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10 Bauxite Boom: Responsible mining for People and the Planet
HEALTH & SAFETY
13 Quick to Forget
FOCUS ON CHINA
16 An insightful Keynote
DIGITALISATION
20 EGA: A Digital Future
22 The Unified Namespace for Digital Transformation in the Industry
AUTOMOTIVE
25 Alumobility: Further Lighthweighting the Porsche Taycan
HYDROGEN
27 Hydrogen in the Aluminium Industry
DECARBONISATION
34 European Aluminium Calls for a Real Industry Decarbonisation Deal
36 Aluminium Industry DecarbonisationA Turning Point?
Coming to a close
Welcome to this special digital highlights issue, which features a round-up of popular news, articles and interviews from the past year.
I look to the 2023 editors’ note for inspiration to write this; I’ll begin by quoting: “While the world remains an uncertain and turbulent place, the day-to-day duties and fastpace of innovations, technical advances and general developments across our industry have resulted in one of the busiest and most content-rich years I have seen in my time as an Editor.” – Nadine Bloxsome 2023. Looking back on 2024, this quote is still relevant.
The world has faced unprecedented challenges such as geopolitical tensions and numerous climate disasters. After reflecting upon 2023, the doomsday clock was once again set to 90 seconds to midnight (after moving to this position in 2022). I wonder how close to midnight we will be for 2024?
But despite the several challenges set in front of us, the industry has maintained its commitment to progressing forward.
The aluminium industry has announced new partnerships, investments, projects, and findings that continue to evolve and improve the industry, highlighting the industry ‘s commitment to innovation and sustainability.
This issue has, hopefully, captured the positives of 2024, despite the challenges.
I hope you have enjoyed all the issues brought to you over the past year. Wishing you and your loved ones a Happy New Year!
Ma’aden and Hexagon Partner
Ma’aden and Hexagon have announced their partnership to launch the Middle East’s very first digital mine.
Hexagon’s life-of-mine technology solutions are being successfully deployed at Mansoura Massarah mine, combining sensor, software, and autonomous technologies to enhance efficiency, productivity, quality and safety across the mine’s operations.
Duncan Bradford, Executive Vice President Base Metals and
New Metals, Ma’aden, said: “This partnership strongly aligns with our digitisation strategy, as we work to use the vast amounts of data that we mine to make our mine safer and more efficient. We look forward to working closely with Hexagon to implement and utilise the region’s first digital mine to elevate Mansourah Massara’s operations.”
Nick Hare, President of Hexagon’s Mining division, said: “We are excited to help bring to life
this important shift toward digitisation of the mine, one that holistically leverages intelligent data and automation across workflows to minimise the impacts of mining while simultaneously improving safety, productivity and operational efficiency. This is about co-authoring the next chapter of mining in this region with a partner who shares in our drive toward a sustainable future.”
Novelis Doubles Capacity in UK
Novelis Inc. has announced it is investing approximately $90 million to increase recycling capacity for used beverage cans (UBCs) at its plant in Latchford, UK. The project will increase the facility’s recycling capacity for UBCs by 85 kilotonnes per year, equaling a growth of more than 100%.
“Of all the recycling players in the European market, Novelis has the highest ambition to maximise its recycled content across our product range,” said Emilio Braghi, executive vice president of Novelis and president, Novelis Europe. “Globally, Novelis had an average of 63% recycled content in our products in fiscal year 2024. This investment marks a
major milestone in our ambitious program to further expand our recycling capacity. It underscores
our strong commitment to sustainability as we continue to drive
the transformation of the aluminium industry towards full circularity and lead the market with innovative, high-recycled and low-carbon aluminium solutions.”
The investment includes the construction of a new dross house, three new bag houses, and the installation of state-of-the-art shredding, sorting, de-coating, and melting technologies. The expansion of recycling capacity, as well as the implementation of advanced technologies, will result in an annual CO2e reduction of more than 350,000 tonnes for Novelis Europe.
The project is expected to begin commissioning in December 2026.
Industry Reports Decline in Emissions
New data from the International Aluminium Institute (IAI) reveals that, for the first time, total greenhouse gas emissions from the global aluminium sector did not grow, even though aluminium production grew.
The 2022 data shows aluminium production grew by 3.9% from 104.1 million tonnes to 108.2 million tonnes. However, greenhouse gas emissions from the industry showed a slight decline from 1.13 giga-tonnes CO2e to 1.11 giga-tonnes CO2e, and the GHG emissions intensity of primary aluminium production
(the average quantity of emissions from the production of a tonne of primary aluminium) has been declining since 2019. In 2022, intensity declined by 4.4% from 15.8 tonnes CO2e per tonne to 15.1 tonnes CO2e per tonne.
IAI Secretary General Miles Prosser said: “Our challenge is to reduce emissions while growing production.”
He continued: “The 2022 data shows the effectiveness of work by the aluminium industry to reduce the emissions intensity of production. While much remains to be done, 2022 was the first year that
these intensity reductions offset production growth.
“The transformation needed in the industry to meet global climate targets is much bigger than the early changes we are witnessing. Emissions reductions must be deeper, faster and more widespread, but for the first time, we can talk about heading in the right direction. If we continue to see investment and implementation of low-carbon energy sources and GHG reduction technologies, 2021 could be the year that GHG emissions from the aluminium industry peaked.”
Industrial- scale Demo of ELYSIS™
Alcoa Corporation has announced further progress on ELYSIS™ technology with Rio Tinto’s plans to launch the first industrial-scale demonstration of the breakthrough technology, which eliminates all greenhouse gas (GHG) emissions from the traditional smelting process and produces oxygen as a byproduct.
William F. (Bill) Oplinger, President and Chief Executive Officer of Alcoa Corporation commented, “we are proud to progress the technology initially developed at our technical center to its next phase within the ELYSIS™ partnership. Aluminum plays a critical
role in the world’s energy transition and decarbonisation efforts; with the ELYSIS™ technology, the smelting of this important metal
can also be done without direct carbon emissions.”
To support the industrial demonstration, Alcoa will man-
ufacture the proprietary ELYSIS™ anodes and cathodes at ATC, which will include installing and operating new equipment. Alcoa anticipates benefitting from the learnings of this phase of the demonstration and expects to apply them to future phases in ELYSIS™’s development. Metal produced through the ELYSIS™ process will further improve upon Alcoa’s lower carbon products already on the market, such as the Sustana™ product line.
Rio Tinto has announced it will be installing carbon free aluminium smelting cells using first ELYSIS™ technology licence.
Transforming to a Circular Economy
Speira is investing 40 million euros for additional recycling capacity to drive the transformation of Rheinwerk and achieve a total saving of up to 1.5 million tonnes of CO2 per year at the site.
Boris Kurth, Head of the can business at Speira as well as the recycling and foundry operations at the Rheinwerk stated, ‘over
the past 20 years, we have already built furnaces with leading recycling capacity in Europe and Europe’s most modern sorting plant for UBC scrap, substituting the highly energy-intensive primary production of aluminium. We are consistently pursuing this path and emphasising our commitment to the circular economy with the fourth recycling furnace at Rheinwerk.’
The furnace will be built in 2025. Production is scheduled to start at the beginning of 2026. Speira is also converting the third of four existing casting centres to be optimised for recycling alloys. This will enable Rheinwerk to further reduce its ecological
footprint. Overall, Rheinwerk will then have a recycling capacity that will save up to 1.5 million tonnes of CO2 compared to primary production of the same quantity of aluminum.
The new furnace and the remodelling of the casting plant are step one that will be followed by others.
One third of the phased-out smelter will be home to the new scrap warehouse. This will provide storage space and facilities for sampling incoming scrap and preparing it for melting.
The new recycling furnace will be used to melt aluminium alloys that are processed into beverage cans after rolling.
Alba and EGA Sign Agreement
Aluminium Bahrain B.S.C. (Alba) and Emirates Global Aluminium (EGA) announced the signage of a Technology Services Agreement for Alba’s Reduction Line 6. The agreement encompasses both onsite and remote assistance wherein EGA will provide Alba with technical support services, monitoring services as well as operational consultation. The agree-
ment also covers operational and process audits, technical training workshops, as well as hands-on operation support among others.
Alba’s CEO Ali Al Baqali stated:
“We are excited to build on our partnership with EGA through this technical services agreement as it will enable our human talent to continuously benefit from EGA’s DX+ Ultra advancements and
achieve our sustainability objectives.”
Abdulnasser Bin Kalban, Chief Executive Officer of Emirates Global Aluminium, stated: “EGA’s longstanding partnership with Alba reflects the vision of our wise leadership to deepen the dynamic relations between our two countries.”
Constellium to deploy low to zero carbon technology
Constellium have announced that its facility located in Ravenswood, West Virginia, was selected by the U.S. Department of Energy Office of Clean Energy Demonstrations to begin award negotiations for up to $75 million as part of the Industrial Demonstrations Program (IDP). This investment will support the installation of low-emissions SmartMelt furnaces that can operate using a range of fuels, including clean hydrogen.
Century Aluminum to Build New Smelter
Century Aluminum Company was selected by the U.S. Department of Energy Office of Clean Energy Demonstrations to begin award negotiations for up to $500 million to build a new aluminum smelter. With the help of this funding, Century plans to build the first new U.S. primary aluminum smelter in 45 years. The smelter would double the size of the current U.S. primary aluminum industry.
Constellium receives grant to increase casting capacity
Constellium announced that its facility in Muscle Shoals, Alabama has been selected by the U.S. Department of Defense for an investment of $23 million to rebuild its Direct Chill aluminium casting centre. Constellium will use the funds to install state-of-the-art casting equipment on the site of a dismantled casting center intended to add up to 300 million pounds of annual casting capacity.
Aluminium Duffel: New Milling Installation
Aluminium Duffel announced the start-up of their new milling installation, an investment worth €26 million. The milling installation has a capacity of no less than 400,000 tonnes of aluminium per year.
A milling 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.
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.
“The new brand identity and logo are a promise to our customers and stakeholders and a tribute to our strong team. Every employee is a hero who contributes to our success and future every day. In recent years, we have experienced several acquisitions and defied the energy crisis. Thanks to our team, we got through this period well. There is no better way to honour this than with a strong symbol,” says Koen Libbrecht.
Alcoa to Supply Nexans
Alcoa have announced that it will supply global cable producer Nexans with aluminium produced from ELYSIS™.
Nexans will be the first cable manufacturer to use metal from the ELYSIS™ process.
Several Nexans facilities in Western Europe and Scandinavia will use aluminium produced from the ELYSIS™ process to start qualifications for the metal’s use in various types of cables, from low, medium to high voltage.
This latest announcement further builds on the two companies’ historic long-term relationship.
Since the launch of ELYSIS™ in 2018, the technology company has produced R&D quantities of the metal. Alcoa is marketing and selling its share of the ELYSIS™ metal, which has also been used for the wheels on the Audi eTron GT. Apple is also an investor in the technology and has used ELYSIS metal for some of its products.
Renato Bacchi – Executive Vice President and Chief Commercial Officer at Alcoa stated, “Alcoa is well positioned to supply low carbon aluminium for the world’s transition to renewable energy, as we know that the true impact of decarbonisation will also include the choice of materials used to build the infrastructure for generation, transmission and distribution networks. While we are developing ELYSIS™for the future, we are also supplying low-carbon aluminium today with our EcoLum™metal, which can help customers meet their own sustainability goals and lower their carbon footprints.”
Vincent Dessale – Nexans Chief Operating Officer Senior Executive VP commented, “In the fight against climate change, solutions that support the world’s energy transition make a real difference. By increasing our use of low-carbon aluminium, we want to lead the way toward a sustainable electrification of the world: the rod produced with this breakthrough technology could eliminate a significant portion of carbon dioxide emissions in the future. We are proud to be the world’s first cable manufacturer to use metal from the breakthrough technology ELYSIS™.”
Alunorte Production Using Natural Gas
Hydro Alunorte alumina refinery has started using natural gas in alumina production, replacing fuel oil. When fully completed, six steam generation boilers and all the refinery’s calciners will operate on natural gas.
The R$1.3 billion investment to replace fuel oil with natural gas at Hydro Alunorte alumina refinery will reduce the refinery’s carbon emissions by 30 percent. The fuel switch project is a key step in Hydro’s climate strategy and global commitment to reduce Hydro’s greenhouse gas emissions by 30 percent by 2030.
Alunorte has an expected annual natural gas consumption of 29.5 Tbtu. When the transition from fuel oil to natural gas is completed, the change in the energy matrix at Alunorte will reduce the refinery’s annual CO2 emissions by 700,000 tonnes.
Significant changes have been made to the refinery’s operation to make this transition possible, with focus on automation and process safety.
“We have implemented the most modern technologies available for using natural gas in
our alumina production. We are proud of our contribution to fulfilling Hydro’s decarbonization commitment,” says John Thuestad, Executive Vice President for Hydro’s Bauxite & Alumina business area.
The natural gas used in the process is delivered to Alunorte via a floating storage and regasification unit (FSRU) and import terminal operated by New Fortress Energy. The project replacing fuel oil with natural gas at Alunorte has been an enabler bringing natural gas to Pará and to other projects in the region.
Event Review: Future Aluminium Forum
The Future Aluminium Forum took place between the 22nd – 23rd May in Istanbul, Turkey. The event saw key players and experts come together to discuss innovative technologies pushing the industry forward to a developed future.
“Future aluminium is all about sustainability”- Erol Metin, Advisor to the Board of Directors, Talsad
Commenting on the event, Nadine Bloxsome, Former Editor, Aluminium International Today said:
“I am pleased that we were finally able to host the Future Aluminium Forum in Istanbul, after having planned this before the COVID pandemic. In collaboration with the Turkish Aluminium Industrialists Association (TALSAD) and various stakeholders, the event showcased the latest advancements in digital manufacturing and Industry 4.0 technologies, promising to revolutionise production processes and elevate quality and sustainability standards within the industry.
“We are delighted to report that the Future Aluminium Forum was exceptionally well-received by all delegates and sponsors alike. Their enthusiastic participation
and positive feedback underscore the importance and relevance of the topics discussed at the event.
The Turkish Aluminium Industry “Turkey’s strategic geographic location and thriving aluminium industry provide the perfect backdrop for this regional event. With its steady growth and significant contributions to the global aluminium market, Turkey serves as a hub for both regional and global players, offering a dynamic environment ripe for exploration and collaboration.” – Nadine Bloxsome
Erol Metin, Advisor to the Board of Directors, Talsad, kickstarted the event with his keynote presentation. Breaking down the Turkish aluminium market, he discussed its position in the global market.
Turkey has:
� 1 smelter
� 18 Wrought aluminium producers
� 22 rollers, plate manufacturers
� 122 extruders
� 14 wire and cable manufacturers
� 28 packaging manufacturers
Commenting on the industry growth in turkey, he reported that Turkey’s imports and exports of aluminium have
doubled over the last 10 years. Despite a 14% reduction in exports in 2023, Metin remained positive with regards to the Turkish aluminium’s future. He observed that the reduction was “mainly due to slow down in main export markets such as the EU and US.”
Moving onto decarbonising the Turkish aluminium industry, he said that “total CO2e emissions from Global Aluminium Industry must come down from 1.1 GT/ year to 250 Mt/year; i.e 80% reduction.” In face of this challenge, he came forward to present the audience with an industry roadmap designed for the Turkish industry. The roadmap focused on decarbonisation of electricity with renewables; shifting to electric furnaces; and carbon reductions in the supply chain. He also noted the importance of National Initiatives, and utilising these to the industries advantage.
“The total carbon footprint of Turkish aluminium industry is estimated to be in the range of 22-28 million tons per year,” said Mr Metin.
Looking further into decarbonising the industry he homed in on the key issue, that “86% of total Carbon budget of Turkish aluminium is due to footprint of primary aluminium imports 18-19 Mt CO2 embedded (scope 3) emissions.”
Metin went onto state the importance of assessing each part of the production chain and finding personalised solution for decarbonising each aspect.
Metin concluded his overview saying, “Overall significant shifts yet to evolve in global demand and supply cycle. Türkiye’s position as global semi and finished products manufacturing industry need to maintain the balance between decarbonisation and global supply / demand flows.”
Future of Aluminium: Technology and Data
“The Future Aluminium Forum was conceived with a singular purpose: to explore the transformative potential of digital technologies in the aluminium industry.” – Nadine Bloxsome Technology, like living things, naturally goes through evolutionary processes. Without evolution technology’s purpose would soon be void in the name of industry. Industry 4.0 signifies the latest industrialisation, but it does not represent the possible futures that could be our reality.
Technologies and developments present the industry with exciting possibilities. Hope is often associated with these possibilities; yet, while beneficial, hope can be misleading. Ron Knapp, Adviser, China Hongqiao Group Limited (HK), addressed the industry stating, “sometimes we have to wait for the research to catch up with the technology.” This statement lingered throughout the forum; there is, somewhat, a unanimous understanding that the industry needs innovation, but at a practical industry scale.
Ron Knapp went onto provide insight into the China Hongqiao Group which has seen 100% production growth in the last 20 years. The company currently has a primary aluminium capacity of 6.46 Mt under China’s 45 Mt Cap. Once again, EU and US production decline was mentioned.
Emirates Global Aluminium (EGA), Chief Digital Officer, Carlo Khalil Nizam
heeded this statement and presented real life examples of AI application in the EGA plants. Providing recordings of digital transformation, digitalisation and digitisation, he defined each term while giving examples of “walk[ing] the talk.” Examples included outlining 10 digital capabilities, as well as implementing AI in the use of industrial cranes.
“The main objective of Industry 4.0, at EGA, is to lead the transformation [of EGA] into a smarter organisation. Using the elements of Industrial 4.0 such as, big data, artificial intelligence, internet of things, and many more.” - Abdulla Karmustaji, Product Owner Industry 4.0, Emirates Global Aluminium (EGA).
Industry 4.0 signifies the next steps of industrial revolution. Rather than it being the next natural step, it could be considered to be the next necessary step. Reviewing the global climate, perhaps the unexpected is the only thing we know for certain. Carlo K. Nizam also discussed EGA’s position and its vision for an advanced sustainable future, quoting Darwin for inspiration on the future: “It is not the strongest nor the most intelligent that survives, it is the ones that are the most adaptable to change.”
Adaptability to change is a natural requirement of evolution. So how can technology assist in ensuring we are as
flexible as we can be?
Amadou Ndiaye, Industry Executive Advisor for Energy and Natural Resources, SAP EMEA, discussed “Forging a Sustainable Aluminium Business with Integrated Data and Next Generation Business Processes.” He presented optimisation strategies that can be put in place with the assistance data collection and business technology platforms. With the aid of platforms, one can combine and embed any technology under the umbrella of development, automation, integration, data & analytics, and AI. With this systematic organisation, technology and data can seamlessly work together to develop a better future.
Pernelle Nunez, Deputy Secretary General, International Aluminium Institute (IAI), noted the IAI’s position towards data, emphasising its importance as a way to communicate with both the industry and stakeholders.
“We are on track, but we need to work together to ensure everyone is on the same track,” said Siri Sande, Marketing Manager, Storvik.
To assist one another by aligning the industry on the same path may be one of the ways that help push the industry forward when looking at both decarbonisation and the adoption of new technologies. Looking at technology, Sande explained that to make sure the industry is progressing, “we need to make sure the numbers are real numbers and not just estimates.” She called for a new era of sustainability that is supported by in-depth data. She provided examples of application enhancement with the assistance of data, as well as data collection methods.
But is this a part of the problem? “We talk about pilot projects, but we are stuck at pilots. We need to scale these projects; this is why digital projects fail.” – Denis Gontcharov, Data Engineer. The issue that Gontcharov raises is that that we have this data, but we don’t know how to utilise it. Not only this but data is often
Gontcharov, Data Engineer. The issue that have this data, but we don’t know how to utilise it. Not only this but data is often
spread everywhere. He presents a solution to organise, understand, and use data to progress the industry.
“Introduction of automation is difficult, but necessary” – Marcus Quantillion It seems that for the industry to develop and evolve technological advancement is necessary. For efficiency, economics, and production benefits, progression to industry 4.0 and beyond is almost a no brainer. But what about in the name of sustainability?
Greener Aluminium: Sustainability
“Aluminium’s properties make it essential for a sustainable future,” said Pernelle Nunez.
It has long been known that the decarbonising is an immoveable part of the aluminium future. But the decarbonising roadmap also understand that innovation and new technologies are essential to bringing a decarbonised future into fruition. Amadou Ndiaye declared that the industry must “embed sustainability into its DNA.” But how?
Ron Knapp presented the decarbonisation roadmap of China Hongqiao Group: “We will strive to peak carbon emissions before 2025 and to achieve net-zero emissions in Scope 1 and 2 before 2055,” said Chairman Zhang Bo, China Hongqiao Group. Decarbonisation is on the global agenda. But this does not mean that the method to decarbonise is one size fits all. New energy is one such way for a company to decarbonise, Ron Knapp elaborated on the company’s
new energy projects: Hongtai & Honghe Facilities. Thes projects aim at utilising wind and solar energy, replacing coal. He also noted that solar and wind electricity generation, in China, is cheaper than coalbased electricity. He demonstrated that the call for decarbonising the industry has been heard and is being acted upon.
Pernelle Nunez discussed the IAI global roadmap which aims to unify the industry and direct it toward a greener future. She also encouraged the industry saying that “sustainability issues are complex, evolving and interconnected,” but with the challenges, opportunities arise. But realism must also come into play here. There is surely a point where challenges present barriers that cannot be broken down?
“Costs are also an important factor” –Marcus Oberhofer, HAI
A reality check when it comes to implementing new technology has already been mentioned, but this is also the case for sustainability goals. Understanding the limits when it comes to adopting technology and making changes is important when it comes to making sustainable aspirations a reality.
Oberhofer noted the importance of creating realistic goals within realistic guidelines by discussing HAI’s opposition to recycled content requirements. In certain circumstances, creating limits can restrict development, but also divert attention from the real issue at hand. Oberhofer analysed that the industry is having the “wrong discussion” when it
comes to recycled content requirements. Rather than assist the scrap market, he claims this will result in further issues. He also called for the industry to be careful of greenwashing, which could also hinder the progress of the industry.
“Biggest global threat of today is global warming” - Asís Quecedo, Sales Engineer, GHI Smart Furnaces
So there is a balance that needs to be found for the industry to successfully decarbonise. It seems apparent that technology and data will have a profound influence on the development of the industry, referring to both economic and sustainable goals. But it is down to the industry to utilise the technology to our advantage.
Conclusion
With the warm Turkish sun heating the evening and the light catching the blue sea, the aluminium industry was given a beautiful setting to network by TALSAD. Hopefully the tranquil view reflected the future of the industry. But perhaps more realistically, the sea represented the unpredictable nature of the industry as rain and a grey sea was reported the following week.
“Moving forward, the Aluminium International Today team is committed to sharing the key discussion topics and relevant announcements with our readers across future issues. We look forward to continuing the dialogue and driving further innovation and progress within the aluminium industry.” - Nadine Bloxsome �
• Ultra-Low NOx up to 80% Reduction
• Highest Melting Rate up to 35% Increase
• CO² Reduction up to 60%
• Energy Savings up to 60%
• Short ROI ∼ 12 Months
IPCU (Furnace Pressure Control)
• Long Lifetime Design
• Hands-off operation
• Ultra-low maintenance
• Tailor-made fit
Bauxite Boom: Responsible Mining for People and the Planet
By Matthew Groch*
The rapid shift towards electric vehicles (EVs) is a cornerstone of the global strategy to reduce carbon emissions. However, the surge in demand for aluminium, a key material for electric vehicles, is causing significant environmental and social impacts. This presents a critical challenge in the race towards a greener future with electric vehicles: how can the urgent need for sustainable transportation be balanced with the urgent need to protect communities and ecosystems?
The need for effective ethical aluminium sourcing
The world’s leading automakers are heavily promoting their electric vehicles as a greener alternative given zero tailpipe emissions; however, green motoring means more than just going electric. A critical consideration is the sourcing and sustainability of materials used in these vehicles.
Aluminium is pivotal in electric vehicles production due to its lightweight and durable properties that enhance fuel efficiency and extend driving ranges. As a result, electric vehicles use significantly more aluminium than gas-powered vehicles, with battery electric vehicles using about 85% more aluminium.[1] Currently, car manufacturers account for approximately 18% of the world’s
aluminium production, and this demand is expected to double by 2050.[2]
The demand for electric vehicles is still high
Quarterly electric car sales tend to decrease from Q4 to Q1 each year, leading some to
incorrectly conclude that the demand for electric vehicles is slowing. This, however, is the wrong comparison as it does not control for seasonality. A more appropriate comparison would be to analyse the first quarter of 2024 to the first quarter of 2023. Using this methodology, sales of
Director for
*Senior
Heavy Industry Decarbonisation at Mighty Earth
Aerial view of Hydro Alunorte, a world-renowned alumina refinery. Alumina is the raw material for aluminium and is produced from bauxite ore Credit to: Tarcisio Schnaider
Former bauxite mine in West Kalimantan, Indonesia Credit to: Rdt Radihan
electric vehicles grew by 25%. In absolute numbers, this means that more than 3 million electric cars were sold in the first quarter of 2024, continuing its year-toyear growth trend from 2023, according to the International Energy Agency, an autonomous intergovernmental organisation.[3]
Assuming this growth trend, it’s imperative to plan for a future with high demand for EVs. The challenges associated with aluminium sourcing will not only persist but will also intensify, leading to greater environmental and community impacts. The unrelenting quest for more aluminium derived from mined bauxite has led to real consequences for the communities and environment surrounding the mines. Bauxite is found in the ground, largely under the forest floor. Miners generally use heavy machinery to strip large surface areas to access the bauxite, which can cause significant deforestation if the bauxite is in biodiverse or forested areas, and the runoff from this open cast mining can lead to the pollution of rivers, streams, and other bodies of water.
In addition, the aluminium sector is responsible for 1.1 billion tons of carbon dioxide pollution per year, about 2% of global emissions. More than 60% of the aluminium sector’s emissions are from the electricity, most derived from coal power, used during the smelting process. As a result of turning bauxite into aluminium, current mining practices have uprooted the lives of those living near the mines and the forest floors surrounding the mines.
A review of bauxite mining’s impact on people & planet Mighty Earth’s recently released report, “The Impact of the Bauxite Boom on People and Planet” [4] is the first report to take a global look at the bauxite and aluminium industry by reviewing and combining all available literature on the industry and its impact on people and the environment for four specific countries: Australia, Brazil, Guinea, and Indonesia. Each of these countries have substantial reserves of bauxite, and each country has incorporated their vast reserves of bauxite into its pursuit of economic development. The people living closest to the mines in Australia, Brazil, Guinea, and Indonesia have protested, filed lawsuits, and advocated for better treatment and healthier environments. This report helps amplify the plights of these individuals. In Indonesia, the government passed laws restricting public criticism and protests against mining companies. One such law states that “anyone who hinders or disturbs mining activities by permit holders who have met the requirements …
may be punished with a maximum prison term of one year and maximum fines of 100 million rupiah [$7,000].” [5] Initially seen as a warning, it has been used in practice to silence criticism. In 2021, 10 people were charged with violating this specific provision, out of 53 total people accused of opposing mining companies.[6]
A Bloomberg report found that much of the aluminium used in the Ford F-150 sold in the United States originated from northern Brazil, where a large mining company dominates aluminium production. This company has been accused of toxic metals pollution in surrounding rivers and streams, which provide water and food for locals. According to one estimate, waterways
mining on their communities:
“Complainants state they have witnessed an unprecedented decline of wildlife and even the total extinction of some species in the region. They believe that water pollution as well as the impacts of mining infrastructure, notably mining roads and the railway lines crossing fields and forests, are probably the main causes. The decline of animals and fish has also significantly contributed to the degradation of livelihoods since communities largely depended on fishing and hunting, in addition to agriculture.”[10] Similar destruction is also taking place in Australia, where the Western Australian Government recently approved a mining company’s plan to clear 800
were “at levels 57 times greater than what health experts consider safe.”[7] Byproducts of the mine are so prevalent that medical staff found at least one woman had “175 times the amount of aluminium considered safe in her hair.”[8] Although the company was faced with monetary penalties in the past by the Brazilian government, local residents remain dissatisfied and have filed a lawsuit in the Netherlands.
In West Africa, residents from 13 Guinean villages in 2019 filed an official complaint alleging that a large bauxite miner had violated their rights and did not provide adequate compensation to locals. The complaint was filed against the International Finance Corporation, a division of the World Bank, which provided a $200 million loan to a mining company. [9] Three nonprofit organisations filed the complaint on behalf of the villages, vividly expressing the negative impact of bauxite
hectares a year for mining.[11] This land is widely recognised as the world’s most biodiverse temperate forest, housing 800 plant species and 10 endangered animal species.[12] A new study found that, “The primary cause of deforestation in Western Australia’s Southwest forests is bauxite mining...Bauxite mining has cleared at least 32,130 hectares of publicly owned forest...and fragmented 92,000 to 120,000 hectares of the Northern Jarrah Forest up to December 2019, and the rate is accelerating.”[13]
The impact of bauxite mining and aluminium production in each of these countries – Australia, Brazil, Guinea, and Indonesia are significant but can be mitigated. Automakers purchasing aluminium and government regulatory bodies have the power to drive this change. The demand for minerals such as bauxite and aluminium will continue to increase as they become more important
Red mud - toxic residue of aluminium production polluting the soil on huge area. Guinea, Africa. Credit to: Igor Grochev
in the transition to a decarbonised world. With the rapid increase in electric vehicle production globally, it’s more important than ever to ensure aluminium is sourced responsibly from bauxite mines.
Mighty Earth and other groups are challenging the world’s leading automakers to adopt ethical practices throughout their EV supply chains. Global campaigns around the world have been pressuring the world’s leading industry to invest in environmental sustainability and
take social responsibility in their operations. They are also urging manufacturers to ensure that the sourcing of materials does not come at the cost of human rights or environmental degradation.
There is a path forward for responsible mining of bauxite and the production of aluminium. Electric vehicle manufacturers and other downstream manufacturers can play a significant role in raising the standards for their supply chains, and national and local governments should
strive to ensure their local constituencies are protected from the negative effects of bauxite mining. The transition from traditional vehicles to electric vehicles should reduce emissions and pollution and make the world a cleaner place. It is the responsibility of governments and automakers to make sure that local and Indigenous communities are not made worse off in the transition, and responsible mining means precious forests, peatlands, and the environment are protected. �
Mighty Earth and local climate organisers perform a dance at the NYC International Auto Show, urging Hyundai to clean up their auto supply chains as the industry transitions to EVs Credit to Jeremy Varner
Quick to Forget
By Alex Lowery*
Many in our industry assume large explosions occur rarely and, for the most part, have been prevented from occurring. This mindset unintentionally downplays the seriousness of the hazard in their workplace(s). It exposes their workers and surrounding community to a deadly hazard. This false safety belief is farthest from the truth. Because for the past 23 years our industry has continued to suffer through one or more catastrophic molten metal explosions annually. An explosion killed six workers and destroyed a casthouse in April, 2022. 2023 seemed to be anomaly with no explosion until an explosion occurred in September killing four and injuring thirty workers. Another explosion occured killing two workers two weeks later.
The hazards associated with molten metal are universal and exist in every workplace that processes molten metal. Still some workplaces downplay the severity of this hazard. No other hazard in our industry caused more financial losses than molten metal explosions. Insurance claims over the past 13 years have been filed for over $400,000,000 in the USA because of molten metal explosions. Why is our industry so quick to forget ?
Workplaces fail to acknowledge this
hazard because of a lack of education and awareness. Understanding how molten metal explosions occur can provide a workplace with the knowledge to inspect and identify machinery, tasks or procedures where an explosion could generate.
Industry knowledge of this hazard progressed through the decades of research by scientists around the globe. These research studies formed the foundation for our industry’s best practice toward safety when handling molten aluminium.
Scientists proved explosions occur when molten aluminum reacts with water in either a physical or a chemical reaction. Physical reactions are the most common. They occur when molten aluminum covers
*Author & General Manager, Wise Chem LLC
China 2020
China 2020
China 2022
water or moisture on a bare substrate (e.g., concrete, steel, stainless steel). The moisture expands rapidly propelling the molten metal covering it away. A common example is during transfer of a crucible and some of the contents spill onto a wet floor. When this occurs the temperature of the water rises instantaneously propelling or throwing off molten metal. The flying molten metal creates other hazards when it lands. If it lands on a combustible (e.g., wood, cardboard, etc.), the combustible will ignite. These explosions damage equipment and workers can be injured or killed.
Chemical reactions occur when aluminium bonds with oxygen (forming aluminium oxide) releasing hydrogen (in the form of energy) on a molecular level. Scientists have calculated that the force generated from one kilogramme of molten aluminium is equivalent to three kilogrammes of Trinitrotoluene (aka TnT) exploding. Furnaces in aluminum plants contain 300,000 to 1,000,000 kilogrammes of metal. The explosions can be very large, destroying workplaces, injuring and killing workers and even create shockwaves detectable by seismic earthquakes stations. It should also be noted that in physical reactions the molten metal that reacts with water is unchanged with regards to its mass. If 1000 kg of molten aluminium physically reacts with water, the result is 1000 kg of solidified aluminium. Thi is not the case with chemical reactions. If the same 1000 kg chemically reacts with water, the 1000 kg instantly transforms to aluminum oxide. This is why after chemical reaction explosions a large mushroom cloud of aluminium oxide generating from the workplace occurs. The aftermath of the site will also look like it is covered in snow because of the aluminium oxide.
In 1980, the Aluminum Association started the Molten Metal Incident Reporting Program. It arose from a request within the industry to develop
a programme where companies could learn from one another on an anonymous basis about molten metal explosions that were occuring. For the past 42 years, this programme has been a valuable safety tool for companies around the globe. There are currently 200 reporting plants worldwide that forward a detailed report when they experience an explosion in their workplace. The Aluminum Association states that the MMIR might catch less than 10% of all incidents. Regardless, this programme is a great resource for educating plants on trends in our industry. All reporting companies receive a detailed annual report listing where in a workplace the explosions occurred (e.g., melting, transfer, and casting).
During the melting phase explosions have been recorded that included scrap, sows, alloy addition, ingot/t-bar, others. Scrap is a growing source for raw material throughout our industry. Scrap can be divided into two categories, internal or
external. Internal scrap is material that was generated internally within the workplace and kept undercover. External scrap is either material received from outside the workplace or internally generated scrap that was stored outside and exposed to the elements. “Careful scrap inspection, storage and, where appropriate preparation, are vital to prevent molten metal explosions and other mishaps. A concern with scrap shipments is that hazards may be hidden or buried and difficult to discover.” states the Guidelines for Aluminum Scrap Receiving and Inspection Based on Safety and Health Considerations. This document is a useful resource on identifying the variety of hazards involved in scrap.
In addition to scrap causing explosions, sows, ingots, t-bars and RSI (remelt secondary ingot) can cause explosions too. For sows and RSI, the process of molten metal cooling in mould can result in a shrinkage cavity. Shrinkage cavities
Norway 2017
Brazil, September 2023
form during the cooling process when the outermost surfaces of the metal solidifies while the center remains molten. Overtime a shrinkage cavity can collect moisture. If a sow or a RSI is charged into a furnace without properly drying moisture in the shrinkage cavity an explosion can result. One workplace reported a sow’s shrinkage cavity with a volume of 19 Liters.
The Molten Metal Incident Reports recorded over 1000 explosions during the casting phase of the direct chill (dc) process and during casting sows. These explosions have been reported at the beginning of cast, steady state and at the end of the cast. Hand tools and tools used by vehicles have been reported to be a source of an explosion. If a tool is “wet” an explosion will result. The MMIR has reported more than 116 reported explosions from “wet tools” over the past 45 years. Tools can become wet either through exposure to moisture (e.g., stored outside, or near an open door) or when the tool comes into contact with chemical salts. All tools, no matter their size, should be preheated prior to use to prevent explosions.
Over 850 molten metal explosions were reported during the transfer phase. These explosions occurred in drain pans, troughs, crucibles, and on floors. The causes varied from wet floor/spill, wet refractory or tools, and wet/rusty drain pans. Drain pans are an overlooked area that have generated a considerable number of explosions. The MMIR lists 357 reports of explosions from drain pans over its history.
There has been one or more force 3 explosions annually in our industry over the past 22 years. The root causes for these explosions vary but many share a common characteristic of molten metal escaping from its holding spot. Molten metal flowing uncontrollably from a furnace leak, trough overflow, bleed out on a casting table, etc. is a workplaces worst nightmare. An explosion may result when molten metal comes into contact with a surface not coated with an approved safety coating. Workplaces need to properly maintain the safety coatings that are applied on steel substrate (e.g. casting table), concrete (e.g, casting pit, adjacent maintenance pit, under furnaces, etc.), and stainless steel (e.g., casting pit and tooling). The history of our industry changed when the Aluminum Association (USA) spearheaded an industry wide effort to research molten metal explosions in 1968. It was through that initial research study and subsequent studies of specific coatings to prevent molten metal explosions in our workplaces was developed. The Aluminum Association’s “Guidelines for Handling Molten Aluminum” lists four coatings that were tested and “found to be effective in preventive molten metal
water explosions where molten metal comes into contact with water with steel, concrete (or stainless steel) following bleedouts and spills during bleedouts and spills during dc casting”. These approved coatings are Wise Chem E-212-F, Wise
USA, 2016
Chem E-115, Carboline Multi Gard 955CP, and Courtaulds Intertuf 132HS products. This hopefully clarifies that other coatings currently in the marketplace, such as Chemglaze and Lord’s E212, as far as I know, have never been tested by the industry and should not be recommended to for use anywhere near molten metal in our industry. If it has been tested and approved, I welcome correcting my statement. In addition, it was noted in the Rustoleum Red coating, that it “did not prevent explosions”. The elimination of untested coatings in our industry will make casthouses safer, as well as protect workers from injuries and fatalities.
The maintenance and reapplication of the approved safety coatings is required because the coatings wear away after repeated molten metal contact. The bare substrate beneath the coating eventually becomes exposed. Scientific studies proved that the minimum bare area to generate an explosion on a steel substrate is 5 cm x 5cm, on concrete it is twice as large. Periodic maintenance of the safety coatings should be completed and recoat of the casting pits every 16-20 months, and tooling every 12-16 months.
Each and every molten metal explosion that destroys an aluminium plant may result in the injury and death of workers and nearby residents. Through the Molten Metal Incident Reporting Program past incidents can be used to prevent future recurrences when workplaces use MMIR’s annual report and inspect their plant for similar hazards. It is hoped that the current record of 23 years of catastrophic explosions will finally be broken. �
Records are made to be broken. Historical forgetting is rarely accidental.
India, September 2023
South Korea, February 2023
An Insightful Keynote
Following an insightful Keynote presentation at the recent Future Aluminium Forum (FAF), Nadine Bloxsome* spoke with Ron Knapp** from China Hongqiao Group, a leading global aluminium producer based in China, to find out more about the company’s long-term goals and how this aligns with a focus on sustainability.
The environmental and commercial challenges for aluminium producers are growing as the consumer – and the global community – expect higher standards of responsibility throughout the production cycle.
Some aluminium producers have had the benefit of being in countries/regions with access to low-carbon sources of electricity, providing a strong foundation for a low carbon emissions production profile. Other producers have been developing in countries/regions where
1.
the electricity and energy supply has been dominated by fossil fuel sources, resulting in a carbon emissions footprint as much as four to five times higher. An obvious example is that of China, where historically coal has been the backbone of the energy supply for industry – India and Australia have similar coal-energy legacies to address in the modern era of cutting carbon emissions as a key element in the fight to address climate change.
In the case of China, now the leading producer in the aluminium industry,
the focus often points to the energy component and the sheer size of the industry with more than 50% of global primary aluminium production. But there’s more to the China aluminium story than just energy. At the recent Future Aluminium Forum 2024 in Istanbul, Turkey, I caught up with Ron Knapp from China Hongqiao Group and asked him about the approach being taken by the company in addressing the challenges facing a major Chinese aluminium producer.
Nadine Bloxsome (NB): Ron, welcome to Istanbul and the 2024 edition of the Future Aluminium Forum! The China Hongqiao Group is one of the largest aluminium producers, not just in China but globally with over six million tonnes of annual production of primary aluminium and 19 million tonnes of alumina. Your FAF presentation showed a commitment to achieving both peak carbon and net zero carbon goals – how will China Hongqiao meet these goals . . . is this achievable by an aluminium producer based in a country traditionally sourcing its energy for aluminium production from coal-fired electricity?
Ron Knapp (RK): Good question, Nadine! From our size and our main production base in Shandong Province, there should be no surprise that we have the biggest carbon footprint in the whole global aluminium industry, but not the most carbon intensive – and let me comeback to that in a minute.
China Hongqiao has several advantages to help us to offset our obvious disadvantages – these advantages will enable us to address the first steps in our carbon abatement challenge and set us on the pathway to the attacking the harder parts of the task. We can’t achieve it all with the wave of a magic wand – it will take time and it will require more research success to give more solutions and
opportunities in fixing the future steps… the Future Aluminium Forum in action!
Looking at our China Hongqiao advantages, the first simple advantage but a key to delivering outcomes is a combination of our ownership, management and workforce. We are spin-off from Shandong Weiqiao Pioneering Group following Weiqiao’s entry into the aluminium industry in 2001; China Hongqiao is listed on the HKEX (Stock Code #1378). People use Weiqiao or Hongqiao in conversation, given our heritage and because Weiqiao is the majority shareholder of China Hongqiao with over 60% shareholding.
Our ownership, with Weiqiao holding a majority of the shares provides a strong
leadership and management structure for the company; Chairman and CEO Zhang Bo is also the chairman of Weiqiao. The workforce is highly committed to delivering positive results for the company and the local communities where the majority of our workforce reside. Zouping/ Binzhou (Shandong Province) takes on an aluminium family characteristic, with a large number of big and small enterprises associated with the aluminium cluster business model that has been a central feature of the Hongqiao organisation from the very beginning. More than 150 enterprises are involved in the cluster, including suppliers and customers as well as a wide range of service providers.
Ron Knapp
2.
NB: You talk about aluminium industry clusters – what is the role or purpose of the clusters?
RK: Here is one of the simplest of concepts and one of the highly valuable parts of the China Hongqiao business model. The most obvious element or contribution comes from the high percentage of aluminium metal delivery to our customers as hot molten metal. Both the producer and consumer receive an advantage. Over 90% of all our aluminium metal is delivered as hot molten metal, reduced cast-house requirement on our side and reduced energy requirements for the customer to remelt their aluminium metal supply. Multiply the per tonne saving by, say, five million tonnes for example – and there is a great saving in energy and another small contribution to lowering carbon emissions.
3.
NB: The Weiqiao carbon reduction roadmap covers a full swathe of actions to be applied to the China Hongqiao operations – how do you see these actions evolving and in what order will they be introduced?
RK: Our Chairman, Zhang Bo, has publicly committed to meeting our responsibilities under China’s dual carbon goals and we will strive to peak carbon emissions before 2025 and to achieve net-zero emissions in
Yunnan Province – this is an energy and environmental game-changer, from coal to clean energy. The Yunnan Hongtai & Yunnan Honghe projects are in line with government objectives to optimise the
Scope 1 and 2 before 2055.
This is a very serious commitment and obligation for our company… we have this very big (total) and heavy (intensity) carbon emissions challenge to deal with across our operations, from upstream through midstream to downstream. Our programme of carbon reduction across our production activities and new aluminium alloys and products will also help the carbon balance of others because we see these actions will be helping consumers face lower Scope 3 emissions. It’s about increased aluminium use and new applications, combined with lower carbon emissions in the aluminium we produce.
Looking at the Weiqiao Carbon reduction roadmap, you will see one of our first priorities is the task of changing the energy structure of our business, particularly the fuel source for the huge electricity consumption required to produce our six million tonnes of primary aluminium metal.
The most dramatic shift in the Hongqiao story is the project currently underway of relocating 60% of our primary aluminium capacity from Shandong to
aluminium industry through supply side management, and to promote green development.
2023 brought a new achievement with production from our Yunnan Hongtai complex achieving one million tonnes. That’s a great boost in moving our energy transition towards our long-term goals.
But we know these are first steps in our journey. By 2026, we will have four million tonnes of capacity located in Yunnan. To complement these moves, Weiqiao has a renewable energy work programme for the development of 13 GW of wind and solar PV across Yunnan Province and Shandong Province. We’re not standing still and waiting to see how things happen – our Chairman Zhang Bo is driving forward to ensure success.
Several of the elements of our net carbon emissions are being progressed concurrently. While it is easy to see why energy is often spotlighted on centre stage, given the size of its contribution to our carbon footprint, we are very active in enhancing operational efficiency and technological advancements. Our lightweighting centre is a major growth segment in the company – and the circular economy is very much in focus with our new recycling facility with capacity to disassemble 100,000 vehicles per annum as the opportunities for such activities grow with the NEVs and higher volume of aluminium scrap available from the vehicle fleet reflecting increased aluminium content.
4.
NB: Where are the yellow warning flags – or even red flags – that need more work before solutions can be found and introduced?
RK: The aluminium industry must keep working on more solutions; we do not have all the answers yet. I immediately think of the carbon anode in the electrolysis segment of the operations –it’s not the “big ticket” item for the whole global aluminium GHG emissions budget, that honour remains with energy but for some producers who already have low- or
introduce the most technically advanced processes in our smelter pot rooms and throughout the production process. This provides us with first class energy efficiency, with the latest 600kA potlines down at sub-12,400 kWh per tonne of aluminium. With this comes a huge energy saving…for example, the average energy efficiency for the North America
zero-carbon energy available, the anode has more GHG emissions prominence in their total GHG emissions. As we pull down the energy emissions number which currently accounts for some 75% of the total aluminium cradle-to-gate GHG emissions identified by the IAI, the 13-14% share attributed to the anode production/consumption segment will increase in significance in the race to net zero. The answer is a new technology breakthrough that can be commercialised, or an additional burden will be placed on negative emission technologies, such as Carbon Capture, Utilisation, and Storage (CCUS).
While the research continues into the alternatives, we are continuing to
and European regions is around 14,000 kWh – that gives us a 1,500 kWh per tonne advantage and a saving to be able to continue R & D investment and further upgrading of production units.
Our smelter fleet is less than 10 years old – and with daily output of around 4.5 tonne of aluminium metal per pot from our 600 kA smelter potlines, this brings further operational efficiencies.
These factors help us to have a per tonne carbon emission lower than the average for aluminium production where coal-fired electricity is the energy input.
Often, aluminium is characterised as one of the sectors that is hard-to-abate, due to the production process involving carbon and the energy input required.
NB: Ron, look into the crystal ball and tell what you see for aluminium and China Hongqiao
RK: An easy one to finish with! A very positive future for global aluminium, with ongoing growth in supply coming from primary and recycled sources – and demand coming from traditional and new innovative applications. China Hongqiao will accelerate sustainability and efficiency outcomes, with the commitment of ownership, management and workforce. We will continue to strive to be the best – and always continue to improve our environmental performance, hand-in-hand with our commitment to the delivery of globally competitive aluminium metal and products. Efficiency, industrial clusters and innovation remain critical elements for the delivery of our vision for the future – and this is reflected in Chairman Zhang Bo’s approach in building a platform for the integration of science, education, innovation, and production - and to promote industry-education integration and industrial innovation to accelerate high-quality development…linking technological and commercial worlds for better outcomes.
5.
NB: What’s next for the Group?
RK: Next is already with us and is being developed and rolled-out …it’s the aluminium lightweighting developments and NEVs, - the next evolution of the Weiqiao Pioneering Group. First it was textiles and the start of the journey, then in 2001 the birth of the aluminium leg of the family.
Twenty years later and with very different commercial and environmental opportunities, a new industrial evolution is emerging and quickly taking shape, drawing several key strands or elements together into a new pillar of activity of the Weiqiao Group.
Recognising the pull of a changing market, Weiqiao has been building an aluminium lightweighting centre, combining vehicle component production and new growth areas created by intense research and development activities. The new pillar, or third leg, of activities also includes recycling facilities to strengthen our march into the circular economy –the Sino-German Hongshun Technology Industrial Park including the China Hongqiao-Scholz JV vehicle dismantling and recycling aluminium production technology facility is all part of the development now underway.
The next step was the acquiring of a majority shareholding by Weiqiao in the vehicle production plant known as BAW or Beijing Auto Works.
With these different elements, we now have the start of the next cluster of industries being combined to build efficiency through co-location of different activities and economies of scale enabling a wider net production across the industry.
In May 2024, Weiqiao-Hongqiao Chairman Zhang Bo joined with his peers in celebrating the delivery of the first batch of REACH NEV aluminium vans, part of the commercial vehicle plan which will include heavy trucks, commercial vans and passenger buses.
The Weiqiao lightweight strategy runs through the entire vehicle development process – and supported by vehicle development standards system, automotive grade aluminium alloy technology development standards and technology patents.
Weiqiao New Energy Vehicles will become a key element in our drive towards sustainability. Primary and recycled aluminium will be partners in these developments.
A modern 600kA smelting pot room part of the China Hongqiao aluminium cluster in Binzhou, Shandong Province
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.
The Unified Namespace for Digital Transformation in the Industry
This article presents the author’s learnings from five years of performing digital transformation in the aluminium industry. The focus lies on highlighting the common pitfalls encountered. Subsequently, the concept of the unified namespace is introduced as a solution to common data-problems in aluminium manufacturing. Finally, a concrete approach of how to build a unified namespace at your plant is presented. The goal is to have a running system that solves a common manufacturing use case within three months. By
Denis Gontcharov*
Why Becoming Digital Matters
The aluminium industry is conservative and therefore slow to adopt modern digital technologies. Nevertheless, by now there’s a consensus that the industry has to digitally transform in order to stay competitive in the future. Various challenges such as artificial intelligence, automation and sustainability and decarbonisation demand a more rigorous use of the vast quantities of available data. However, processing vast quantities of data is easier said than done.
“Saying aluminium+++ manufacturers have an abundance of data is like saying the earth’s crust has an abundance of aluminium.”
Most Data Projects Fail
Many manufacturing companies have already started their digital transformation journey. The focus was often on implementing various industrial use cases, for example preventive maintenance or image analysis. Unfortunately, the results of many of these use cases were unsatisfactory. In fact, according to a 2021 study by the McKinsey consulting company, 69 percent of digital transformation projects fail. According to the author’s experience, the two most
common reasons are exceeding the project’s budget and being stuck in “pilot purgatory”.
Projects Exceeding the Budget
Most digital projects that go over budget do so because the time to complete the project turns out to be much longer than initially planned. Nearly always, the reason is that the part of “getting the data” takes much longer than expected. Data is often assumed to “just be there” and little regard is given to the often messy state in which this data is stored.
Projects Stuck in Pilot Purgatory
The second way in which a technically successful digital use case fails to deliver on its promises is by not being scalable. Often, there’s a wish to roll out successful solutions of one plant across the other plants. Assuming the new solution is merely a copy, this challenge appears trivial.
However, the data infrastructure always differs slightly between two plants. This means that each roll out requires some modifications to the way data is fed. In practice, these modifications most of the time turn out to be substantial. In that case, the roll is often abandoned.
The Two Underlying Data Problems
Why do unsuccessful projects fail because they go over budget, and successful projects are stuck in pilot purgatory? The devil is always in the details: there are two main problems plaguing your data.
First, the various required data sources are never found in one place. After all, a manufacturing plant consists of many individual software systems that only communicate with each other through laboriously constructed point-to-point connections. Combining disparate data sources into one collection suitable for data analysis therefore requires a connection to each individual source system.
Second, technically having all data in one place does not yet solve the challenge of finding this data, if the data was already hard to find in the source system.
The company you work for may have a data lake or data warehouse that contains data from various source systems. But how do you navigate this large data repository to find a particular variable? More often than not, the data model (i.e. the structure under which the data is saved) is an exact copy of the data model in the original source system. This requires the person looking for the variable to have an intimate knowledge of the original
*Denis is a data consultant who helps aluminium manufacturers break down data silos.
source system’s data model, which is unlikely if the person has no experience working with this system in the first place. In consequence, the data lake or data warehouse are difficult to work with: people are simply getting lost in there.
The Unified Namespace
The unified namespace is a software architecture that addresses the two data problems raised in the previous chapter. Before delving into how the unified namespace solves both problems, the concept is illustrated on a high level in Fig 1
The philosophy of the unified namespace entails collecting all data of the entire company in one place, and making it available to anyone who needs it in an easy-to-understand way. In technical terms, this means building a single source of truth where data is organised in a semantic hierarchy. Both concepts are further detailed below.
A central idea in the philosophy of the unified namespace is the separation of process control and data analytics. The former is already handled by the various layers of the so-called “automation pyramid”. The unified namespace strives to be a parallel system to support the latter. This separation is important because it allows a plant to implement a unified namespace without risking interrupting production. In addition, the original control systems of the automation pyramid don’t need to be upgraded.
Single Source of Truth
By connecting all data sources of the enterprise with the unified namespace, it becomes the single source of truth for all real-time information of the business. This way, any use case (e.g. a new software application) that requires data will only have to implement one connection: from the application to the unified namespace. In the case that the application produces new data on its own (by processing data coming from the unified namespace), the application will write this data back
to the unified namespace. This way, the unified namespace can supply this data to any future application requiring such data. This approach guarantees that each new application requires only one new additional connection (to the unified namespace).
Semantic Hierarchy
Up to this point, the unified namespace may not look much different from the data lake and data warehouse mentioned earlier: both strive to be the single source of truth. The crucial difference lies in the way data is stored in the unified namespace, i.e. the data model. Where the latter solutions simply replicate the original data model of the source system, the unified namespace organises its data in a semantic hierarchy.
Simply put, this means that all data in the unified namespace is organised according to a hierarchy of subsequent levels that reflect the actual structure of the enterprise. This hierarchy is not arbitrary, but instead derived from the ISA-95 Part 2 specification, acting as a standard across the globe. Any data analyst with a basic understanding of manufacturing will be able to find a variable by navigating down the hierarchy.
The following example illustrates how a particular value belonging to a certain machine can be found within the semantic hierarchy:
Imagine a fictive primary aluminium smelting enterprise “Aluminium Smelting Co” with a smelter located in Iceland. An engineer is interested in the “pot voltage” of pot number 124 on potline 1 of the electrolysis area of the plant. The pot voltage will be found under:
• Aluminium Smelting Co
• Iceland smelter
� Electrolysis area
� potline 1
� pot number 124
� pot voltage
The “raw data” tag contains all the raw process values coming from the machine, in this case electrolysis pot 124.
Getting Started with a Unified Namespace
Let’s say you want to try out the unified namespace at your plant. How do you get started? The approach suggested below is straightforward to implement. It does not require any financial budget if completed fully in-house, and can be completed within three months with one dedicated engineer and support from the in-house IT department.
A common use case in manufacturing is the calculation of the Overall Equipment Effectiveness (OEE) of a given machine, e.g. a rolling mill. Calculating the OEE requires data from only two source systems: the process data coming from the machine (most often found in the process historian) and the Manufacturing Execution System (MES). The project consists of 1) deploying a unified namespace 2) connecting the machine and the MES to the unified namespace and 3) calculating the OEE.
Instead of building a unified namespace from scratch, it’s recommended to deploy the open-source solution provided by the [United Manufacturing Hub](https://www.umh.app/product). Their product is free to use for commercial purposes and already implements the OEE calculation for a given machine. This way, a use case demonstrating the merits of a unified namespace can be developed in minimal time and risk
Conclusion
This article highlighted that most digital transformation use cases fail because of two data problems: the data not being in one place, and data being hard to find. The unified namespace offers a solution to both problems via its single source of truth and semantic hierarchy, respectively. It’s important to note that the unified namespace does not require changing the existing systems at the plant. Rather, the automation pyramid is extended by the unified namespace, who becomes the single interface for all data in the enterprise. This greatly facilitates data analytics without jeopardising process control. The presented use case to calculate the OEE of one given machine presents a quick-win to implement a unified namespace and convince the plant’s leadership of the merits of this approach.
If you would like to know more about the unified namespace, have a look at the [website of Denis Gontcharov](https:// gontcharov.eu).
�
Image source: United Manufacturing Hub, Unified Namespace, https://www.umh.app/
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Alumobility:Further Lightweighting the Porsche Taycan
Zahra Awan* spoke with Prof. Mark White** on the project, its outcomes, and the future of BEVs.
In 1939 Porsche released what is considered its first vehicle, the Porsche Type 64. Perhaps considered to be one of the most iconic and well-known sports cars, the Porsche 911 was released in 1964 featuring a 2.0-litre, flat-six making 148 horsepower and 140 lb-ft of torque. In 2019, Porsche moved from a traditional Internal Combustion Engine (ICE) and released its first Battery Electric Vehicle (BEV), the Porsche Taycan. To date the Porsche Taycan production volume is > 140,000.
An Alumobility-Porsche cooperation came together to further develop this milestone vehicle. A theoretical case study focused on converting the existing steel-intensive mixed-material body Top Hat structure of the Porsche Taycan to an all-aluminium Top Hat. This study would result in approximately 40% weight savings against the steel reference parts, while also maintaining the attributes for safety, body stiffness and performance. The project demonstrated that aluminium-intensive vehicles offer manufacturing efficiency opportunities by reducing the number of parts, joint types, and total joint count. In addition, it was determined that recycled aluminium would lower lifetime emissions compared to the steel Taycan reference.
The Porsche Project: How did the joint study come about?
The importance of lightweighting for Porsche, therefore, becomes clear (Table 1).
Providing a realistic answer for the solutions to become a reality is essential for a sustainable future. “Alumobility demonstrates the significant benefits in converting automotive steel components and systems to aluminium, but it also shows how this can be achieved at an automotive industry level,” said Prof. White.
“We are moving towards more electrified vehicles, whether they are hybrids or fully electric, and that tends to come at a cost of weight because the batteries are heavy. To get the full benefit from hybrid and electric vehicles, beyond reduced tailpipe emissions, lightweighting is key.” – Prof. White
Table 1
*Editor, Aluminium International Today **Technical Director, Alumobility
Alumobility was approached by Porsche while showcasing the results of their fifth project: A Vehicle Conversion of the Genesis GV70EV from a Steel intensive mixed material Body to an all-Aluminium Design. And so, the study collaboration was born.
The project looked at the lightweighting of the Top Hat (See image) with the aim of replacing all steel components with aluminium alternatives, without compromising any performance. The current production Taycan Top Hat body structure is mixed material with a total weight of 158.3 Kg. 63% of the Top Hat is made of steel; “it was our job to convert all that steel into aluminium to not only save weight, but to also reduce complexity,” Prof. White.
The project began in Q1 of 2023 and was a nine-month project.
When asked how Alumobility worked with the team at Porsche, Prof. White explained “We worked hand in hand with the Porsche engineers both in the body department and in the simulation department. We had weekly reviews throughout the project; we worked together.”
Reducing 40% of weight from the Top Hat 111kg of the 158kg current production Taycan Top Hat is steel. With the full aluminium concept Top Hat, the total weight is less than 120 kg.
Prof. White explained that the study was broken down into two phases. The first phase was to take the existing architecture, the existing panel make up, and number of joints that the existing car body had and convert it into aluminium.
“But we went on and completed a further study which looked at redesigning the car body [with ‘design for aluminium’ as a consideration],” said Prof. White. When optimising the vehicle Top Hat with aluminium production in mind, “rather than copy and pasting the steel car body,” a further 5kg was saved. Bringing the total weight saving to 43% of the steel reference.
But as well as optimising the production of an aluminium body, the team also took circularity into consideration: “Circularity was one of our key parameters that we agreed on with Porsche.”
Alumobility chose to follow through
with a uni-alloy body concept. The team chose 6000 series alloys for the study after assessing technical, sustainable, and production feasibility. Porsche currently uses 5000 series and 6000 series alloys in their Top Hat, so supply of the 6000 series alloy would be a realistic option, should a fully aluminium body be implemented at production level. 7000 series alloys were not included as it is not as easy to recycle multi-alloys; the 5000 series was eliminated for the same reason, due to its high magnesium content with related higher CO2e per kg (higher than the 6000).
Looking from a recycling end of life point of view, it is easier to recycle a 6000 series alloy on its own, utilising the range of strength and formability in the different 6000 series, rather than blend it with the 5000 and 7000 series. Full closed loop recycling was also an aspect that was considered by Alumobility, looking further at the sustainability benefits of an aluminium body over steel, Prof. White noted that “an aluminum car body takes approximately 35% less energy to remelt than a steel car body at end of use.”
Why should theoretical studies be carried out?
When asked what a theoretical study includes, Prof. White stated that it is not just about words on paper, but that Alumobility and its partner network go on to test examples in the real world to provide real data to validate the theory of: “Forming and joining technologies in what we call the virtual world. We conduct simulations of forming and simulations of joining techniques, but we do not stop there. We will make up examples of the joint stacks that we’re proposing and then validate them with the appropriate joining technology as coupon samples.” He continued, “we sat down with Porsche’s
joining experts and went through the details so that they concurred the results of the tests.”
Some argue that steel cannot be replaced with aluminium, what is your views on this?
“We don’t say aluminium is better than steel. What we say is here’s the data, you make the decision on what you think is the best.” - Prof. White
When discussing steel and aluminium, naturally competition arises between the two materials. Prof. White went onto explain that Alumobility “is showing OEMs that you can replace every steel part on the car with an aluminium equivalent. Now whether a company wants to do that or not, it’s up to them. It is up to them to conduct their own evaluations on the economics, sustainability, and feasibility related to the change. We just prove to them that it is possible and show the OEM and customer benefits that come along with the switch.”
“We debunk what I would call urban myths and barriers surrounding aluminium.” - Prof. Mark
Providing an example of such myths, he went onto debunk the perception that heavier cars are better in a crash than lighter cars. Looking at the laws of physics, a heavier vehicle means more mass is brought into an accident, therefore a greater load is exerted on the human body. “If cars were lighter weight, there would be less energy in any crash. This coupled with the fact that aluminium absorbs more energy per kilogramme than steel in an impact provides occupants with an alternative view of aluminium – not just lightweighting.”
If you had one magic wish, what would it be?
“I would wish the automotive industry moves from performance to efficiency.” –Prof. White
Rather than performance, Prof. White suggested that cars are measured on carbon emissions and vehicle weight. This measure would change the automotive industry as we know it, “we would have completely different cars on the road.” Prof. White hopes that the industry and customers shift their priorities towards sustainable solutions, and vehicles that are “fit for purpose rather than building a car that has lots of latent potential that in most cases never gets used.” We need to consider our future impact on the environment and our total energy consumption. �
The Element with the Atomic Number 1
The lightest, colourless, odourless, tasteless, non-toxic, and yet most abundant, most combustible, and one of the most needed elements; hydrogen is one of today’s number one most problematic topics.
The simplest element to exist in our universe has a trail of fans, and as a result, a shadow of conflict. Which turns out to be not as simple. Naturally occurring, the element is found as, in the form of a compound with other elements, liquid, solid, or gas. 75% of all mass in the universe is hydrogen and 90% of all atoms in the universe are hydrogen atoms [1]. This element, as effortless as it appears, is perhaps one of the most complex we have in our periodic table.
The Element with the Atomic Number 13
Aluminium is the 12th most common element in the universe. Its low density, high strength, corrosion- resistant, highly recyclable, parallel nature makes it a material that fits to THE job. The main inconvenience that this metal is bonded and latched upon oxygen. About 8.2% of the earth’s crust is aluminium [2]; of this, aluminium most commonly occurs in the form of alumina (aluminium oxide –Al2O3).
This unfortunate occurrence leaves the aluminium industry in conflict with supplying demand, and sustainable consciousness.
1 and 13: The Annoying Prime Numbers
Hydrogen can, and has been, used in two main ways in the production of aluminium: As a combustion fuel for a direct flame source, usually in smelting or secondary aluminium production; or as a source to create electricity, which can then be used throughout the production of aluminium.
Hydrogen in the Aluminium Industry
By Zahra Awan*
was 903,980 GWh. The total primary aluminium production for 2022 was 69,038 thousand metric tonnes of aluminium. That’s 13 GWh per tonne of aluminium. See table 2.
Unfortunately, as abundant as hydrogen is, all industries have common challenges to contend with if they are to successfully implement the use of hydrogen. Namely: supply, storage, and cost.
In 2022, the worldwide primary aluminium smelting energy consumption (reported as AC and DC power used for electrolysis by the Hall-Héroult processes per tonne of aluminium production) by the International Aluminium institute (IAI) was: Total AC energy 14,103 kilowatt hours (kWh) per tonne of aluminium (see table 1, data from IAI)[3]
In 2022, the world average primary aluminium smelting power consumption
In 2022, global hydrogen use reached 95 million tonnes (Mt) [5: Page 20] (global hydrogen production reached almost 95 Mt in 2022 [5: Page 64]). Of which, 53 Mt of hydrogen was used in industry [5: Page 25]. The usage of one tonne of hydrogen outputs approximately 33 MWh of energy” [6] Theoretically, this means that we would need 27.39 Mt of hydrogen to produce the current amount of energy for primary aluminium smelting alone! That’s 28.8% of total global hydrogen production of 2022.
What is more troubling is that only 0.7% of the global production of hydrogen in 2022 qualified as low-emission. [5: Page 64]
is produced from unabated fossil fuels” [5: page 25]. This statistic blatantly shouts out that there are major challenges that need to be overcome, should hydrogen be a realistic solution.
The Colours of Hydrogen
The type of hydrogen is another topic of discussion where further issues tend to surface. Different colours refer to the way in which hydrogen has been produced[7] Grey hydrogen is the most common occurring hydrogen fuel, which supports the rather shocking statistic that only 0.7% of hydrogen is qualified as low-emission. The global Hydrogen Review 2023, noted that “virtually all hydrogen used in industry
*Editor, Aluminium International Today
Cranfield University is one of the leading universities collaborating in the international partnership, HyPT, which aims to make “low-cost, large-scale, Net Zero hydrogen production a reality.” [8] The Global Hydrogen Production Technologies Centre (HyPT) is a £14.1 million, five-year project led by Arizona State University (US), University of Adelaide (Australia), University of Toronto (Canada), and Cranfield University (UK). The aim is to achieve approximately one dollar per kg of hydrogen [8]. Commenting on the types of hydrogen, and its future in the aluminium industry, Professor Vasilije Manovic, Professor of Carbon Systems Engineering, School of Water, Energy and Environment, Cranfield University, said:
“Hydrogen, if sourced from renewables (green hydrogen), provides a highly promising avenue for decarbonising aluminium production. However, additional considerations should be given to the viability of utilising hydrogen produced from fossil fuels and employing carbon capture and storage (CCS), for example, blue hydrogen. I would anticipate that the direct integration of
Table 1. Primary Aluminium Smelting Energy Intensity 2022
* The AC value refers to the power consumed by facilities for the smelting process including rectification from AC to DC and normal smelter auxiliaries (including pollution control equipment) up to the point where the liquid aluminium is tapped from the pots. It excludes power used in casting and carbon plants. The DC value is a process efficiency
Three current main types of hydrogen [7]:
� Green hydrogen: Green hydrogen is made by using clean electricity from surplus renewable energy sources, such as solar or wind power, to electrolyse water. Electrolysers use an electrochemical reaction to split water into its components of hydrogen and oxygen, emitting zero-carbon dioxide in the process.
� Blue hydrogen: Blue hydrogen is produced mainly from natural gas, using a process called steam reforming, which brings together natural gas and heated water in the form of steam. The output is hydrogen, but carbon dioxide is also produced as a by-product. So, the definition of blue hydrogen includes the use of carbon capture and storage (CCS) to trap and store this carbon.
� Grey hydrogen: Currently, this is the most common form of hydrogen production. Grey hydrogen is created from natural gas, or methane, using steam methane reformation but without capturing the greenhouse gases made in the process. Grey hydrogen is essentially the same as blue hydrogen, but without the use of carbon capture and storage.
(Visit source for more definitions)
CCS with aluminium production is likely to be less technically challenging and more cost-effective than the integration of CCS with hydrogen production, followed using decarbonised hydrogen for aluminium production.
“In general, when decarbonising carbon-intensive industrial processes using hydrogen, key considerations include the availability of green hydrogen and prioritisation between utilising renewable sources to meet the high energy demands of those processes, as well as the
Global Data for 2022 in Gigawatt hours (GWh)
production and use of green hydrogen for mitigation of inherent process emissions. Green hydrogen represents a long-term solution, while blue hydrogen serves as a short- to mid-term alternative. The latter still needs to prove its competitiveness compared to the direct decarbonisation of industrial processes with inherent process emissions employing CCS.”
Reviewing the figures from the previous section, it is evident that as the demand continues to run parallel and match consumption year on year, the
need for more hydrogen is obvious. The production of more hydrogen is pivotal for hydrogen to be a realistic assistant in the global sustainability agenda. However, it is also clear that hydrogen faces many challenges, globally, let alone the aluminium industry.
Professor Manovic raises an important point: “The latter [blue hydrogen] still needs to prove its competitiveness compared to the direct decarbonisation of industrial processes with inherent process emissions employing CCS.” Assessing whether hydrogen is in the decarbonisation picture at all is essential for the progression of industry. We do not want to take a giant, complex, and expensive detour.
As a solution, perhaps Professor Manovic’s recommendation that green hydrogen becomes a long-term solution, and blue hydrogen a short- to midterm alternative, is what hope looks like. Allowing for time to tell whether hydrogen is indeed a long term, realistic solution.
Looking to hydrogen for a positive future, key players in the aluminium industry are investing in projects, experimentations, and tests to assess the applications that hydrogen could assist with in the aluminium production process. In this article, we will be looking into some of the investments that have experimented with hydrogen application in the secondary production of aluminium, as well as prompting you to question whether hydrogen is on our side.
Or is hydrogen just salt disguised as sugar?
Hydrogen as a Fuel to Secondary Aluminium: Examples Already in the Industry
Hydro: Hydro Havrand “Hydro Havrand’s ambition is to be the
Data from International Aluminium Institute[4] . Note: Electrical power used in
Table 2. Primary Aluminium
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leading provider of industrial fuel switch solutions.” – Jan Helge Mårdalen, Head of Hydro Havrand.
Aluminium and renewable energy company Norsk Hydro, set up Hydro Havrand, in 2021, to with the aim of achieving and investing in a sustainable future[9]. Hydro Havrand is pioneering the fuel switch from fossile alternatives to green hydrogen in aluminium.
Hydo Havrand states that they aim to “develop, operate and own green hydrogen facilities, and provide expertise to enable transition to renewable energy.”[9] They are working on a pipeline of projects[9]
In a previous interview with Aluminium International Today (see Vol.36 No. 5 2023[10]), Per Christian Eriksen, former Head of Hydro Havrand, spoke about the inspiration behind Hydro’s recent test to create the first batch of recycled aluminium with 100% hydrogen fuel, a project that took place in Jun 2023 [11] first batch.
Hydrogen was chosen to decarbonise a “processes where it’s difficult to use electrification directly. This typically refers to the high heat processes and calcination process,” [10] therefore, this test focused on replacing the fuel used in a furnace to melt scrap metal. The project, in collaboration with the Fives Group, worked using an adapted a furnace to suit hydrogen.
Eriksen stated that “One of the biggest challenges we faced was getting a hold of the volume of green hydrogen that we needed to execute these tests. We had two trucks of hydrogen per day during the nine days of testing. We ended up burning around three tonnes of hydrogen during these weeks, and we produced, in total around 200 tonnes of [recycled] aluminium. 150 tonnes of the aluminium were produced using only hydrogen.” [10]
Despite this rather hard to ignore challenge, Hydro have announced that they will be completing a Pilot Test on “local production of hydrogen, with an electrolyser (5 Megawatt), to produce hydrogen leading directly into the furnace.” [10] They have stated that they aim for an industrial scale pilot to work on this set up, in Norway, where they intend on running the furnaces on hydrogen over a longer period. This is scheduled for “a year or two from now.” [10]
However, referring to the figures of global production and observing the figures from this test, one questions once again whether the implementation of hydrogen is truly achievable, or sustainable. Charles Schroer, Vice President, Sales & Marketing - Fives North American Combustion, Inc., when asked whether he believes hydrogen to be a realistic fuel of the future, answered:
“There are many variables with respect to the manufacture, distribution, availability, and cost of hydrogen to be worked out before it will become a realistic fuel. From the perspective of a thermal process solution provider though we, at Fives North American Combustion, plan to be ready if it does become a reality. All we can control is making sure we develop ‘Hydrogen Proven’ products for processes that safely and efficiently combust hydrogen for customers that want to use it on their high temperature thermal processes. We have partnered with early adopter companies such as Hydro Havrand to study the use of hydrogen on their high temperature
thermal processes. Their interest was in the metallurgy and process performance; our interest was in the design and reliability of the combustion system. Both in our test furnaces and at customer sites we have worked with aluminium, forging, steel and whiteware companies to investigate the metallurgical and material effects on their end product when exposed to high temperature hydrogen products of combustion instead of those from natural gas. We have invested over a half million dollars to install a permanent bulk compressed hydrogen gas pad and stainless-steel pipe distribution system to all our lab furnaces so that we can run extended time tests on our burner equipment to confirm their durability and performance with 100% hydrogen under conditions approximating our customers’ thermal processes.”
When asked whether the current Head of Hydro Havrand, Jan Helge Mårdalen, thinks Hydrogen is a realistic fuel of the future, he replied:
“Green hydrogen is key to tackle the hard-to-abate emissions, where direct electrification isn’t an option. The world will not get to zero without green hydrogen. But we need to find the right applications for it. One example could be the high heat processes in industry, where green hydrogen is an alternative to fossil fuels. So yes, green hydrogen is a realistic fuel.”
If we narrow down the use of hydrogen to the production of secondary aluminium, we can establish the conditions where hydrogen has a positive future.
Novelis and HyNet: Implementing in Recycling
In June of 2023, Novelis announced that they were awarded £4.6 million to “establish hydrogen burning trials as part of the UK Government’s £55m Industrial Fuel Switching Competition, as part of the £1bn Net Zero Innovation Portfolio (NZIP), and the wider regional HyNet project.”[13]
Novelis have noted that the first of the trials will use a recycling furnace located at Novelis Latchford, and the test is expected to take place during 2024. Results of this trial will be announced later this year.
In a press release, Emilio Braghi, Executive Vice President, Novelis, and President, Novelis Europe, stated:
“Switching to renewable energy sources is a key initiative to advance on our journey toward carbon-neutral production.” [13]
Adding to this, Allan Sweeney, Plant Manager, Novelis Latchford stated:
“We are proud to be one of the pioneers using hydrogen within the aluminium industry and that these trials at Latchford will additionally advance research on the viability of integrating hydrogen power in our recycling operations around the world.” [13]
It will be interesting to see what the outcome of this project will be. We will have to sit tight in the meantime.
Rio Tinto: Can Hydrogen Help Reduce Emissions in the Aluminium Industry
In July 2023, Rio Tinto announced it will be building a ‘first of its kind’ hydrogen plant, in partnership with Sumitomo Corporation and the Australian Renewable Energy Agency, at their Yarwun alumina refinery in Gladstone, Queensland, Australia.[14]
The project aims to demonstrate the viability of using hydrogen in he calcination process, where hydrated alumina is heated to temperatures of up to 1,00 degrees Celsius. [15]
Providing details of the project, Rio Tinto have stated that:
“The project will consist of construction of a 2.5MW on-site electrolyser to supply green hydrogen to the Yarwun refinery and a retrofit of one of Yarwun’s four calciners so it can operate at times with a hydrogen burner. If successful, the programme could pave the way for adoption of the technology at scale globally.
“The trial is expected to produce the equivalent of about 6,000 tonnes of alumina per year while reducing Yarwun’s carbon dioxide emissions by about 3,000 tonnes per year.
“Converting the entire plant to green hydrogen could reduce emissions by 500,000 tonnes per year, which is the
What is HyNet?
HyNet is the leading UK industrial decarbonisation project focused in the North West.
HyNet is made up of several different elements. Together, these elements aim to provide the infrastructure to produce, transport and store low carbon hydrogen across the North West and North Wales. There will also be the infrastructure to capture, transport and lock away carbon dioxide emissions from industry. [12]
equivalent of taking about 109,000 internal combustion engine cars off the road.
“Construction will start in 2024. The hydrogen plant and calciner are expected to be in operation by 2025.” [14]
This investment, again, shows the dedication to hydrogen within the aluminium industry, and with millions of dollars being invested in projects that intend to go ‘global’, one begins to believe that hydrogen does in fact have a place in the aluminium industry. The top five global hydrogen generation market
leaders are: ITM Power plc, Linde plc, Engie SA, Air Liquide S.A, and Messer Group GmbH,.[16] Four of the five are European companies.
So, what about Governments, policies, and wider assistance? Are we looking at local hydrogen or global hydrogen?
Making Hydrogen Stable: The UK Government
It is well known that Hydrogen is highly flammable. With this, and many other challenges in mind, the success of hydrogen implementation within any industry is the surrounding support that strengthens this fuel. Without Government and policies, hydrogen will not be successful.
We have already seen global research and development projects, such as HyPT, and large local projects, which work with global players, such as HyNet. So now let’s look closer into government support: The UK has announced funds for the investment of hydrogen, the Hydrogen Production Business Model (HPBM) and Net Zero Hydrogen Fund (NZHF).
What are the intentions of The Hydrogen Production Business Model (HPBM) and Net Zero Hydrogen Fund (NZHF): [17]
� Kickstart the low carbon hydrogen economy across the UK, helping meet the ambition of up to 1GW of electrolytic hydrogen production capacity in operation or construction by 2025,
� Deploy at scale at the earliest opportunity, advancing government’s aim to deploy up to 10GW of low carbon hydrogen production capacity by 2030, subject to affordability and VfM, with at least half from electrolytic hydrogen production capacity, and to do so at affordable costs by harnessing economies of scale. This could potentially unlock up to £11 billion of private investment and support more than 12,000 jobs by 2030,
� Help deliver carbon savings to allow us to stay on track to meet Carbon Budget 5, Carbon Budget 6 and other net zero commitments, by providing hydrogen to a range of end user sectors.
The first Hydrogen Allocation Round (HAR 1: July 2022) announced 11 successful projects, totalling 125 MW capacity.[21] Over £90 million from the Net Zero Hydrogen Fund has been allocated in support of these projects [21]. But how many of these projects were rejected? And, how many will continue to be successful. The UK Government anticipate that the first projects will become operational in 2025. How many will make it to 2030?
HAR 3 has already been announced, despite projects from HAR 1 predicted to
What is the UK standard of low carbon hydrogen?
The UK Department for Energy Security and Net Zero have published a UK Low Carbon Hydrogen Standard. This standard was published after a report on the ‘options for a UK low carbon hydrogen standard [18] and Consultation from the government on ‘designing a UK low carbon hydrogen standard [19]
There is now a version three of this standard, and a low carbon calculator for industry to use to calculate their standard of hydrogen.
The 169-page standard with numerous criteria’s, requests for endless data, and space for the unknown, sums up how simple defining low carbon hydrogen is. I wonder, does this UK standard differ from the EU, USA, China, Far East, African, South American, Russian, Australian, Middle East etc definition. Does that mean we have to read 100 plus pages for each standard?
View the UK Low Carbon Hydrogen Standard through reference [20]
start in 2025. This could be seen as longterm thinking, or it could be considered as a rash decision to satisfy the industry in the short term.
With obvious millions, and perhaps billions being spent on the investment of the hydrogen industry, it is clear that we will be taking this path with or without my scepticism, and multiple questions. However, what is clear is that without government collaboration hydrogen would not have a future.
Industry Point of View
Fives, when asked what the biggest challenge is when looking into hydrogen for industry, their opinion of a solution, and what their advice is to the industry, Charles Schroer, Vice President, Sales & Marketing - Fives North American Combustion, Inc. replied:
“Each industrial customer will face different challenges when looking into the use of hydrogen to replace their carbon-based fuels. The challenges are many and well documented: manufacture of hydrogen, availability in sufficient quantities, the distribution network, and its cost to name a few. Many of these challenges are outside the control of the industrial customers. Our advice to industry is to be ready for the day when hydrogen is your only available fuel: start preparing now. Work with suppliers to run tests now to confirm the effect that hydrogen will have on the quality of your product. From these tests determine if your thermal processes need to be changed to maintain the quality of product you currently manufacture. Investigate your internal gas distribution system to confirm its compatibility with a hydrogen fuel. Start to train your people to safely work around hydrogen pipelines. Make the lists of equipment and action items that would need to change or be
upgraded to work with hydrogen. You have the time now to study what you need to do to make the conversion to a ‘Hydrogen Proven’ process; spend your time wisely and be ready. Fives stands ready to support its customers and all industry players looking to make the transition to hydrogen.”
Alternative methods of producing primary aluminium are well known for keeping the industry in suspense: Elysis being the biggest culprit. Hydro have come forward with HalZero technology aimed at revolutionising this primary process. When asked whether he thinks hydrogen will be compatible with HalZero Technology/ high energy demanding processes, Jan Helge Mårdalen replied:
“Well, hydrogen and HalZero really address different parts of the primary aluminium production process. HalZero
is a revolutionary technology that can replace the current CO2-emitting electrolysis process in the production of primary aluminium. This step is where the white powder alumina is made into liquid aluminium metal. But after the alumina has been made into aluminium, it still needs to go into a casthouse and be formed to aluminium moulds. The casting require high heat temperature, and is often today fueled by natural gas. By replacing natural gas with green hydrogen, we can remove these emissions.”
Conclusion
Per Christian Erikson, when asked whether he considers hydrogen as a feasible global solution, he replied:
“Definitely. That is one of the motivations for doing these tests. The roadmap, at this stage, aims to bring up the maturity level of both the technology and the hydrogen to later implement these permanently in the process of producing aluminium. So, this is definitely the plan. The pilot project aims to assist this vision, and to bring this fuel switch technology to full maturity.”[10]
Predictions that demand for hydrogen will reach 500MtH2 by 2050, relying on carbon capture and storage to qualify as low carbon, which means that for now there is a clear need for more hydrogen. Hydrogen has a long way to go and requires a lot of global monetary investment for it to be the saviour, and it also needs a global standard.
It seems like secondary aluminium is the place for hydrogen. However, and without going on a tangent, it has long been known that the demands for aluminium cannot be satisfied by the quantity
produced by secondary aluminium alone, as each year demand continues to rise. Plus, the quantity and accessibility to scrap metal is yet another issue that we must contend with and consider. Of all the issues we face, knowing that people want more of our material is a juxtaposing blessing and curse.
I look forward to seeing how our adaptable aluminium adapts to this fuel. I suppose with great power comes great responsibility. �
References and Citations:
[1] Norwegian hydrogen, Norwegian Hydrogen. Available at: https:// norwegianhydrogen.com/greenhydrogen/facts-about-hydrogen (Accessed: 24 January 2024).
[2] Cardarelli, François (2008). Materials handbook: A concise desktop reference (2nd ed.). London: Springer. pp. 158–163. ISBN 978-1-84628-669-8. Available at: https://books.google.co.uk/ books?id=PvU-qbQJq7IC&printsec=fr ontcover&source=gbs_ViewAPI&redir_ esc=y#v=onepage&q&f=false
[3] Primary aluminium smelting energy intensity - International Aluminium Institute (2022) International Aluminium Institute. Available at: https:// international-aluminium.org/statistics/ primary-aluminium-smelting-energyintensity/ (Accessed: 24 January 2024).
[4] Primary aluminium smelting power consumption - International Aluminium Institute (2022) International Aluminium Institute. Available at: https://internationalaluminium.org/statistics/primaryaluminium-smelting-power-consumption/ (Accessed: 24 January 2024).
[5] Global Hydrogen Review 2023International Energy Agency (IEA) (2023) Global Hydrogen Review 2023 . Available at: https://iea.blob.core.windows.net/assets/ ecdfc3bb-d212-4a4c-9ff7-6ce5b1e19cef/ GlobalHydrogenReview2023.pdf (Accessed: 14 February 2024).
[6] Goodall, C. (2021) Some rules of thumb of the hydrogen economy, Carbon Commentary. Available at: https://www. carboncommentary.com/blog/2021/6/11/ some-rules-of-thumb-of-the-hydrogeneconomy (Accessed: 14 February 2024).
[7] The hydrogen colour spectrum (2023) National Grid Group. Available at: https://www.nationalgrid.com/stories/ energy-explained/hydrogen-colourspectrum#:~:text=Why%20is%20a%20 colourless%20gas,between%20the%20 types%20of%20hydrogen (Accessed: 24 January 2024).
[8] Cranfield University at the forefront of new £14.1m Global Initiative to Transform Net Zero Hydrogen production
(2023) Cranfield University. Available at: https://www.cranfield.ac.uk/press/ news-2023/cranfield-at-the-forefront-ofnew-global-initiative-to-transform-netzero-hydrogen-production (Accessed: 14 February 2024).
[9] Hydro Havrand (2023) Hydro.com. Available at: https://www.hydro.com/ en-GB/energy/hydrogen/ (Accessed: 14 February 2024).
[10] Awan, Z. (September October 2023) ‘Worlds first batch of recycled aluminium using Hydrogen ’, Aluminium International Today ,pp. 20–22.
[11] World’s first batch of recycled aluminium using hydrogen fuelled production (2023) Hydro.com. Available at: https://www.hydro.com/en-GB/media/ news/2023/worlds-first-batch-of-recycledaluminium-using-hydrogen-fueledproduction/#:~:text=Hydro%20has%20 produced%20the%20world’s,of%20 aluminium%20during%20the%20test (Accessed: 14 February 2024).
[12] Hynet North West (no date) HyNet. Available at: https://hynet.co.uk/ (Accessed: 14 February 2024).
[13] Toward carbon neutral production: Novelis to trial use of hydrogen in recycling furnaces (2023) Novelis. Available at: https://www.novelis.com/toward-carbonneutral-production-novelis-to-trialuse-of-hydrogen-in-recycling-furnaces/ (Accessed: 14 February 2024).
[14] Could hydrogen help reduce emissions in the aluminium industry? (2023) Rio Tinto. Available at: https:// www.riotinto.com/en/news/stories/ could-hydrogen-help-reduce-emissions (Accessed: 14 February 2024).
[15] Rio Tinto and Sumitomo to build Gladstone Hydrogen Pilot Plant to... (2023) Aluminium International Today. Available at: https://aluminiumtoday.com/ news/rio-tinto-and-sumitomo-to-buildgladstone-hydrogen-pilot-plant-to-triallower-carbon-alumina-refining (Accessed: 14 February 2024).
[17] Department for Energy Security and Net Zero (2023) Hydrogen production business model / net zero hydrogen fund: Successful projects, GOV.UK. Available at: https://www.gov.uk/government/ publications/hydrogen-productionbusiness-model-net-zero-hydrogenfund-shortlisted-projects (Accessed: 14 February 2024).
[18] Department for Energy Security and Net Zero (2021) Options for a UK low carbon hydrogen standard: Report, GOV. UK. Available at: https://www.gov.uk/ government/publications/options-for-auk-low-carbon-hydrogen-standard-report (Accessed: 14 February 2024).
[19] Department for Business, (2022) Designing a UK low carbon hydrogen standard, GOV.UK. Available at: https:// www.gov.uk/government/consultations/ designing-a-uk-low-carbon-hydrogenstandard (Accessed: 14 February 2024).
[20] Department for Business, (2022) Designing a UK low carbon hydrogen standard, GOV.UK. Available at: https:// www.gov.uk/government/consultations/ designing-a-uk-low-carbon-hydrogenstandard (Accessed: 14 February 2024).
[21] Hydrogen production business model / net zero hydrogen fund: HAR1 successful projects (published December 2023) (2023) GOV.UK. Available at: https://www.gov. uk/government/publications/hydrogenproduction-business-model-net-zerohydrogen-fund-shortlisted-projects/ hydrogen-production-business-modelnet-zero-hydrogen-fund-har1-successfulprojects (Accessed: 14 February 2024).
[22] Hydro at Herøya contributes to zero emissions in the aluminium industry (no date) Herøya Industrial Park. Available at: https://www.heroya-industripark.no/en/ news/hydro-at-heroeya-contributes-tozero-emissions-in-the-aluminium-industry (Accessed: 20 February 2024).
[23] Halzero process (no date) Hydro. com. Available at: https://www.hydro. com/en-GB/media/on-the-agenda/hydrosroadmap-to-zero-emission-aluminiumproduction/halzero-zero-emissionelectrolysis-from-hydro/ (Accessed: 20 February 2024).
European Aluminium Calls for a Real Industry Decarbonisation Deal
The European Commission unveiled its Communication ‘Securing our future: Europe’s 2040 climate target and path to climate neutrality by 2050 building a sustainable, just and prosperous society’ outlining the needed climate and energy policy framework post-2030. European Aluminium provided Aluminium International Today with an exclusive interview with Emanuele Manigrassi*.
The Industry Decarbonisation Deal: The framework recommends an ambitious greenhouse gas (GHG) emissions reduction target of 90% by 2040, compared with 1990 levels. This presents a significant opportunity and challenge for the aluminium industry, as demand is set to surge in support of the green transition. European Aluminium emphasises the pressing need for coherent energy, trade and industrial policies that facilitate the industry’s decarbonisation and incentivising recycling while remaining competitive on global markets. This will enable the industry to meet the growing demand with sustainable aluminium ‘made in Europe’.
The EU is significantly ahead of other countries and regions in climate ambition, mandating substantial emission reductions in every sector and installation. Achieving this goal requires a harmonised policy approach across various domains, including trade, energy, and industrial strategy, ensuring that Europe remains competitive while progressing towards decarbonisation. Aluminium is the most used non-ferrous metal globally, delivering energy and CO2 savings in leading sectors, including mobility and transport, packaging, consumer goods, and building and construction. Large volumes of aluminium will also be required to produce solar panels, batteries, electric vehicles, wind turbines, heat pumps and hydrogen electrolysers. To satisfy the EU’s targets for a fast energy transition, the additional demand for aluminium in
Europe will reach 5 million tonnes per year by 2040, equivalent to an increase of 30% compared to Europe’s total aluminium consumption today[1]
However, Europe’s higher climate ambitions cannot be achieved at the expense of its manufacturing capacity nor increase import dependencies across the aluminium value chain. Energy costs in Europe are still too high compared to our global competitors, hindering the possibility to invest in the decarbonisation and recycling processes needed to achieve climate neutrality by mid-century [2 and 3]
“The link between climate, trade and industrial policy must be strengthened and at the forefront of the agenda of the next EU Commission. We are ready to work with the EU Commission and the Member States on bridging solutions to bring down the cost of energy and boost the transformation of our industry while remaining competitive on global markets,” notes Paul Voss, Director General of European Aluminium. The EU needs to therefore step up its overall energy security by scaling up investments in decarbonised energy systems, clean technologies, and infrastructure, while making full use of the provisions of the Critical Raw Materials and Net Zero Industry Acts, which both recognise aluminium as a strategic raw material and component for Europe’s green transition. Both pieces of legislation will have to be thoroughly implemented to ensure aluminium manufacturing, processing and recycling remains and grows in Europe.
Last year, the EU27 lost 50% of its primary aluminium production as a result of the energy crisis. Prior to the crisis, the EU had already lost one-third of its primary aluminium production capacity over the preceding 15 years due to uncompetitive operating conditions in Europe. This European production was replaced by production in other countries, with a much higher carbon footprint.
“The proposed ‘Industrial Decarbonisation Deal’ will have to include strengthened carbon leakage protection measures that go well beyond existing untested mechanisms such as the Carbon Border Adjustment Mechanism (CBAM). We regret to see that in the Communication, there is no reference to any additional carbon leakage protection measures complementing the CBAM. These will be urgently needed to ensure our industry can remain competitive while delivering on our commitment to reach net zero by 2050. The European Aluminium value chain needs enhanced carbon leakage measures beyond the unproven CBAM. The current tool has numerous loopholes and avenues for circumvention, which are insufficient to safeguard the European aluminium industry against carbon leakage and to effectively reduce global emissions,[4]” he concludes.
In response to these policy challenges, European Aluminium has published a study identifying technological pathways for which more research and financial resources will be urgently needed to achieve net-zero emissions by 2050.
*Director of Climate Change & Energy, European Aluminium.
European Aluminium emphasises the pressing need for coherent energy, trade and industrial policies that facilitate the industry’s decarbonisation and incentivising recycling while remaining competitive on global markets. Could you expand on ‘coherent energy’ policy, in light of the energy crisis of 2023? What do you wish to see from the European commission with regards to energy policy, will this focus on energy security over renewability and/or vice versa?
In Europe, energy costs for aluminium producers remain excessively high compared to other regions worldwide. The energy crisis of 2022-2023 highlighted the vulnerability of European producers, resulting in approximately 50% curtailments of EU27 primary aluminium capacity. This trend followed a 15-year period during which the EU lost onethird of its primary aluminium production capacity due to uncompetitive operational conditions because of the too high-power prices in Europe. Furthermore, the spike in gas prices severely hit the recycling and transformation sectors. While gas prices in Europe are lower than last year, they are still too high compared to other regions. Consequently, European production is replaced by production from countries, which tend to have significantly higher carbon footprints.
So what we really need is costcompetitive, low-carbon energy, at a price that allows us to compete with other global players. This issue is particularly sensitive in Europe due to variations in energy cost structures, especially on electricity, among EU Member States. The variations are due to the countries’ electricity mix, national surcharges, and to what extent the indirect carbon costs of the EU Emissions Trading System (ETS) are passed on in the power price by electricity suppliers. Additionally, the possibility to enter long-term contracts varies across the Union, depending on whether
An Interview with Emanuele Manigrassi:
Member States have State Aid schemes to support their national champions, storage, infrastructure, and level of grid interconnections.
The recent energy crisis highlighted this reality: countries with deep pockets could support their industrial champions, whereas others faced challenges. Notably, 82% of total national aid approved by the EU Commission was allocated to just three Member States: Germany (53%), France (24%), and Italy (7.6%). Therefore, a “coherent” energy policy should encompass measures to align with Europe’s broader industrial, trade, and security objectives. This means diversifying energy sources to mitigate overreliance on any single source, implementing a unified European approach to boost investments in renewable energy infrastructure, incentivising renewable energy projects, fostering research and development in renewable energy technologies, and finding ways to reduce the cost of consuming low-carbon energy for tradeexposed industries like aluminium.
“The proposed ‘Industrial Decarbonisation Deal’ will have to include strengthened carbon leakage protection measures that go well beyond existing untested mechanisms such as the Carbon Border Adjustment Mechanism (CBAM).” How do you suggest CBAM is strengthened? How will a strengthened CBAM benefit EU industry?
We have always opposed the idea of the Carbon Border Adjustment Mechanism (CBAM). In our view, it cannot be designed in a way that would offer us the same level of protection provided by the existing carbon leakage protection measures in place in Europe. Additionally, we identify many unaddressed loopholes, ranging from the potential risk of resource shuffling (i.e. redirecting low-carbon aluminium to Europe while exporting carbon-intensive aluminium to other regions) to the manipulation of declared trade codes at the border, the over declaration of scrap content to lower costs, or simply importing higher value-added products further down the value chain that are not yet covered by the CBAM’s product scope. This is why it is vital for our industry that the EU does two things: firstly, acknowledging that the CBAM cannot serve as the sole carbon leakage protection measure for European industry, and secondly, exploring alternative tools to safeguard industry interests should the CBAM fail to achieve its intended
objectives. Even with the implementation of the CBAM, our low-carbon producers will continue to pay the indirect carbon costs embedded in power prices due to the ETS and the marginal pricing mechanisms applicable to European electricity markets. Conversely, low-carbon imports will remain unaffected. So, we need to look at alternative carbon leakage protection measures that can truly level the playing field.
Interestingly, the need for alternatives was initially included in the first draft of the 2040 target plan but was subsequently removed, probably because of the fear that mentioning “alternatives” could undermine the credibility of one of the EU’s flagship climate policies.
“In response to these policy challenges, European Aluminium has published a study identifying technological pathways for which more research and financial resources will be urgently needed to achieve net-zero emissions by 2050.” More research and financial support are easy to request, but what is the likeliness that this will come about? How can EU industries support your call for an “industry Decarbonisation Deal”?
The report is much more than a request for financial support. It marks the beginning of a journey and dialogue with energy and technology suppliers, as well as other industrial value chains, national, European, and international organisations, on how we can truly deliver a net-zero aluminium value chain in Europe. While European producers are already leading the way in decarbonisation, regulatory constraints and carbon costs in Europe are eroding the resilience of the value chain.
The EU has only 16 years left to achieve its ambitious 90% Greenhouse Gas (GHG) reduction target, yet this imperative should not lead to deindustrialisation, a stark reality faced by industries in Europe. Our report reveals that without intervention, the necessary enabling conditions for a fully decarbonised energy system and most of the technologies required to achieve a fully decarbonised value chain will not be available before 2035. Every sector of the economy must contribute, and we propose three main lines of action: accelerating the decarbonisation of power generation and hydrogen at a competitive price for industry, prioritising and increasing investments in R&D for low-carbon technologies, and increasing scrap recovery and recycling in Europe. �
Aluminium Industry Decarbonisation
– A Turning Point?
By Pernelle Nunez*
Aluminium is a key material that has the potential to reduce GHG emissions in other sectors including transport, building & construction, and food & drink packaging. It is also an essential material for the energy transition, widely used in solar panels, energy storage and electrical cabling. As such, demand for the metal is expected to grow strongly over the coming decades. Strong demand growth provides many upsides for the sector with opportunities for both primary and recycled metal, but growing production in a world where GHG emissions are becoming increasingly constrained and stakeholder expectations are growing, means the sector faces significant challenges.
The realities [1] of the ambitious Paris climate goals of limiting global warming to well below 2 degrees and ideally, 1.5 degrees are now well understood across the sector. Producers are making significant investments and taking decisive action to reduce emissions from production and to keep global climate targets in reach but alignment with a 1.5 degrees trajectory is a major undertaking. Under this scenario, total emissions from the sector would have to be reduced from over 1 billion tonnes CO2e today to just over 50 million tonnes by 2050 – a 97% reduction.
Over the past few years, decarbonisation projects [2] have emerged across all major aluminium producing regions aligned
with the IAI’s three key decarbonisation pathways [3]. The projects are varied and widespread, from increasing zerocarbon electricity to technologies and fuel switches to eliminate direct and thermal emissions, and advances in recycling and material efficiency innovations. The latest data from IAI [4] now shows these efforts are starting to bear fruit and 2022 marks a potential turning point for the sector. For the first time, data shows total greenhouse gas emissions from the global aluminium sector did not grow, even though aluminium production grew.
Decoupling Production and Emissions
The latest available data shows that some progress towards that 2050 end point is being made. In 2022, aluminium production grew by 3.9% from 104.1 million tonnes to 108.2 million tonnes but total greenhouse gas emissions from the industry showed a slight decline from 1.13 billion tonnes CO2e to 1.11 billion tonnes CO2e. This noteworthy growth in production but slight decline in emissions is the first indication of a potential decoupling of historic trends. The last time the aluminium industry’s GHG emissions did not grow was in 2009, following the global financial crisis where a decline in production was the main driver.
As well as the modest reduction in total
emissions, the GHG emissions intensity of primary aluminium production (the average quantity of emissions from the production of a tonne of primary aluminium) has also continued to decline – a trend that has been emerging since 2019. Intensity of primary aluminium declined by 4.4% from 15.8 tonnes CO2e per tonne in 2021 to 15.1 tonnes CO2e per tonne in 2022.
These changes have been driven predominantly by shifts in the electricity supply used in aluminium smelting, the most significant contributor to the industry’s GHG emissions. In China, the world’s largest aluminium producer, there has been a shift towards increased hydropower electricity sources and in other regions, including the Middle East, Europe and Australia, variable renewable energy sources such as wind and solar are becoming increasingly integrated into supply chains.
The data indicates the sector could be at a critical point however it is important that this progress is not overstated at this stage; there is still much more to do, and continued progress will require implementation of new technologies, the integration of new energy sources and adoption of new ways of working at a scale and pace never before seen in the sector. To stay on track with the 1.5 degrees aligned trajectory for the sector,
*Pernelle Nunez is the Deputy Secretary General and Director of Sustainability at the International Aluminium Institute (IAI)
emissions over the next 10 years have to decrease annually by over 9% year-onyear.
Challenges and Opportunities
Over 60% of the sector’s emissions could be eliminated through the use of lowcarbon power but challenges remain with access to decarbonised grids and integrating ever-larger quantities of variable renewable energy power sources into a production process that requires constant, reliable electricity.
Many of the other technology pathways are well known but as yet, relatively untested at a commercial scaletechnologies such as inert anode, carbon capture and storage (CCS) and electric boilers and furnaces are still in test phases or single-site operation. There is an urgency across the sector and stakeholders that the window of opportunity to reach medium-term milestones is rapidly closing. For many, 2030 is a key check point for progress and with it just over five years away, the second half of this decade will prove to be vital for the roll out of these breakthrough technologies.
There are other opportunities though that can have an impact alongside the progress already made with the integration of low-carbon power sources. Fuel switching in alumina refining, increased aluminium recycling rates and efficiency offer opportunities for the sector to make significant strides relatively quickly. Crosssector collaboration, mobilisation of capital, and enabling policy environments remain critical to success in both the medium and long term.
It is promising to see in the data, the industry is heading in the right direction for the first time, but it also highlights emissions reductions need to significantly accelerate to align with global climate goals. Unlike some other heavy industries, many of the decarbonisation solutions for the aluminium sector are already known, and in some cases in the process of being implemented, this provides an opportunity for the sector to engage with key partners looking to rapidly accelerate and amplify efforts in the next few vital years.
Accelerating & Tracking Progress
Accelerating progress on an issue that is already exceptionally challenging is not easy. As highlighted earlier, in many cases, the industry is going to need to work closely with stakeholders to instigate structural change and coordinate targeted action. These stakeholders whether they be end-use industries, the energy sector, financiers, policymakers or civil society, have varied and evolving demands of the sector and sometimes it can be difficult for them to access the information they need to make informed decisions.
This is why at COP28, the IAI launched a new Aluminium Industry GHG Initiative [5] which aims to bring much needed transparency and consistency to GHG disclosures. It commits to tracking IAI member company GHG reduction ambitions and progress over the medium and long term as well as total sector emissions - essential insights for key stakeholders. Often, this information, though publicly available, is fragmented, inconsistent and dispersed. The initiative,
supported by major aluminium producers accounting for over 250 million tonnes of CO2e emissions, will consolidate this key information. It is hoped that the initiative can foster greater decarbonisation ambition across the sector as well as bringing a new level of tracking and accountability to the sector’s reporting.
More Than Carbon
GHG emissions have been the central focus of the aluminium industry’s sustainability ambitions for many years. It is easy to quantify, understand and track using a single metric and indeed, aluminium production can be an emissions intensive process, so it is rightfully a priority issue. It is clear though that sustainable aluminium is about more than just a low-carbon footprint. A truly sustainable metal or product is one that considers and manages impacts beyond just GHG emissions; it considers impacts related to people, nature, water, circularity and waste. This need for an integrated and holistic approach to sustainability is being acknowledged more widely today and will likely be more so in the future with evolving stakeholder expectations.
Reflecting this holistic approach, the IAI launched Aluminium Forward 2030 [6]. A gathering of producers, transformers, and users from across aluminium-consuming market segments to work together to move toward net zero carbon in a way that is inclusive of broader sustainability challenges, and still meeting the growing needs of society.
The aluminium industry will have to continue to pursue its decarbonisation ambitions in parallel with managing other major sustainability issues such as bauxite residue, the impact on communities and biodiversity, in order to maintain the sector’s social licence. With an important role to play in modern societies and in the energy transition, it is essential that the industry continues to drive action across the value chain and across all sustainability issues to maintain aluminium’s position as a material of choice for end-users and consumers in the future. �
Visit the QR Code for more information on the IAI’s GHG work programme.
