aluminium production. The organisation sets a standard for responsible production, sourcing, and stewardship of aluminium across the value chain.
Meanwhile, a report by the IAI and the climate leaders’ lobby Mission Possible Partnership (MPP) called ‘MAKING NET-ZERO ALUMINIUM POSSIBLE’ has underlined an industry-backed transition strategy to decarbonise aluminium. Some of the levers for aluminium industry decarbonisation this report has highlighted are:
� Switching to renewable power
� Maximising aluminium recycling
� Deploying low-emissions refining and smelting technologies
* CEO - Phinix LLC ( skdas@phinix.net )
� Material and resource efficiency
We will explain how the major aluminium producers are planning and executing their decarbonisation roadmaps, which are aligned with these suggestions.
The changing power mix
The global aluminium industry has been working towards shifting to renewable fuels by reducing coal-fired plants and procuring electricity generated through alternative fuels, including hydro, solar, and wind power.
The Primary Aluminium Smelting Power
Consumption statistics from the IAI show a gradual change in the power mix over the last four years, from 2019 to 2023.
The share of coal-based power in primary aluminium smelting decreased from 55.4% in 2019 to 50% in 2023. Meanwhile, the share of hydropower increased from 26% in 2019 to 33.1% in 2023. The increase was primarily driven by China’s shift to hydropower, as the country pledged to achieve peak CO2 emissions before 2030 and carbon neutrality by 2060.
Fig 2. Image: Phinix LLC, Data: IAI
China’s hydropower consumption in aluminium smelting increased to 19%
Fig 1
in 2023 from 10% in 2019, while coalbased power decreased to 72% from 80% during the same timeframe.
A handful of aluminium producers, such as Rusal, Hydro, Rio Tinto, and Alcoa, are already equipped with hydroelectricity due to their geographical locations in Russia, Norway, and Canada. Hydro’s primary aluminium production in Norway is powered by 100% renewable energy, and globally, about 70% of its operations are run by renewable energy.
Simultaneously, the Gulf aluminium producers’ source 100% of their electricity from natural gas produced at local oil facilities. This keeps the CO2 intensity of their aluminium production at around 8tCO2/t aluminium.
The biggest decarbonisation challenge is faced by coal-fired aluminium producers, who see an average emission of 15-20 tons of CO2 per ton of aluminium.
Chinese aluminium major Hongqiao Group has strategised to shift 2.03 million mt of its electrolytic aluminium production capacity to the Yunnan hydropower region. The company already achieved about 1.3 million mt of capacity in Yunnan operations.
Meanwhile, in UAE, EGA became the first aluminium producer to use solar power to produce aluminium commercially. Bahrain’s Alba is currently commissioning an on-site solar project. Simultaneously, Indian aluminium producers Hindalco and Vedanta are increasing their renewable power capacity to decarbonise their operations.
Alcoa Australia, South 32, Aluar, and Press Metal Aluminium are undertaking similar developments to increase hydro/ renewable capacity.
We must understand that hydropower plants are limited, and it is impossible to discontinue all coal-fired power plants. Hence, the sector is considering alternative ways to cut GHG emissions.
The Launch of Low Carbon
Aluminium Products
Several aluminium producers have launched their brands of low-carbon aluminium products in the market. The products are in high demand and are drawing a premium from consumers. Most of the brands utilise a mix of renewable energy, recycling, and alternative smelting technology to produce the products.
All the current green aluminium brands tend to range around 4 tons of direct and indirect CO2 emissions, as defined by the Carbon Trust’s Methodology statement. Fig 3. Image: Phinix LLC, Data: Collected
Maximised Recycling
Decarbonisation efforts go beyond using renewable fuels to cover resource efficiency and circularity.
The IAI’s life cycle assessment suggests that secondary aluminium’s share of
aluminium demand can rise to 54% (81 Mt/y) in 2050. If this can be achieved, secondary aluminium production can address the expected demand growth over 30 years, reducing the role of new carbon-intensive primary production.
Primary aluminium producers worldwide are investing in recycling capacities or increasing the recycled content of their products to reduce the impact of primary emissions.
India’s Aditya Birla Group’s US counterpart Novelis remains a global aluminium recycling leader, which recycled 2.3 million of aluminium in FY2024. Simultaneously, Hydro boosts a recycling capacity of 2 million tons per year. The company will process 0.85 - 1.2 million tons of post-consumer scrap by 2030. The US is witnessing a steady expansion of secondary aluminium capacity production and fabrication spearheaded by Novelis, Hydro, Novelis, Steel Dynamics, and Matalco. In Asia, EGA is constructing UAE’s largest aluminium recycling plant with a capacity of 170,000 tons annually. Further, it also acquired German aluminium recycling firm Leichtmetall and bought an 80% stake in Spectro Alloys to boost recycled capacity.
Simultaneously, keeping recycling at its forefront, the stakeholders in the aluminium beverage can industry are looking at global aluminium beverage can recycling targets of at least 80% by 2030 and near 100% by 2050, up from the present 70%. This was endorsed during the September Climate Week NYC.
Alternative Smelting Technology
The deployment of energy-efficient
Fig 3
Fig 2
technologies and Industry 4.2 innovations has significantly reduced emissions in aluminium smelting.
For example, Inert or non-consumable anodes are made of materials with hightemperature conductivity and resistance to the molten bath. They generate O2 rather than CO2 and PFCs during electrolysis, eliminating the need for anode replacement in Hall-Héroult cells.
Rusal, Rio Tinto, and Alcoa are deploying inert anode technology in different ways in their Greenfield and Brownfield smelters. Elysis is a joint venture of Alcoa and Rio Tinto. The Canadian government supports it, which made its first commercial batch of low-carbon aluminium using inert anode technology at the Alcoa Technical Center in Pittsburgh.
Reference:
Rusal’s Krasnoyarsk aluminium smelter has produced aluminium with inert anode technology with specific emissions of 0.01t/tAl. The smelter has already delivered its pilot batches to consumers.
Beyond this, aluminium producers in the Gulf and China have been modernising their smelters with the latest smelting technology, which is showing significant results in energy efficiency and helping them reduce GHG emissions.
Bottom line
Opportunities for decarbonisation lie across the supply chain, from bauxite mining to closed-loop recycling of endof-life scraps. Passing some UBC deposit laws in non-deposit states can make a huge difference in aluminium recovery in
a country like the United States, which is dependent on secondary aluminium and imports.
Meanwhile, effective recycling of bauxite residue and aluminium dross offers further possibilities for resource efficiency. The industry is also considering landfill mining to recover a large volume of aluminium from landfills, which can be a topic of discussion in another article.
Retrofitting to alternative fuel and technology might not be a short-term option for the industry. However, strategic investment in recycling technologies can make recycled aluminium the new primary in the medium term. The industry must continue collaborating globally with suppliers, customers, and competitors to realise aluminium decarbonisation goals.
3. “The Case for Low Carbon Primary Aluminium Labeling: Methodology Statement to Define the Market Category,” A report by Carbon Trust, April 2020, Page 14
Automatic cutting line to cut aluminum and PVC profiles with 90° cuts
Flexible Minimal setup times through automatic adjustment to profile geometry. Huge cutting area, part lengths of 10-7200mm possible, as well as integration of further processing steps like measuring, marking, deburring, etc.
Fast 18,5KW saw motor, up to 180m/min positioning speed
Precise Saw module servo driven, horizontal saw blade movement, curb widening after each cut, repetition precision of +/-0, 1 mm
The Vital Role of Recycling in Achieving Carbon Neutrality Goals
From the recycling process itself to the innovative technologies supporting it, aluminium recycling offers a myriad of benefits for producers, processors and recyclers alike. Here, Frank van de Winkel* outlines the current aluminium recycling landscape and explains how, by embracing cutting-edge sorting technology, numerous industries can pave the way for a more circular economy.
Aluminium recycling:
A pivotal solution
In an era of heightened environmental consciousness and intensified global sustainability goals, the aluminium industry stands as a dynamic force for positive change. As companies race to reduce their carbon footprints and embrace more sustainable practices, aluminium recycling has emerged as a pivotal solution. This versatile metal – found in everything from beverage cans to aircraft parts – offers a unique opportunity to conserve resources, minimise environmental impact and drive operational efficiencies.
Aluminium exists in two primary forms: cast aluminium and wrought aluminium. Cast aluminium is characterised by its high silicon content, while wrought aluminium contains minimal silicon. When cast and wrought aluminium are combined, the
resulting alloy is primarily used in the production of cast aluminium because there isn’t a straightforward or widely used method to completely remove silicon. This process, sometimes called ‘downcycling’ results in different products than those present in the scrap mix.
The source of aluminium significantly impacts its composition. Scrap aluminium feedstock can be categorised into two main types: post-production and postconsumer. These two categories, though both crucial to sustainable practices, differ significantly in their origins and characteristics.
Post-production scrap, as the name suggests, is generated during the manufacturing process itself. It often arises as byproducts or offcuts in the production of industrial goods such as automobiles, construction materials and appliances.
* Market Strategy Manager – Metal at TOMRA Recycling
This type of scrap is typically in a relatively pure state, having not yet been exposed to general usage.
Conversely, post-consumer scrap originates from the end of a product’s lifecycle. It is generated by consumers who have used aluminium-based products and have subsequently discarded them. This type of scrap can come from a variety of sources, including end-of-life vehicles, households, businesses and public spaces. Unlike post-production scrap, postconsumer scrap is often contaminated with various substances, such as food residues, dirt and other debris.
Recognising these differences in the origins of the scrap allows recyclers to tailor their sorting and processing techniques accordingly, ensuring that the recycled aluminium meets the required standards for various applications.
A primary obstacle in aluminium recycling is the difficulty of separating it from other metals once it has been combined in alloys. With advanced sorting technology, this is now possible
The challenges of aluminium recycling
A primary obstacle in aluminium recycling is the difficulty of separating it from other metals once it has been combined in alloys. Given the vast array of aluminium alloys – with hundreds of different cast and wrought varieties – it is vital to maintain the scrap aluminium as close to its original composition, or at least to the desired composition of the final product.
Different aluminium alloys possess distinct properties, such as strength, corrosion resistance and malleability. By identifying the specific alloy of the aluminium being recycled, recyclers can optimise the recycling process to preserve these valuable characteristics and ensure that material is processed efficiently and cost-effectively. This knowledge enables reprocessors to produce recycled aluminium that is equivalent in quality and performance to primary aluminium, expanding its potential applications and increasing its market value.
Understanding the source of aluminium is crucial for maximising recycling efficiency. By identifying potential contaminants or impurities, recyclers can implement targeted cleaning and sorting methods to remove these unwanted materials. This not only improves the quality of the recycled aluminium, but also reduces energy consumption and minimises waste.
The power of precision sorting
Advanced metal sorting solutions are revolutionising the recycling industry by transforming scrap into valuable resources. These sophisticated systems leverage cutting-edge technologies, such as X-ray Transmission (XRT) technology – a powerful tool used for sorting and analysing materials based on their atomic density – and artificial intelligence (AI) to accurately identify and separate various metals, ensuring high-purity outputs. This precision sorting enables recycled
aluminium to be used as a direct substitute for virgin material in various industries. From beverage cans to construction materials and automotive components, recycled aluminium can be seamlessly integrated into manufacturing processes without compromising product quality or performance. This not only conserves valuable resources, but also reduces the environmental impact associated with aluminium production.
TOMRA’s AUTOSORTTM PULSE is a prime example of such a solution. Leveraging advanced laser-induced breakdown spectroscopy (LIBS) technology, this innovative sorting system can rapidly analyse the composition of metal objects, distinguishing between different types, grades and even alloys, closing another gap on the journey towards full material circularity. This enables high-throughput production of alloy scrap fractions, maximising their economic value and paving the way for a more sustainable aluminium supply chain.
Another key benefit of AUTOSORT TM PULSE is its ability to minimise contamination and subsequently enhance the value and marketability of the recycled materials. The system’s precision sorting reduces the risk of cross-contamination, safeguarding the integrity of recycled materials and ensuring that the recycled materials are suitable for their intended applications.
The high purity of the aluminium scrap fractions delivered by AUTOSORT™ PULSE enables the material to be used in the aluminium melting and production process without downgrading valuable materials. In extensive material testing at TOMRA’s test centers and at customers’ plants, AUTOSORT™ PULSE is consistently delivering purity levels of 95% and above.
Looking to the future
The growing demand for recycled aluminium is being driven by the shift towards lighter, more sustainable
products, particularly in the automotive and construction industries. The shift to electric vehicles has further accelerated the demand for recycled. Government regulations and industry initiatives, such as the EU’s ban on CO2-emitting vehicles and its ambitious Green Deal targets, are also driving the demand for recycled aluminium as part of efforts to reduce greenhouse gas emissions and promote a circular economy.
As many countries and regions strive to fulfill their pledges of achieving carbon neutrality by 2050, the role of recycling in meeting these targets cannot be overstated. Among the various materials that can be sustainably repurposed, aluminium is a particularly valuable resource. Its recycling process offers a significant reduction in energy consumption compared to primary production, leading to substantial cuts in carbon emissions.
Those core industries where aluminium is widely used – such as automotive, transportation and construction – have a unique opportunity to lead the transition to a circular economy, minimising environmental impact and accelerating progress towards carbon neutrality.
The future of aluminium recycling lies not only in recycling production scrap, but also in substituting primary raw materials with secondary scrap. This will require continued significant advancements in processing technologies, particularly in alloy sorting. Some of our customers are already pioneering this approach by implementing our range of advanced metal sorting solutions to facilitate more efficient and precise recycling.
New aluminium eBook
To highlight opportunities that aluminium recycling presents, TOMRA recently published an eBook which also outlines the range of sensor-based sorting technologies that can be used and configured to create a clean aluminium fraction based on recyclers’ specific requirements. �
The eBook can be downloaded at https://www.tomra.com/green-revolution-aluminum
AUTONOMOUS CHARGING & SKIMMING MACHINES
“Aluminium has long been a preferred material from a sustainability point of view, given its combination of being lightweight, strong and recyclable,” said Matt Aboud, Century Aluminum’s senior vice president of strategy and business development. “And because of that, it is expected to increasingly be a key enabler of the green transition.” However, he went on to note that the way that aluminium is produced determines whether aluminium will in fact be a key enabler of the green transition.
Jerrod Hoeft, Hydro’s vice president and commercial transportation and sustainability, agreed with Matt Aboud. He highlighted that the most significant quality that aluminium has is the fact that it is infinitely recyclable, and that due to its corrosion resistance, it tends to last longer.
But despite these advantages, Daria Efanova, head of research for Sucden Financial, noted that its production, especially the smelting of primary aluminium, is energy intensive. She said it is this energy intensity and the significant carbon emissions that have pushed companies in North America, and elsewhere in the world, to make improvements to reduce their carbon footprints.
That being said, the North American aluminium industry has a substantial carbon footprint advantage compared with the rest of the world. Charles Johnson, president and chief executive officer of the Aluminum Association, during a roundtable at the Aluminum Association’s October annual meeting,
Sustainable Aluminum
Aluminium is considered to be big contributor in the push to achieve greater sustainability, this is down to its naturally sustainable characteristics.
North American companies throughout the aluminium supply chain, like their global counterparts, have been stepping up their efforts to be greener and support their customers’ efforts to do the same.
stated that North American aluminium is on average emits produces around 50% less carbon emissions than the global average, and that aluminium production in North America is around 2.5 times less carbon intensive than that seen in China.
But despite that, the North American aluminium industry isn’t resting. At the Aluminum Association’s October annual meeting Henry Gordinier, president and chief executive officer of Tri-Arrows Aluminum and chairman of the Aluminum Association, said that the North American aluminium industry isn’t resting on its laurels. He said that there is still more that needs to be done for the industry to improve its sustainability.
This summer the Aluminum Association released its “Pathways to Decarbonisation”, a North American decarbonisation roadmap which lays out pathways to achieve industrywide carbon emissions reductions to reach the target of net zero by 2050, set by the International Energy Agency (IEA).
Gordinier pointed out that this roadmap isn’t a set document and that it is going to grow and change as transformations and the adoption of emerging technologies come in. He added that that to achieve the IEA’s net zero goals, an “all of society” approach is required. Only a third of the industry’s goals are achievable if we relied solely on the development and implementation of technologies across the aluminium industry. The remaining two thirds require a broad decarbonisation of wider industry, namely the energy sector. “That is something that we could perhaps
By Myra Pinkham*
influence, but not control,” Gordinier noted.
While there have been moves to address sustainability throughout the North American aluminium supply chain, there are clearly differences between the sustainability challenges that upstream and downstream aluminium producers face.
“The majority of the emissions embedded in aluminium is the result of primary production – the production of primary aluminium from aluminium oxide through the smelting process,” Century’s Aboud pointed out. He added that the typical aluminium smelter uses as much power as a medium-sized city.
Aboud continued, stating that a lot of downstream North American aluminium producers, including rolling mills, extruders and fabricators, are moving in the right direction and doing what they can to minimise their own emissions. While these actions, including converting natural gas furnaces to electric furnaces and trying to burn clean hydrogen instead of natural gas, has been meaningful, he maintained that these actions won’t overcome the carbon intensity of the primary metal.
Some, however, question whether that is the case given North American moves to increase recycling rates and recycled content in some aluminium products, which Gordinier said is one of the technologies that is in the industry’s control.
For example, Pierre Labat, chief strategy and sustainability officer of Novelis, stated that not only can you repeatedly recycle
aluminium without any loss of properties, but the process of recycling aluminium uses only about 5% of the energy and emits about 5% greenhouse gas compared to that used in the production of primary aluminium. He also noted that because of its recyclability about 70-75% of the aluminium that was ever produced is still in existence today. Novelis has reduced its carbon footprint by 27% since 2016.
Sucden’s Efanova agreed that the recyclability of aluminium has a big impact on its sustainability pathway, maintaining that by using more scrap, companies need less primary aluminium which will potentially result in as much as a 95% reduction in emissions. And there is a lot of potential for the recycling rate in North America to continue to grow.
Gordinier observed that the Aluminum Association is in the midst of an advocacy push regarding two proposed US recycling bills, the bipartisan Recycling Infrastructure Accessibility Act and the Recycling and Composting Accountability Act. He commented that the implementation of these bills could both improve access to recycling in underserved areas, as well as provide critically important sustainability data tracking.
Optimising the utilisation of scrap material has its obvious benefits; several domestic aluminium producers have been investing in their recycling capabilities. For example, Duncan Pitchford, president of Hydro Aluminum Metals USA and Hydro’s head of commercial – America, discussed the company’s recycling plants and projects: Cassopolis, MI, plant; Cressona, PA; and The Dalles, OR.
Further displaying their commitment to recycled aluminium, Hydro recently announced a joint venture between Hydro’s Alusort and scrap recycler, Padnos. The joint venture is going to be supplying its Cassopolis and Henderson, KY, recycling plants with raw material for large scale production of CIRCAL – a recycled aluminium product with 75% post-consumer scrap content.
Labat pointed out that Novelis also has, and continues, to invest in recycled
aluminium. For example, its new recycling center in Guthrie, KY and an expansion of its recycling center in Latchford, UK. Novelis has also announced that it has broken ground on the first new integrated rolling and recycling plant to be built in the US in 40 years, located in Bay Minette, AL. The facility is due to start up in 2026.
Century Aluminum’s Aboud said that primary aluminium producers are currently looking at how they can “green up” their energy mix. That, he said, involves looking at how they can use cleaner electricity or less electricity to make their aluminium. “The good news is that the North American electricity grid is becoming greener every year with a number of coal-fired power plants being retired or converted to natural gas and a substantial amount of wind, solar and hydro power generation coming onstream.”
Aboud said the impact of that could be seen with Century’s Sebree, KY. While it is in coal country, only about a third of the electricity used there comes from coal. Around a third is produced by natural
gas and the other third from renewable sources – mainly wind and nuclear power.
Matt Meenan, an Aluminum Association spokesman, pointed out that the North American industry is closely watching two developing primary aluminium technologies: the ELYSIS inert anode technology being developed by Alcoa and Rio Tinto, and Hydro’s HalZero process to produce zero emissions aluminium.
As far as ELYSIS is concerned, Rio Tinto announced plans to launch the first industrial-scale demonstration plant in June 2024. The technology has the potential to eliminate all greenhouse gas emissions from the traditional smelting process, instead producing oxygen as a byproduct. The demonstration plant, which will be located at Rio Tinto’s Arvida smelter in Quebec, plans to include 10 ELYSIS smelting pots. It expects to produce its first results in 2027.
Looking at Hydro’s HalZero technology, the company has said it has already successfully tested and modeled the
process at its R&D laboratory in Porsgrunn, Norway, and plans to produce its first aluminium using this process by 2025 and to reach industrial-scale pilot volumes by 2030. The process is based on converting alumina to aluminium chloride prior to electrolysis, emitting oxygen instead of carbon dioxide, therefore eliminating emissions from both electrolysis and anode baking.
Another big player for the US aluminium industry is the US Department of Energy (DOE). The DOE provides grants to decarbonise its industry. Funded by the Infrastructure Investment & Jobs Act (IIJA), bipartisan infrastructure bill, and the Inflation Reduction Act (IRA), these grants are part of the Industrial Demonstration Program managed by the DOE’s Office of Clean Energy Demonstrations.
Of the $6 billion awarded to 33 projects across multiple industrial sectors in the US, four were allocated to aluminium projects. These grants amassed to over $650 million, with the largest grant (up to $500 million) going to Century Aluminum to build a new smelter, which would be the first aluminium smelter built in the US since Century’s Mt. Holly, SC, smelter, which was built 44 years ago.
Aboud said that his company plans to incorporate traditional smelter technology
in the new smelter. But he expects the smelter to be more efficient than current US smelters, given that every generation of pots have been able to run at higher amperages, with newer technology and digitalisation, which results in better efficiencies and yields of aluminium per unit of electricity.
Meenan went onto discuss the other grants awarded to the aluminium industry. $75 million was allocated to Constellium to deploy a first-of-a-kind zero carbon aluminium casting plant at its Ravenswood, WV facility. Around $22.3 million was given to Golden Aluminum to
upgrade its Fort Lupton, CO, facility using the Nexcast process to reduce natural gas consumption, improve process efficiency and recycle more mixed grade aluminium scrap. $67.3 million was allocated to Real Alloy to construct the first zero waste salt slag recycling facility in the US, located in Wabash, IN.
“I’m very excited about the future sustainability of aluminium,” Hydro’s Hoeft said. “It is already a very sustainable product and we are going to continue to make it more sustainable.”
But the industry is also aware that the journey to sustainability is a longterm process. Efanova said, “that is why most of the industry’s goals are for 10 years or longer now.” The industry road map aims to reduce carbon emissions by 24% by 2050 and 90% by 2050.
Aboud agreed, pointing out that it is important to realise that sustainability isn’t a fad and that its change is a process, not an event. That being said, he pointed out that over the past few years those changes have been occurring at an accelerating rate, which is positive as the industry in the US has some catching up to do, especially compared with industry in Europe.
But the greener aluminium becomes the more desirable it will be. �
By Zahra Awan*
The Industry Went to Düsseldorf with an Agenda
The ALUMINIUM world trade fair and exhibition opened its doors on the 8th October 2024. With 20,904 visitors from 99 countries and 819 exhibitors and partners from 50 nations, ALUMINIUM, the three-day event welcomed the energetic aluminium industry, and in response, the industry has responded with significant developments, announcements, and beginnings.
News of all things new “Optimism and confidence were the defining feelings at ALUMINIUM 2024, despite the various challenges in the individual markets,” said Michael Köhler, Managing Director of RX Deutschland GmbH, the event organiser.
“Aluminium remains a crucial factor in the future of many industries worldwide, particularly in the context of decarbonisation. As the leading global event, we are not just a platform; we are a vital driver of innovation and progress.”
Taking the taxi parallel to the river Rhine, we were welcomed by the sound of birds, and the busy excitement of the industry.
Before the event had been officially opened, Hydro announced the appointment of Erik Fossum and Jeff Lehman as the new leaders for its aluminium extrusion businesses in Europe and North America.
This news set the scene for the event; Novelis hosted the official signing of the Novelis and TSR three-year strategic partnership to advance circularity in the aluminium industry on the 9th October. This new partnership was signed by Emilio Braghi, Executive Vice President, Novelis, and Denis Reuter, COO TSR Group.
“We are very proud to publicly demonstrate our strong partnership” –Emilo Braghi, Executive Vice President, Novelis
Aluminium Duffel also exhibited at the event with a stand promoting their new logo and milling installation project. Read more about this in the January/February 2025 issue of AIT.
It became clear that the event was a place for new beginnings and relationships. Another significant first was the first Women With Metal Awards.
Women With Metal
In collaboration with Women With Metal, the UK Aluminium Federation (ALFED) and Aluminium International Today, RX Global ALUMINIUM hosted the Women With Metal awards for the first time.
The awards were launched at the beginning of the year to recognise the achievements of women in the industry and promote equality and diversity, as well as recognise the male colleagues who have shown support for women in the industry. (See winners of the awards in separate box)
“It’s about giving women the space they
*Editor, Aluminum International Today
deserve and showing them, they are heard and supported” - Yasmin Ouiriemmi, Project Manager of ALUMINIUM
It’s all about sustainability The celebratory feelings felt at the show did not, however, mean that the key challenges that the industry face were ignored.
In his speech to the audience, Rob
THE WINNERS OF THE AWARDS WERE:
� Role Model: Negisti Gebreegziabher Gared, N A Y S Aluminium Engineering PLC
� Unsung Shero: Gerd Aalborg Aas Norsk Hydro
� Young Leader: Pia Reuß Speira
� Sustainable & Innovative Leader: Ramona Tosone, AMAG Austria Metall AG
� Male Ally: Carlos André Valim, Alcoa
Van Gils, CEO, HAI commented, “I am sure we will see many partnerships and relationships form from this conference;” but he reiterated the statement made by Paul Voss, Director General, European Aluminium, that “a serious shift for European needs to happen.”
“We are talking about survival” –Paul Voss, Director General, European Aluminium
The industry has faced many challenges over the past few years, and in recent times. In light of this, Paul Voss stated that the industry is currently in need of “survival.”
CBAM was a key topic mentioned across the event. The challenges that the industry face when it comes to understanding what the Cabon Border Adjustment requires, as well as definitions when it comes to measuring carbon emissions highlighted another challenge that the industry faces.
Moving to sustainability, sustainability was at the forefront of the event.
Walking through the halls, most, if not all stands presented their commitment to sustainability. Aluminium International Today spoke with AMOVA SMS Group on automative technologies which increase efficiency and implement sustainable technologies to reduce carbon emissions. Make sure to read this article on page …. Recycling was another hot topic as Aluminium International Today spoke with Hydro on the latest development seen across their European aluminium branches. Read the full interview on page
The event came to a close on the 10th October. The industry saw a number of developments during the show and presented us with a positive outlook for 2025, despite the challenges we face.
RX Global have announced that the next ALUMINIUM show will take place from 6 to 8 October 2026 in Düsseldorf, Germany. We look forward to seeing how the next two years progress. �
Kingfisher Packaging Exhibits Innovative Solutions at UK Metals Expo
In today’s fast-paced manufacturing and engineering landscape, efficiency is paramount. Industry leaders continually seek out the latest technologies to streamline production, reduce costs, and minimise environmental impact. However, one critical aspect of operations is often overlooked: packaging. This essential process can be the missing link in achieving optimal efficiency.
At the recent UK Metals Expo, Kingfisher Packaging showcased their cutting-edge machinery, demonstrating how their solutions bridge this efficiency gap for the metals industry. Their presence at the event highlighted their expertise in delivering innovative and sustainable packaging solutions tailored to manufacturers, engineers, and fabricators.
The lineup on display, including Omegatech® wrapping machines, is designed to meet the rigorous demands of wrapping sheet materials, profiles, extrusions, rods, pipes, and coils. These machines, available in both semi-automatic and fully automatic configurations, ensure a reliable and efficient packaging process – vital for any high-output environment.
Reflecting on the event, George Martin, Director at Kingfisher Packaging said, “It was fantastic to engage with businesses, hearing about their specific challenges and discussing how we can help them overcome them to optimise their packaging processes. It was also great to catch up with existing customers and hear how our machinery has been performing in the field.”
In line with their commitment to sustainability, Kingfisher Packaging also showcased their eco-friendly consumables at the expo, including recyclable and biodegradable packaging materials. Their Autoknot® string-tying machines, which offer an alternative to plastic strapping, were particularly well received by those focused on reducing their environmental footprint.
The event provided an opportunity for Kingfisher to highlight their free consultancy programme, designed to help businesses optimise their packaging processes. As George Martin explains, “Many manufacturers aren’t aware of how much their packaging setup could be improved until we partner with them to offer tailored recommendations. It’s rewarding to see the difference that can make in terms of both efficiency and cost savings.”
No matter the size or sector of your business, Kingfisher Packaging can identify the most efficient packaging solution for you – whether that’s through ready-to-ship machines or customdesigned systems.
Curious about how they can enhance your packaging operations? Simply send your product to their showroom, and they’ll demonstrate the improved process tailored specifically to your needs.
Get in touch with Kingfisher Packaging today to revolutionise your packaging efficiency!
At Hydro, we’re changing the aluminium game by using innovative technology and a higher percentage of post-consumer aluminium scrap to produce premium, recycled aluminium.
Using advanced recycling sourcing and sorting technology, we’re turning your old cans and cars into high-quality, lower-carbon aluminium—helping aluminium-dependent industries like automotive and construction meet their sustainability goals.
Our recycled aluminium products offer the same strength and reliability as primary aluminium, with a fraction of the environmental impact.
By choosing recycled aluminium, you’re investing in a circular economy where the materials of today become the products of tomorrow. Together, we can shape a more sustainable future.
