Aluminium International Today November December 2023 by Quartz Business Media

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AUTOMOTIVE

www.aluminiumtoday.com November/December —Vol.36 No.6

THE JOURNAL OF ALUMINIUM PRODUCTION AND PROCESSING

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TOGETHER TOWARDS PERFORMANCE

NOW IS THE TIME TO ACT REEL is on a journey contributing towards a net-zero Aluminium Industry.

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REEL Aluminium is a major solution provider dedicated to reduce the carbon footprint in the Aluminium industry. Both internal and external par tnership, new ways of understanding and innovative technological investments in the development of net-zero solutions for the Aluminium industry are the best conditions for REEL‘s goals to work together on its path to decarbonization and to green Aluminium future.

CONTENTS 1

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LEADER

NEWS FAF 24

7 Volume 36 No. 6 – November/December 2023 Editorial Editor: Nadine Bloxsome Tel: +44 (0) 1737 855115 nadinebloxsome@quartzltd.com

Future Aluminium Forum returns

SUSTAINABILITY

COVER

In the eye of the storm?

Scaling circularity: How to reach decarbonization goals

Assistant Editor: Zahra Awan Tel: +44 (0) 1737 855038 zahraawan@quartzltd.com

All cans considered

Production Editor: Annie Baker

TECHNOLOGY

Sales Commercial Sales Director: Nathan Jupp nathanjupp@quartzltd.com Tel: +44 (0)1737 855027

Sales Director: Ken Clark kenclark@quartzltd.com Tel: +44 (0)1737 855117

CO2 capture solutions

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Advertisement Production

The heat is on

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ENERGY

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Decarbonising the UK energy system and

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Aluminium industry in The United Arab Emirates

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Why aluminium is the material of the future for automakers

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2 COMMENT

TOP STORIES

Start-up of pilot pots

Looking to the future

I mentioned in my last column that it seems to be that everything gets going again as the year starts to draw to a close. As I write this, the team are preparing for the final few events of the year and are heading out to Nashville and Saudi Arabia for the ALUMINUM USA and ARABAL shows and conferences. Aligned with the ARABAL conference in particular, this issue includes a dedicated update on the industry in the Gulf and Middle East regions. The team will also be making a special announcement, which I can let you into...this is that the Future Aluminium Forum is set to return again on the 21st - 23rd May, 2024 in beautiful Istanbul. We are proud to announce that the event will be supported by our colleagues and friends at TALSAD and we are looking forward to exploring how the adoption of digital technologies in the aluminium industry can drive economic growth, attracting investments and fostering innovation, ultimately contributing to the overall economic development of the region. Find out more about the Forum in this issue and make sure not to miss out on the excellent Earlybird delegate rate discount! With energy prices and the race to renewables still high on the agenda for many, there are also a selection of articles highlighting decarbonisation projects and technologies helping to accelerate in this area. And, on the sustainability theme, we also have an in-depth report from CRU, which asks the question of whether commodities firms are running out of time to get ahead on sustainability and a look at decarbonising the can sector. I hope you enjoy the issue! nadinebloxsome@quartzltd.com

November/December 2023

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Emirates Global Aluminium and PT Indonesia Asahan Aluminium (INALUM) have announced the completion of the start-up of five pilot reduction cells at INALUM’s Kuala Tanjung aluminium smelter upgraded with EGA’s technological know-how. The pilot reduction cells are the first step in a larger planned project to upgrade a further 298 pots in Potlines 1 and 3 of the smelter, targeting to increase the amperage from 195ka to 215ka and boost production capacity by approximately 10 per cent. EGA has completed a series of similar upgrades across its Jebel Ali site in Dubai and Al Taweelah site in Abu Dhabi in recent decades. EGA technologists and engineers have dedicated more than 10,000 hours of work on the Kuala Tanjung upgrade project so far in design and implementation, including 4,300 hours spent at the smelter. As many as 20 different EGA staff were deployed at various times during the project,

more than third of them are UAE Nationals and a quarter of them are women. Abdulnasser Bin Kalban, Chief Executive Officer of Emirates Global Aluminium, said: “The successful completion of the start-up of these pilot pots is an important milestone both in our project to deploy EGA’s technological knowhow in Indonesia, and our potentially wider partnership with INALUM. EGA’s technology team has a decades-long track record of success, creating value for EGA not just in the UAE but internationally.”

The upgrades to the pilot reduction cells at Kuala Tanjung include significant improvements to superstructure and potshells, as well as incorporating EGA’s proprietary Pot Control System which is stateof-the-art software that maximises metal production while reducing energy consumption and environmental emissions. EGA has signed a separate agreement with INALUM giving the UAE company the exclusive right to provide its proprietary DX+ Ultra aluminium smelting technology for an expansion of the Kuala Tanjung smelter, should prove feasible.

Water treatment at legacy plant Hydro operates and maintains three bauxite residue facilities at the Schwandorf legacy site in the eastern part of Bavaria, Germany. The site holds residue from operations by German aluminium producer VAW in the period 1930s-1990s. The site became a part of Hydro with the acquisition of VAW in 2002. It was a legacy site already then. Due to various water streams at the site, there is a water management system which collects and treats water, consisting of rainwa-

ter falling within the parameters and run-offs from the deposits. Up until September 30, the water treatment was outsourced. Since October 1, 2023, Hydro has taken over the water treatment and will implement several improvements as the company is building a new water treatment plant. Improvements are including reduced use of chemicals and increased level of automation, which will reduce the HSE risk of workers at the site. In addition, the new water treatment plant

is engineered for climate adaptation preparing for future extreme weather events. The new permanent water treatment plant at Schwandorf is planned to be in operation during Q2/Q3 2024. Hydro is carrying out the project at Schwandorf in close collaboration with local authorities and with support from local expertise. Over the next two years, Hydro plans to invest approximately EUR 5-6 million at the legacy sites in Schwandorf and Stulln in the Region of Oberpfalz.

Metals sector optimistic says report Rising energy prices, the impact of life after the EU and labour shortages continue to be the main challenges facing the UK metals sector according to a new report due to be launched next week. Nearly a quarter of firms in the UK Metals Council’s State of the Metals Industry in the UK 2023/24 survey admitted to adjusting supply chain strategies or sourcing alternatives, whilst just under a third

want enhanced Government support to navigate trade barriers and custom procedures in the wake of Brexit. 22% of manufacturers are also looking for improved energy supply contracts to bring prices down to more affordable levels, with just 31% of businesses saying that they have an effective recruitment strategy in place for filling the well-documented labour gaps.

There were positive sentiments in the report, which will be officially published during the opening address at the UK Metal Expo in Birmingham on September 13th. Despite the widespread challenges, 70% of respondents are optimistic or very optimistic about future business prospects, underlining the resilience of the sector and its ability to innovate.

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NEWS 3

Novelis to supply can sheet to Ball Novelis Inc. have announced that in early 2023 it signed a new anchor customer contract with aluminium can maker Ball Corporation in North America. Under the contract, Novelis will supply aluminium sheet to Ball can making plants in North America. With this contract and other commitments, Novelis has secured all of the beverage can capacity from its new plant in Bay Minette, Ala., underscoring the strong demand for the company’s high-recycled-content beverage can sheet. The new plant, expected to begin commissioning in 2025, will be the first fully integrated aluminium manufacturing plant built in

the U.S. in nearly 40 years and will have an initial capacity of 600,000 tonnes of finished goods primarily for the North American beverage can and automotive markets.

“Securing contracts for beverage can production capacity at Bay Minette two years before the plant is expected to be completed demonstrates our customers’ confidence in our ability to plan, construct and operate our new plant in Alabama,” said Steve Fisher, president and CEO of Novelis. “We’re proud to continue our partnership with Ball in such a meaningful way and look forward to bringing our new plant online in the next couple of years.” The agreement between Novelis and Ball advances both companies’ sustainability commitments by including closed-loop recycling and joint efforts to improve

New casting line opens to meet growing demand for low-carbon Alu Hydro reaches a milestone with the opening of the new HyForge casting line at its aluminium recycling plant in Rackwitz, Germany. The 40 million EUR investment responds to the automotive industry’s drive to decarbonize, significantly increasing the use of recycled, post-consumer aluminium scrap. The opening ceremony on September 14 marked the introduction of Hydro’s innovative HyForge forge stock segment at the Rackwitz plant. The technology allows for serving customers with smaller diameter aluminium billets with a superior surface quality that can

be forged directly into high quality automotive components and other products, skipping further process steps such as extrusion or homogenization. Light weighting

with aluminium is one of the most effective ways to improve the energy efficiency of vehicles without compromising safety. “With HyForge, Hydro is literally forging the future of automotive, responding to the industry’s increasing demand for low-carbon, lightweight aluminium components. The expansion enables us to further develop our strategic partnership with automotive customers, while meeting both their high quality standards and increasing focus on sustainability,” says Eivind Kallevik, Executive Vice President for Hydro Aluminium Metal.

EPIQ Machinery is further extending its presence in India EPIQ Machinery Chief Executive Officer, Éloïse Harvey, Bhushan Bachhav, Operation Manager, ADF Engineering and Nilesh Shelke, Vice-President, Stymer Technologies announce the recent transaction confirming the acquisition of Stymer Technologies under ADF Engineering, a subsidiary of EPIQ Machinery, a Canada-based company. As the main share holder of ADF Engineering, EPIQ Machinery states that it is delighted with this acquisition. EPIQ Machinery adds Aluminium International Today

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that it is in line with the company growth vision and its ongoing commitment to timely deliver high quality materials handling systems to its Primary Metals and Pulp & Paper customers worldwide.

“This acquisition is a landmark. We are reinforcing our synergies and consolidating our global presence.” - Éloïse Harvey, CEO, EPIQ Machinery

NEWS IN BRIEF 25 Years of Innovation at Combilift Combilift celebrates 25 years in business with 3 exciting new product launches. The 3 new releases were premiered at Combilift headquarters at an exclusive media event to mark Combilift’s 25th year in business.

ALFED report investigates impact of global conflict on the UK aluminium industry ALFED, the UK Aluminium Federation, has launched a new report examining the impact of the Russia/Ukraine war on the UK aluminium industry. Developed in partnership with CRU International Ltd, the document explores the short, medium and long-term consequences of government import sanctions, as well as suggesting alternative future options to maintain primary aluminium supply. Caldera partners with Manufacturing Technology Centre to design heat cell gigafactory Heat storage specialist Caldera has engaged the Manufacturing Technology Centre (MTC) to design a heat cell gigafactory to mass manufacture its unique low carbon heat storage system at scale. The company plans to commence commercial production in 2025 and scale up rapidly thereafter. ICMM publishes guidance The ICMM have published Scope 3 Emissions Accounting and Reporting Guidance that aims to provide a standardised framework for mining and metals companies to calculate and disclose their value chain emissions. It aims to improve transparency and accelerate collaborative action with suppliers and customers on reducing these emissions. November/December 2023

01/11/2023 10:41:04

4 GREEN NEWS

www.aluminiumtoday.com

Hydro invests in modernisation of ˛ Poland recycling plant in Kety,

Hydro will invest in the modernisation and expansion of the ˛ Alumetal recycling plant in Kety, Poland.

The investment of around NOK 200 million will increase capacity at the plant by approximately 30,000 tonnes of foundry alloys and strengthen Alumetal’s position in the automotive market. The project is the first investment in Alumetal under Hydro’s ownership. It will replace existing furnaces and ingot casting equipment with new and more modernised equipment that will enable capacity growth as well as providing safety and operational efficiency improvements.

“We are pleased to have Alumetal as part of the Hydro family. We have been impressed by the achievements of the Alumetal organisation. In Alumetal we see a good fit with Hydro’s ambitious strategy for growth in recycling. This investment confirms our intention to develop and grow the business further,” says Eivind Kallevik, Executive Vice President in Hydro Aluminium Metal. The modernised recycling facility is expected to be operational during first half of 2025.

New IAI study reveals environmental benefits of increased can recycling A new study on recycling of aluminium cans has identified that 60 million tonnes of CO2e per annum could be saved through effective global recycling of used beverage cans by 2030. The study was commissioned by the International Aluminium Institute and co-funded by Emirates Global Aluminium, Crown Holdings, Australian Aluminium Council and Novelis. The result of the assessment is contained in a report produced for the IAI by global management consultants Roland Berger.

It proposes 25 levers to increase recycling and a prioritised set of strategic recommendations to improve aluminium can recycling for six countries in the Middle East, Oceania and Asia. The findings and recommendations are based on the assessment of can waste management systems in Australia, Cambodia, South Korea, Thailand, United Arab Emirates and Vietnam. Together, these countries provide representative insights into can usage, collection, and process-

ing across different countries and cultures. The assessment also provides insight into the regional trade flows of used beverage cans (UBC) scrap in the Gulf and Asia Pacific regions – both major trading hubs. For each of the six countries, various aspects were analysed including waste management and regulatory schemes, collection infrastructure, recycling and landfill rates, volumes put on market, usage trends, overall performance, used beverage can trade, material flows and future targets.

2023-24 DIARY NOVEMBER 21st - 23rd ARABAL The Arab International Aluminium Conference and Exhibition (ARABAL) is the premier platform for the aluminium industry in the Arab world. www.arabal.com

DECEMBER 4th - 6th IBAAS-JNARDDC This International Aluminium Conference and Exhibition is a global platform dedicated to fostering innovation, collaboration, and knowledge exchange within the aluminium industry. Held in India www.ibaas.info

2024 FEBRUARY 14th - 16th IBAAS-JNARDDC Reflecting the solutions based philosophy of the exhibition and conference, SIM-PAC aims to avoid the ‘blah blah blah’ and highlights the incredible innovation in sustainability across what is a large manufacturing ecosystem. Held in Brisbane, Australia www.sustainableindustrialmanufacturing.com/ sim-pac/

MARCH

LME enriches ESG data source The London Metal Exchange (LME) is collaborating with producers and standards bodies around the world on enriching its digital ESG data platform, LMEpassport. This will provide the metals community with access to comparable, verified and wide-ranging sustainability credentials and data regarding global producers. Georgina Hallett, LME Chief

Sustainability Officer, commented: “ESG data transparency and comparability are vital components in addressing industry level sustainability challenges. We’re delighted that already more than 50% of LME-listed brands are now sharing sustainability credentials on LMEpassport and we’ve recently added 12 new sets of certifications, metrics and standards against which producers are able to disclose. Galvanising our industry to advance the global sustainability agenda is a core part of the LME’s strategic focus and we look forward to further collaborating with our industry partners.”

LMEpassport now lists a total of 466 disclosures from 219 brands (compared to just 22 when launched in 2021), with 54 available certifications, standards and metrics across the ESG spectrum. Additionally, producers are now able to show a broad range of sustainability-related targets and commitments and, importantly, track their progress against them. In response to increasing engagement and data, a new sideby-side viewing functionality has been introduced on LMEpassport, enabling users to compare up to five producers’ ESG disclosures simultaneously.

3rd - 7th TMS Annual Meeting & Exhibition The TMS Annual Meeting & Exhibition brings together more than 4,000 engineers, scientists, business leaders, and other professionals in the minerals, metals, and materials fields for a comprehensive, cross-disciplinary exchange of technical knowledge. Held in Orlando, Florida, USA www.tms.org/ AnnualMeeting/TMS2024

For a full listing visit www.aluminiumtoday.com/ events Aluminium International Today

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The Future Aluminium Forum is set to return and will take place in Istanbul on the 21-23 May 2024. The Forum was originally developed to explore the transformational impact of digital technologies in the aluminium manufacturing processes and by hosting this next edition in Istanbul, we will be looking to uncover the potential to revolutionise the industry in Turkey and the surrounding regions. By bringing together major aluminium manufacturers, suppliers of digital and sustainable technologies, and industry experts, the Forum aims to foster collaboration and knowledge-sharing, paving the way for a more efficient, sustainable, and competitive aluminium sector. INTERESTED IN EXHIBITING OR SPONSORING?

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FAF 7

Future Aluminium Forum returns The Future Aluminium Forum is set to return and will take place in Istanbul on the 21st - 23rd May, 2024. The Forum was originally developed to explore the transformational impact of digital technologies in the aluminium manufacturing processes and by hosting this next edition in Istanbul, we will be looking to uncover the potential to revolutionise the industry in Turkey and the surrounding regions. By bringing together major aluminium manufacturers, suppliers of digital and sustainable technologies, and industry experts, the Forum aims to foster collaboration and knowledge-sharing, paving the way for a more efficient, sustainable, and competitive aluminium sector. The Future Aluminium Forum 2024 will highlight the latest digital manufacturing and Industry 4.0 technologies that can optimise production, improve quality, and enhance overall efficiency in the aluminium industry. Due to the demand for more discussions around the importance of sustainable practices at the most recent event, we will also be incorporating a live session based on the Greener Aluminium Summit, to showcase technologies that promote energy efficiency, waste reduction, and eco-friendly manufacturing processes. Turkey serves as a significant hub for the aluminium industry, with a strategic geographic location connecting Europe, Aluminium International Today

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Asia, and the Middle East. It attracts both regional and global players, making it an ideal location for a regional event. Turkey’s aluminium industry has experienced steady growth over the years, making it a crucial player in the global aluminium market. Hosting the event in Turkey allows attendees to explore a dynamic and thriving industry. We are pleased to announce that this Forum will be hosted with the help of the Turkish Aluminium Industrialists Association (TALSAD). The adoption of digital technologies in the aluminium industry can drive economic growth, attracting investments and fostering innovation, ultimately contributing to the overall economic development of the region and it is our aim that by partnering with TALSAD for this event, we can help to develop this growth in Turkey and present the offerings of the Turkish aluminium sector. “I am thrilled to announce that the Future Aluminium Forum 2024 will be hosted in the vibrant city of Istanbul, with the invaluable support of TALSAD. This upcoming event promises to be an absolute highlight for the aluminium sector and one that no industry professional can afford to miss. In today’s rapidly evolving landscape, Industry 4.0 has become more than just

a buzzword; it’s a transformative force reshaping the very core of the aluminium industry. Our 2024 Forum will shine a spotlight on the importance of Industry 4.0, addressing the digital and technological advancements that are revolutionising aluminium production, processing, and supply chain management. We firmly believe that staying at the forefront of these innovations is crucial to drive progress, efficiency, and sustainability in our industry. But that’s not all. This event will also feature the exciting combination of the Greener Aluminium Summit, where we’ll examine the intricate link between automation and sustainability. As we explore new frontiers in automation, we’ll keep our focus firmly on the green agenda, emphasising how these advances can lead us towards a more sustainable supply chain. So, mark your calendars, prepare to network with industry experts, and join us in Istanbul for the Future Aluminium Forum 2024. Together, we will embrace the challenges and opportunities of Industry 4.0, while taking the critical steps towards a greener, more sustainable future for the aluminium sector. It’s an event you won’t want to miss,” says Nadine Bloxsome, Conference Director. � November/December 2023

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Aluminium Today Ad-2023.pdf

CMY

12/10/2023

11:05 AM

SUSTAINABILITY 9

In the eye of

the storm?

By Mark Jeavons*

There are dark storm clouds on the horizon. Commodities producers, buyers and traders may be eyeing them nervously, aware that when the storm breaks, a deluge of regulations and supply chain demands will pour down on them. Now is the time for firms to ensure they are aware of the sustainability characteristics of their operations and supply chains, so that risks and new expectations can be managed well. Those who do may find they don’t just weather the storm but find rich opportunities as the world moves towards net zero. Disclosure demands These particular clouds have been on the horizon for a while. The EU’s Sustainable Finance Disclosure Regulation (SFDR) was adopted in 2019, with the first stage of application in March 2021. However, it was January 2023 when it really began to bite, with the launch of the second phase which tightened the standard of reporting demanded of financial institutions. Discussions are underway for further refinement. Commodities businesses tend to be capital intensive and demands placed

on financial institutions for better sustainability reporting will quickly impact commodities firms. However, it won’t just be financiers demanding more reporting from commodities firms, it will be their buyers and suppliers, too. The EU’s Corporate Sustainability Reporting Directive (CSRD), also launched in January 2023, requires businesses operating in or exporting to the EU to publish environmental and social information across their entire supply chain. Europe is a leader in this regard, but not an outlier. The G20-launched Taskforce for Climate-Related Financial Disclosures (TCFD) framework sets global, cross-sector standards for firms’ climate-related disclosures; this includes reporting on emissions, climate and transition risks, governance and the strategies adopted to manage the impact of risks and benefits from opportunities. The TCFD has support from more than 3,900 organisations, spanning 101 countries and accounting for a combined market capitalisation of $26 trillion. It seems inescapable then, that commodities firms will need to ramp up reporting on their operations’ sustainability

footprint – but merely reporting won’t be enough. Change will be demanded too. Counting the cost of carbon Carbon pricing is not new but, historically, low prices have limited its impact on commodities markets. In the EU Emissions Trading Scheme (ETS), allowances (EUAs) traded under $10 per tonne for almost a decade – too low to incentivise deep decarbonisation. However, carbon prices for EUAs have started to move higher over the last few years. In theory, carbon pricing encourages the easiest, cheapest decarbonisation actions to be taken first, e.g. substituting coal power generation (made expensive by carbon prices), for renewables. This of course affects commodities markets, lowering demand for some materials (coal) and raising it for others (e.g. steel for wind turbines). However, much higher carbon prices will be needed, along with government support, to decarbonise some of the remaining big-ticket items, which will have seismic impacts on commodity markets. These are the hard-to-abate, expensive to eliminate emissions – those involved

*Head of Sustainability, CRU Group Aluminium International Today

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10 SUSTAINABILITY

in sectors such as steel, ocean freight and ammonia. Current thinking is that these sectors will rely on hydrogen to decarbonise, which though the most abundant element in the universe, is fiendishly expensive to produce. CRU estimates that carbon prices will need to rise above $200 per tonne to drive that shift at scale. Considering that at the time of writing, EUAs are around $80 per tonne, there appears to be some way to go. However, we forecast that prices will top $150 per tonne by 2030. Given that major decarbonisation actions – such as re-tooling a steel plant to use hydrogen – are often major capitalintensive projects, 2030 is uncomfortably close. The trajectory of carbon prices in Europe, and the acceleration of policies to green economies globally, represents a mounting pressure that should spur commodities firms to action sooner rather than later. The great green policy wave Direct regulatory support has the potential to greatly accelerate the energy transition. For example, headlines have been dominated by Joe Biden’s Inflation Reduction Act (IRA). While the IRA is a significant increase in ambition that will likely reduce US emissions substantially, more will need to be done if the USA’s climate target for 2030 greenhouse gas (GHG) emissions are to be reduced by 50-52% below 2005 levels by 2030, the USA’s current climate target. For example, the 45Q tax credit of $85 per tonne for CCS is too low to fully incentivise projects according to CRU analysis – at least $125 per tonne would be required for hydrogen, and $200 per tonne for other applications. However, what the IRA did do is spur a global scramble to match the level of November/December 2023

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ambition and, following that, there is a renewed focus on bilateral cooperation to accelerate the transition, notably from Europe. In March 2023, Joe Biden, and the President of the European Commission, Ursula von der Leyen, met and stressed the need for policy alignment, and to make any incentive regimes mutually reinforcing. The same month saw Canada launch its own financial support package for green-tech, with France following in May, and South Korea is in the process of doing the same. It is fair to say that we are seeing a renewed invigoration of the global energy transition spurred by an influx of legislation. Mineral movements At the same March meeting, the USA and EU announced cooperation on boosting domestic production and processing for the commodities that would underpin the energy transition, helping to lower emissions and reduce labour abuses. Likewise, the other G7 countries Canada, Australia and the UK are similarly revising their critical mineral strategies, informed by cost, sustainability and geopolitical concerns. This won’t be easy. For example, the EU has set a benchmark of at least 40% of annual consumption for processing critical materials, but today CRU estimates it processes around 14% of nickel – less than half the target. We may be witnessing the start of a G7 green-tech club, with coordinated policy to protect the security of supply chains of critical minerals. Whether or not that comes to pass, commodities producers are going to have to adapt. To at least some degree, they are likely going to have to increase production within these

territories, which tend to carry higher labour, regulation and operational costs, plus there will be a great deal of scrutiny on local environmental impacts, such as effects on water supply and biodiversity. A Taskforce for Nature-Related Financial Disclosures [TNFD] is due to follow hot on the heels of TCFD. Don’t gamble on delay In our opinion, the unnegotiable realties of climate change will mean that these trends are more likely to accelerate than be delayed. However, even if a commodity producer were to pin its hopes on delay, it would be mistaken to do so. Delay would only mean that greater and faster emissions cuts would be demanded at a later date, and given these are likely to be in the hard-to-abate sectors we have described, that would hit commodities sectors extremely hard. For this reason and the others we have outlined, commodities firms are running out of time to get ahead of the sustainability agenda. Pressure so far may have been relatively ‘soft-touch’, but in reality we are in the eye of a storm that will transform commodities markets worldwide. However, it need not be a negative thing – those who successfully adjust their strategies may see huge opportunities and competitive advantage. The foundation for good strategy though is understanding: understanding of commodity and carbon markets, of the policy outlook and the intricate web of interconnected causes and effects that move along the energy transition. CRU Group’s new Sustainability Services combine expertise on commodities, policy and regulation, emissions trends, green tech and carbon markets to support commodities businesses in navigating the energy transition. � Aluminium International Today

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Altek Ingot Casting Lines Reducing energy, delivering value and maximising productivity Altek Ingot Casting Lines are used to convert liquid aluminium, typically from Tilt Rotary Furnaces or Holding Furnaces, into small ingot stacks. Altek’s ingot casting lines come in a variety of sizes depending on the size of ingot mould required, throughput requirements, and preferred cooling methods, and are manufactured to high standards of precision. Benefits include •3 Bespoke ingot mould design in cast iron or cast steel

•3 Multiple water-cooling technologies

•3 Innovative star wheel pouring design – no dross skimming requirement on the moulds

•3 Automated stacking, weighing and labelling options

•3 Decades of ingot casting design development

•3 Operator and maintenance friendly

PART OF OUR LEADING END-TO-END DROSS MANAGEMENT SOLUTION

Altek - Ingot Castings Advert 2023 A4 AW_UK Spec_final.indd 1

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SUSTAINABILITY 13

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Scaling circularity: How to reach decarbonization goals By Suzanne Lindsay-Walker* In a world experiencing the impacts of a warming climate, decarbonization is imperative. Around the globe and across industries, stakeholders are raising their expectations for companies to lower their carbon emissions and are looking for transparent reporting and meaningful progress toward sustainability goals. Low-carbon, sustainable aluminium can play an important role in advancing business, industry and society toward a more sustainable future. At Novelis, the most effective way for us to uniquely contribute to the decarbonization of the industry is by maximizing the circularity of aluminium. Aluminium’s core properties allow it to be recycled infinitely with no loss in quality, and recycling aluminium uses approximately 95% less energy than producing primary aluminium. Novelis’ efforts – as demonstrated in our recently released sustainability report for the 2023 fiscal year – attest to the success of this approach as we reduced our Scope 1, 2 and 3 absolute emissions by 14% in fiscal year 2023. We achieved this through the execution of our global decarbonization strategy. The central tenet of this strategy is maximizing circularity by keeping aluminium “in the loop” and using the highest amount possible of recycled inputs in our products. Last fiscal year, we achieved a global average of 61% recycled content, including recycling more than 82

billion used beverage cans (UBCs). Using recycled inputs minimizes the need for higher carbon primary aluminium and significantly reduces our carbon footprint, as well as that of our customers. As we continue to execute our decarbonization strategy, we will move closer to meeting our goals to reduce our carbon emissions by 30% by 2026 and to be carbon neutral by 2050 or sooner. Because circularity is such an important part of our journey, let’s review seven strategies to scale circularity. If widely implemented throughout the value chain, these strategies can positively impact the aluminium industry. Design for Recycling In the automotive market, Novelis is collaborating with key original equipment manufacturers (OEMs) to industrialize aluminium sheet supply striving to contain high percentages of recycled content, contributing to OEMs’ targets of increased use of secondary materials in vehicle production. As an example, to further improve the sustainability of BMW’s vehicles, we support the Group’s Car2Car research project. As part of the project, we aim to produce an outer skin panel from 100% recycled aluminium. The program is also working toward a break-even point between post-shredding technology, material quality, economics,

and ecology. Using artificial intelligence (AI) technology, sensors can identify the different aluminium alloys in vehicles at the end of their life, allowing for better material sorting and, therefore, recovery and reuse. Innovate to Improve Recycling When it comes to recycling, it’s vital that we preserve the value of the materials, especially aluminium, in the scrap stream. Our partnership with Sortera Alloys, an innovative industrial scrap metal sorting and recycling company, is helping us to preserve the high quality of aluminium alloys. Sortera employs data analytics and advanced sensors to sort the scrap generated during our customers’ manufacturing processes, as well as postconsumer scrap. Sortera’s process aims to preserve the quality of aluminium alloys by more accurately sorting materials so they can be remade into the same products. This allows our products to have a lower carbon footprint and improves circularity overall. Closed-Loop-Recycling Partnerships Novelis also manages scrap at an ecosystem level through closed-loop recycling. We take the scrap created during our customers’ manufacturing processes and return it to Novelis’ recycling centers where it is recycled, cast into new ingots and rolled into new coils before it goes

*Vice President, Sustainability, Novelis Aluminium International Today

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back to customers for future production. This helps reduce waste, preserve resources and reduce customers’ carbon footprint. Novelis has major closed-looprecycling agreements with customers in the automotive industry, including with original equipment makers (OEMs) such as Ford, BMW, Volvo, Honda, Jaguar Land Rover and more. Innovating Alloys to Maximise Recycled Content Another way Novelis is enhancing circularity and decreasing the carbon footprint of our products is by developing new high-recycled-content alloys. We work with customers in all our value streams – beverage packaging, automotive, aerospace and specialties – to develop these alloys. Globally, our beverage can sheet contains an impressive 80% recycled content on average, but we continue to look for ways to increase that amount. In fact, Novelis is working on a single-alloy design for a beverage that could be made with more than 90% recycled content. Another example of an ecosystem partnership is our team enhancing Novelis’ evercycle™ product for cosmetic packaging to be made from certified 100% recycled content alloys. This new alloy provides packaging customers in the wellness, beauty and skincare industries with an alternative to plastic. Advocating for Policies to Support Recycling Novelis also seeks to improve recycling by impacting legislation at the state and federal levels. We advocate for recycling, specifically to help increase the U.S. beverage can recycling rate. Recently, we supported two bipartisan federal recycling bills in the U.S. Congress – The Recycling Infrastructure and Accessibility Act and The Recycling and Composting November/December 2023

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Accountability Act. Novelis issued letters of support for these two recycling bills. If enacted, they will advance the recycling of aluminium and could pave the way for additional recycling policies. We feel it is our duty to support efforts to expand the circular economy for aluminium. Investments to Support Circularity Increasing our recycling and manufacturing capabilities around the world enables Novelis to produce products with higher amounts of recycled material and helps us meet the growing demand for sustainable aluminium products. Novelis has completed or announced nearly $2 billion in recycling capacity and capability investments since 2011, including recent expansions in the U.S., Germany, England, South Korea, and Brazil, among others. There also will be operational benefits within many of these facility expansions, which in turn will increase our recycled content. The recent launch of a Batch Intelligence System (BIS) at our Alunorf joint venture facility in Germany is an example. The new system is projected to reduce our carbon footprint by saving 500,000 tCO2e each year through increasing the scrap input rate and reducing the use of primary aluminium in our recycling furnaces. Industry Challenges to Decarbonization Scaling circularity and decarbonizing the aluminium industry will require action by players throughout the value chain. To best compete against other substrates that are also vying to become the lowcarbon solution of choice, the aluminium industry must collaborate and create solid working partnerships that address our common challenges. For example, we need to create universally accepted methods and standards for tracking and reporting

aluminium recycling’s contribution to carbon emissions reduction – which requires transparency, accuracy, traceability and accountability from all aluminium industry value chain participants. To that end, Novelis has advocated for a standard formula to calculate recycled content. An independent third party has reviewed and approved our recommended methodology, which aligns with the best practices established by industry groups like the Aluminium Association, Mission Possible Partnership, and the Can Manufacturing Institute. Using a standard formula for recycled content increases transparency and gives customers confidence in our industry’s recycled content claims. We also need to make sure aluminium gets recycled instead of ending up in landfills. That’s why we’ve invested in recycling education programs, encouraged legislative changes and more, as we work toward the goal of maximizing recycled content. Improving the consumer recycling rate globally is an important factor in meeting demand for low-carbon aluminium products. Novelis is advocating to accelerate recycling rates globally, connecting with partners across the world on projects such as the recent International Aluminium Institute (IAI) study showing that effective global recycling of used beverage cans could reduce annual CO2 emissions by 60 million tonnes. Though we recognize and value other methods of decarbonizing the aluminium industry – increasing efficiency, reducing the use of fossil fuels, and implementing innovative carbon capture technologies, for example – the effect of scaling circularity cannot be overstated. We must come together as an industry to continue to improve our collective sustainability profile and be open and willing to collaborate with others. We cannot do it alone. � Aluminium International Today

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All cans considered Zahra Awan* spoke with María Alegre** on the position of Ball Corporation***, with regards to decarbonising the global aluminium beverage packaging industry and its own business.

María Alegre Energy and climate professional working to spark the systemic change needed to decarbonise and build a circular economy and tackle climate change. María is the global stakeholder relations director at Ball Corporation, working on strategy and advancing the narrative around circularity and aluminium decarbonisation with key external stakeholders, and reporting to the Chief Sustainability Officer, Ramon Arratia.

***Ball Corporation Ball, founded in 1880, is a world leading supplier of innovative, sustainable aluminium packaging for beverage, personal care and household products. The company has embarked on a business journey to transform aluminium cans, cups and bottles into circular solutions that span high recycled content, ultra-low-carbon primary aluminium, and reuse and refill applications.

*Assistant Editor, Aluminium International Today **María Alegre, Global Stakeholder Relations Director November/December 2023

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SUSTAINABILITY 17 INTERVIEW WITH MARÍA ALEGRE: 1. WHAT ARE THREE GOALS THAT BALL CORPORATION WANTS TO ACHIEVE? Sustainability is at the core of our business strategy, and we want to show our customers, stakeholders and value chain that we are a reliable partner at the forefront of developing and delivering low-carbon, circular aluminium packaging solutions. With that in mind, we created a Climate Transition Plan with circularity as its key lever. The three main goals of the plan are: � Achieving a 55% emission reduction across all scopes by 2030, without relying on offsets. � Advocating for a 90% recycling rate by 2030 that will enable an 85% recycled content rate for aluminium cans, bottles and cups in the regions where we operate. � Supporting the scaling up of existing technologies, such as the use of inert anodes, that can help to produce virtually carbon-free primary aluminium. 2. WHY SHOULD WE BE INTERESTED IN CIRCULARITY? Circularity is one of the main solutions many needed to address climate change, eliminating waste and circulating products and materials to retain embodied emissions within the economy. Aluminium has outstanding competitive advantages that spring from its physical properties, which maximise the reuse and recycling of the resource, making it ideal for circularity, lower emissions, and climate change mitigation. Recycling aluminium only takes 5% of the energy needed to make new aluminium. Aluminium remelts at 700 degrees Celsius (glass, for reference, melts at 1600), and is easy to collect and handle largely due to its fantastic compression rate of 12 to one. Hence, when considering collection, sorting, remelting and the making of new cans, systemic circularity is easier with aluminium than with other substrates. 3. ROLE IN INFLUENCING DEMANDS ON A GLOBAL MARKET: PRIMARY ALUMINIUM Ball is also working to decarbonise primary aluminium. The company is a member of the World Economic Forum’s First Movers Coalition, a global initiative harnessing companies’ purchasing power to unlock the untapped potential of emerging technologies needed to decarbonise hard-to-abate sectors by 2050. Ball has committed to purchasing 10% of primary aluminium annually as low-carbon aluminium by 2030. To deliver on this commitment, we are working across the value chain with both our suppliers and their suppliers, exploring innovative collaboration to advance progress. 4. REGION-BY-REGION VARIATIONS Ball works region-by-region to identify the specific obstacles they may face to become circular and decarbonise, be it technology, finance, or collection and recycling rates. Ball’s sustainability team is currently working on translating our Climate Transition Plan into regional pathways and, with that, identifying the distinctive efforts we need to make.

BALL ALUMINUM CUP® A few years ago, we identified an opportunity to build on our successful aluminium can and bottles business to create the Ball Aluminum Cup®, an innovative, aluminium alternative to plastic cups that can be used in a variety of indoor and outdoor settings. The Ball Aluminum Cup® offers a sustainable solution to consumers and venues, sports teams, festival organisers and others looking to replace waste accumulated at sports and entertainment venues with a recyclable alternative. Ball Aluminum Cups® can now be found in numerous stadiums and retail locations, are available in 5 different sizes, and are made up of 90% recycled content.

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5. HOW HAS CIRCULARITY CHANGED IN THE US VERSUS EUROPE? I think circularity has become a larger global priority over the last decade. Effectively tackling Scope 3 emissions will result in winners and losers at an accelerated rate, and that realisation has made circularity a much bigger topic worldwide, not just across our industry, as it offers a short to medium-term opportunity for companies to reduce emissions and develop a competitive advantage. Having said that, progress on the circularity of the aluminium beverage packing value chain is different depending on the region you’re focusing on. While aluminium beverage cans are the most recycled beverage package in the world, 33% of all cans are not being collected at all. This is the greatest challenge we face in North America, especially in the United States where the recycling rate has stagnated around 50% over the last decade. More than 40 billion cans, approximately $1 billion worth of aluminium, end up in landfills every year in the region. For reference, European countries have an average recycling rate of 76%. There is no structural economic barrier to achieving high recycling rates. In Europe, average collection rates above 90% are commonly achieved in countries where a robust Deposit Return Scheme (DRS) is in place. DRS applies an extra monetary charge in the

form of a deposit on beverage containers which is returned to consumers when they bring them to recycling collection points. It has been proven as a tried and tested method of increasing recycling rates all over the world, including in the United States, where the average amount of aluminium recycled in DRS states is more than three times higher than in non-DRS states. It’s worth noting that Brazil’s**** recycling rates are the highest in the world. While the country is one of the largest consumers of aluminium cans, it achieved a 100% recycling rate of aluminium cans in 2022. This outstanding achievement is the result of Brazil working for decades, investing in recycling programmes and partnering with policymakers, waste pickers associations and local businesses.

****BRAZIL CASE STUDY: About Brazil Brazil is located in South America and occupies half of the continent’s landmass. As the fifth largest country in the world, Brazil is also one of the uncommon countries that sees the entire production line of aluminium. Brazil is the fifteenth producer of primary aluminium and is the fourth producer of Bauxite. [3] It is one of the few countries to have recorded can recycling rates of over 94%. World Record In 2022, Brazil recycled 100 percent of the aluminum cans it produced. With this unprecedented feat, Brazil is a world leader in aluminum can recycling, beating out the European Union, which recycles 73 percent, and the United States, which recycled 60 percent. [4] The 2022 recycling rate is the highest in

Brazil’s history, surpassing the previous 2021 rate of 98.7%. Over the last 15 years, the average has been above 95%, confirming Brazil as one of the largest can recyclers in the world and making this sector an example of a circular economy.

economy. � VISION: The recognition of aluminium cans for beverages as the most sustainable packaging in Brazil. � VALUES: Transparency, trust, innovation, respect for the individual and the environment.

Associations and Presence in Legislation:

Legislation: Although Brazil has no legislative framework specifically regulating packaging waste, the National Solid Residues Policy (2010) encompasses the responsibility of recycling required of manufacturing, importers, distributors, and traders. [7] With decades of education, advocation and economic encouragement, Brazil has successfully constructed a recycling economy that has led to the results we see today. Brazil has also implemented a Deposit Return Scheme (DRS) which looks at recycling plastics.

[5]

ABRALATAS: Brazilian Association of Aluminium Can Manufacturers is a non-profit association established to promote the development, increase the competitiveness, and exchange experiences of the aluminium can industry, with the world. Mission, Vision, and Values [6] � MISSION: Represent the common interests of members, promoting the development of the aluminium beverage can sector with incentives for the circular

[1] chrome-extension://efaidnbmnnnibpcajpcglclefindmkaj/https://european-aluminium. eu/wp-content/uploads/2022/12/14-12-2022_European-Aluminium_Report-alumniumbeverage-can-recycling-rates-2020.pdf [2] chrome-extension://efaidnbmnnnibpcajpcglclefindmkaj/https://www.aluminum.org/ sites/default/files/2021-11/KPI_Report_2021.pdf [3] http://abal.org.br/en/statistical-information/industry-profile/ [4] https://www.france24.com/en/live-news/20230720-aluminum-recycling-in-brazil-

scraping-by-in-a-billion-dollar-industry) https://ciclovivo.com.br/planeta/desenvolvimento/brasil-recicla-100-das-latinhasde-aluminio-em-2022/

[5] [6] [7]

https://www.abralatas.org.br/ https://cms.law/en/int/expert-guides/plastics-and-packaging-laws/brazil

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6. WHAT ROLE DOES CORPORATION PLAY IN THIS?

BALL

At Ball, we believe policy is of the essence to achieve circularity, and this is the reason our sustainability and public affairs teams are one and the same. With circularity being the key lever in Ball’s Climate Transition Plan, we advocate strongly and work alongside policymakers for Extended Producer Responsibility (EPR) regulation, which mandates businesses to collect and recycle, and the implementation of DRS, which makes collection and recycling of beverage packaging more efficient.

8. UN GUIDELINES AND BALL CORPORATION’S PATHWAYS The UN’s “Integrity Matters” report that provides guidelines for net zero commitments was released last year at COP 27 and highlights the urgent need to go past mere pledges and into robust, ambitious and transparent climate transition plans. While our Climate Transition Plan, entirely developed in house, was already long in the making back then, it was quite reassuring to confirm the vision and pathway outlined in our plan were very much aligned, and we made our best effort to make as many adjustments as possible. Ball’s Climate Transition Plan is transparent, 1.5C aligned, and feasible yet ambitious. Interestingly, it focuses on concrete, shortterm action, and does not rely on offsets.

7. WHAT KIND OF POLICIES AND ADVOCACY WOULD YOU LIKE TO SEE FROM COUNTRIES AND POLICYMAKERS? We advocate for national or state recycling targets for aluminium cans, for policies to help achieve them, and for keeping aluminium cans in can-to-can recycling loops. The environmental benefits of creating a strong circular system come from displacing primary resource production – ensuring that recycled materials are used to create new, high-quality products. However, not all levels of recycling are the same. Aluminium products are made of different alloys which when mixed together, cannot be re-used into the same product again. Instead, the mixed volume becomes cast aluminium, which is used in applications such as motor blocks for cars, in what is called open-loop recycling. On the other hand, closed-loop recycling enables the material to come back into the market to serve the same purpose as the original product, preserving the value

of the substrate, and keeping it in use at its highest and best value for as long as possible. Aluminium cans are a textbook example of a packaging option that is well-suited for closed-loop recycling, as used beverage cans (UBC) are consistently recycled back into new beverage cans, with a minimal loss of material value. UBC closed-loop recycling, or can-to-can recycling, truly preserves aluminium value over time. The amount of material that is kept in the loop depends on the losses at each stage of the recycling value chain: collection, sorting, re-melting and then making a new can. Since UBC have high recycling yields and is sorted with inexpensive technologies, the biggest opportunity is continuing to increase collection through EPR and DRS, creating economic and employment opportunity for waste collectors, recyclers, industrial materials users, recycling equipment providers, and other stakeholders.

We have considered and described three different pathways to adjust to the degrees of uncertainty that we have, including technology deployment and policy development, without compromising the delivery of the targets we have set for ourselves. In doing so, we want to show our customers and stakeholders that Ball is capable of effectively contributing to their own decarbonisation goals and triggering a systemic change in the way we produce and consume our products. In this sense, we are also exploring refill and reuse applications, including the Ball Aluminum Cup® and a partnership with Boomerang Water, a bottling system that collects, processes, washes, sanitises, and refills reusable and recyclable aluminium water bottles in closed settings like campuses, stadiums, venues or cruises. 9. CONCLUSION I think that the challenge our industry and other industries - face is getting past empty words and working effectively together to implement solutions and drive climate advocacy and action at the necessary pace and scale in this decisive decade for climate change. Our sustainability commitment is unwavering, yet we cannot do it alone: 74% of our Scope 3 emissions come from aluminium, and we rely on collaborating with our supply chain to become a fully circular and decarbonised business, delivering value to our stakeholders and our planet.

Aluminium International Today

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For you, industry brings innovation to life. Behind lightweight and recyclable cans, is an industry that produces the finest quality of aluminium, using high performance manufacturing technologies. ALUMINIUM

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TECHNOLOGY 21

CO2 capture solutions This consortium, which brings together the world’s leading expertise to implement an innovative process, aims to achieve a 50% reduction in direct CO2 emissions (excluding energy sources) from primary aluminium production by 2030. With more than 60 years’ experience in the capture and processing of industrial emissions, Fives, an international leader in industrial engineering, has unique expertise to contribute to the production of greener aluminium. Primary aluminium production accounts for 2% of global greenhouse gas emissions, which corresponds to an average of 16.1 tonnes of CO2 emitted globally per tonne of aluminium produced (in France, the average is less than 5 t/CO2). A partnership based approach, a key success factor Fives has been committed to decarbonising industry for over twenty years. The Fives Group has built its technological leadership in partnership with numerous industrial companies in every sector. After joining forces with the world’s leading players in the hydrogen sector, the digitalization of industrial processes and the best research centers, Fives is now extending its partnership approach to carbon capture. “Working in partnership guarantees the development of solutions that meet the needs of the ﬁeld and are tested immediately under real operating conditions. Combining the experts in each technology means that a complete, highperformance solution can be achieved quicky”, Sebastien Gauguier, CEO of the Aluminium Division � Aluminium Dunkerque and Trimet in St Jean de Maurienne will be combining their expertise to help develop this technology on their respective sites. � Rio Tinto, one of the world’s largest aluminium producers, has expertise in the electrolysis process. � Fives brings its technology for capturing and treating gas emissions from primary aluminium production. From pilot to industrial phase The project, which is part of the France Aluminium International Today

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FOCUS: Aluminium is a strategic material for the low-carbon transition (lighter, more workable and recyclable). Aluminium is a strategic material for the low-carbon transition. Its use contributes to the lightening of vehicles, in which its share is expected to grow by 13% between 2014 and 2050. Demand for aluminium in connection with electriﬁcation will also increase, as will requirements in the packaging sector, due to the elimination of single-use plastics, its light weight and excellent recyclability. Aluminium is one of the most easily recyclable metals, and ﬁts in perfectly with the development of a circular economy that consumes less energy and resources. Volumes are therefore expected to rise sharply in the coming years.

2030 plan, will shortly be submitted to the French Environment and Energy Management Agency (ADEME). As the ﬁrst step towards radical decarbonisation, the project comprises two main stages at the Trimet St Jean de Maurienne and Aluminium Dunkerque sites: 1. 2024-2027: experimentation in test pots and prototype installation 2. From 2028: industrial deployment of the technology on part of the sites. The aim is to reduce emissions by 50% by 2030 About the technology This involves using carbon capture technologies to collect the carbon emitted during the production of primary aluminium in the pots at source. The aim of the project is to help design,

prototype and develop this technology for the aluminium sector. While the carbon capture process has already been tried and tested in various industrial sectors, such as petrochemicals and thermal power stations, it is still at the industrial research stage for aluminium. Three main steps: � Collection of CO2-laden gases as close as possible to the source of emission in the electrolysis pot. This choice optimizes the concentration rate and the volume of CO2collected in the ﬂue gas. � Installation of an innovative gas treatment center to purify these gases, which are more concentrated than usual, to make them compatible with the CO2capture process. � Capture of CO2 using an absorption process with amine solvents. � November/December 2023

01/11/2023 10:43:25

precimeter.com

GREEN ELECTRICITY 23

The heat is on With the rapid rise in electric vehicles, there is a growing glut of aluminium engine blocks – and few new users for the low-grade alloy. Now British startup Caldera has a solution – they have developed a novel way of storing green electricity as heat, using giant blocks made of recycled aluminium and volcanic rock. Their electric storage boilers will have multiple applications in industry – including delivering green heat to alumina refineries. Aluminium engine blocks are becoming a problem to recycle. Made from low grade aluminium alloys they would traditionally be remelted to make new engine blocks. But with the rapid growth in electric vehicles, fewer engines are needed, and industry is seeking new uses for the lowgrade alloy. Now British startup Caldera has come up with a potential use for large volumes of this increasingly unwanted by-product of the fossil-fuel age. Caldera has developed a groundbreaking electric boiler which comprises multiple heat cells, each filled with a special aluminium-rock composite, a ‘thermal super material’ designed by the Hampshire firm to cheaply and effectively store low carbon electricity as heat. The purpose of their boiler is to enable industry to switch off fossil fuels and use lower-carbon energy. Their storage boiler takes renewable energy – such as solar power and offpeak wind generation – and stores it onsite as heat. This can then be delivered when required as hot water or steam, the main heat source for many processes in pharmaceuticals, food manufacturing and brewing – and refining Alumina, where around 80 percent of the energy used is steam. Each system can be set to charge from the grid at night when cheaper and greener electricity is available and can take power directly from on-site or nearby renewables, such as solar or wind. Aluminium International Today

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Caldera believes that in sunny countries their technology can help decarbonise over 80 percent of the energy supply to an alumina refinery by combining massive solar pv farms with thermal and electric storage. James Macnaghten explains:

rapid decarbonisation to take place. “It is also quite symbolic and very circular to use an aluminium-based thermal store as the solution to decarbonising alumina production,” James says. He goes on to explain that each heat cell contains a novel mixture of aluminium

Caldera founders (l to r) Guy Winstanley and James Macnaghten

“We have done some high-level modelling and for a refinery that uses, say, 250MW of steam, you would build a 1,000MW solar farm and connect it to the refinery on a private wire. The energy from the solar farm is fully consumed on site either as heat or electricity and none of it needs to be exported. This avoids the need for expensive grid upgrades and allows

and either basalt or granite, all readily available materials which can be procured at low cost. “We use scrap aluminium, which is cheap and abundant, and by combining it with natural rock in the right way, we’ve created a thermal super material which heats up phenomenally well. “Each heat cell houses a solid core of November/December 2023

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24 GREEN ELECTRICITY

our aluminium-rock composite encased in vacuum insulation which can store heat at temperatures from 200 to 500C, and hold it for hours, ready to be released when required. “It can be thought of as super conductive, ultra tough concrete. It can deliver heat 50 times more quickly than concrete, yet unlike concrete it does not

crack when thermally stressed,” James concludes. In June, Caldera was awarded £4.3 million from the UK Department for Energy Security & Net Zero to build a full-scale demonstrator at their Southampton site, where they will showcase the technology to potential customers. Each heat storage unit will comprise

ten solid heat cells, each of which can store 200kWh, offering a total of 2MWh storage. These can be combined to deliver as much capacity as needed. Work has already begun on site, and the project will complete in 2025. They are now seeking commercial partners, with plans to commence sales and rapidly ramp up production thereafter. Contact: https://www.caldera.co.uk/

INTERVIEW 1. CAN YOU PROVIDE AN OVERVIEW OF YOUR COMPANY’S MISSION AND ITS APPROACH TO ELIMINATING FOSSIL FUELS THROUGH ENERGY STORAGE?

James Macnaghten

Caldera’s mission is to eliminate the use of fossil fuels in industry by storing renewable energy as heat, ready to be used when required. Around 70 percent of industrial fuel demand in Britain is for heat – and around 30 percent of this is for industrial steam in the range 100-200 C – for use in processes such as pharmaceuticals, food

manufacturing and brewing. Typically, this is provided by steam boilers that burn gas or oil. In contrast, we have developed a novel type of storage boiler which takes cheap, green off-peak electricity and stores it in heat cells made of low-grade scrap aluminium and rock – ready to be released as hot water or steam when required.

2. RENEWABLE ENERGY SOURCES OFTEN HAVE INTERMITTENT AVAILABILITY. HOW DOES YOUR COMPANY ADDRESS THE CHALLENGE OF STORING AND EFFICIENTLY UTILISING THIS ENERGY WHEN NEEDED? We believe heat storage is the key! One of the challenges with renewables is that the sun does not always shine and the wind does not always blow. Rather than storing this energy as electricity in batteries, which then has to be converted into heat, we have developed a means to store this renewable energy efficiently directly as heat, ready to be used when required. 3. HOW DOES IT WORK? Our ground-breaking electric boiler comprises multiple heat cells, each filled with a special aluminium-rock composite. Each heat cell houses a solid core of aluminium-rock composite encased in vacuum insulation which can store heat at temperatures from 200 to 500C and can retain this heat at high efficiency for many hours. Each system can be set to charge either from on-site renewables, such as solar, or from the grid when cheaper and greener November/December 2023

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electricity is available. These modular cells can store this electricity with very high efficiency for hours, ready to deliver heat on demand at temperatures between 80 to 200C – the sweet spot for many industrial processes. Alumina production requires higher temperature steam and, as James Macnaghten explains, ‘we can easily adjust the system to supply 300C steam with only a small reduction in thermal storage capacity per tonne of material. Aluminium International Today

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GREEN ELECTRICITY 25

5. WHERE HAVE YOU REACHED IN THE DEVELOPMENT OF YOUR TECHNOLOGY? In June Caldera was awarded £4.3 million from the Department for Energy Security & Net Zero to build a full-scale demonstrator at our Southampton site, where we will showcase the technology to potential customers. This will be operational later this year. The system can store 4MWh’s of heat and charges at 1MW. We have already signed an Memorandum of Understanding (MoU) with a major NHS Trust to pilot the use of our heat storage system, and we have also engaged the Manufacturing Technology Centre to design a ‘gigafactory’ where we can start to manufacture and roll out hundred and ultimately thousands of heat storage systems in the years ahead.

4. HOW IMPORTANT IS ALUMINIUM IN YOUR PRODUCTS/PROCESSES AND WHAT ROLE DOES IT PLAY? Aluminium is a vital component of our technology. It can be combined with volcanic rock, such as basalt, to create our aluminium-rock composite, which can be thought of as super conductive, ultra-tough concrete. It can deliver heat 50 times more quickly than concrete, yet unlike concrete it does not crack when thermally stressed. Crucially, the quality of the aluminium is not important, and therefore we can become a key user of low-grade, recycled aluminium, such as old engine blocks, which will become increasingly available with the demise of internal combustion engines.

6. ENERGY STORAGE CAN BE CAPITAL-INTENSIVE. CAN YOU DISCUSS THE INVESTMENT STRATEGIES AND FINANCIAL MODELS YOUR COMPANY USES TO FUND ITS PROJECTS AIMED AT ELIMINATING FOSSIL FUELS? Because our technology uses low-cost materials, our storage is around a third of the cost of batteries. And our input energy is cheap. On-site solar power is now incredibly cheap and getting cheaper, and our heat batteries can soak up all of a nearby solar farm’s output, without putting any pressure on the electricity grid. In addition, we can take advantage of off-peak electricity by importing electricity from the grid when it is abundant and prices are low. Together, this gives industrial users a cost-effective route to decarbonise some or all of their heat demand.

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ENERGY 27

Ulf Nahrath

Decarbonising the UK energy system and options for the industrial sector Effectively decarbonising operations continues to dominate the conversation for the UK’s industrial sector, with net-zero ambitions widely considered a key corporate focus alongside competitively meeting production demands. In this article, Ulf Nahrath* discusses the possible options available, the economic implications of each, their potential challenges and the benefits of adoption. The UK’s future net-zero energy system must balance cost, reliability and broader economic benefits. It should offer resilience, ensure security of supply and support new jobs. In parallel, it must quickly transition towards the use of cleaner products, with the ambition of achieving net-zero by 2050. After all, tomorrow’s energy demands will increasingly be delivered by a wider portfolio of more sustainable, more circular, more decentralised alternatives. Alongside a significant increase in the generation of renewables, we’re likely to see investment in alternative fuels, such as greener hydrogen, nuclear and bioenergy, as ever-more pivotal elements of the energy landscape.

As businesses continue to seek new and innovative solutions to further reduce the impact of energy costs on their bottom line, buying better is no longer enough. Instead, they must focus on managing consumption, embracing efficiency and test feasibility of electrification, hydrogen or post combustion carbon capture. This is the most effective long-term solution to reduce both cost and carbon. The challenges of decarbonising the industrial sector According to insight from HSBC, the UK’s industrial sector is responsible for more than 12% of our national greenhouse gas emissions. From chemicals and cement manufacture, to the production of iron,

steel, plastics, glass and textiles, keeping up with escalating demand is highly resource intensive. While the sector has reduced its emissions by 57% since 1990, pace and change is needed to further decarbonise. Reducing emissions requires major transitions, including a substantial reduction in overall fossil fuel use, the deployment of low-emission energy sources, switching to alternative energy carriers and maximising energy efficiency. The benefits of doing so, however, are widespread – lower operational costs, increased revenues, access to cheaper capital and an enhanced reputation to name but a few, alongside a backdrop of lower carbon intensity.

*Shell’s VP of UK Energy Transition and Infrastructure Aluminium International Today

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28 ENERGY

The first priority is helping industrial businesses to secure the energy they need at an affordable price in a sustainable way. Immediately available decarbonisation pathways include biomethane, solar PV and natural gas. Switching to the provision of zero-carbon power or buying carbon credits through your energy provider is yet another fast and effective solution. In the medium and long-term, businesses should be looking towards solutions such as clean biofuels, carbon capture and storage (CCS), battery technologies and carbon offsetting. Hydrogen (both blue and green) will become ever-more readily available across the UK over the coming decades, offering yet another low carbon option for energy intensive users. Each offer numerous financial and environmental opportunities, but also come with their own set of specific challenges. Understanding their strengths and limitations is key to identifying the right approach for your business. A. Option 1: electrification A simple yet proven approach, replacing gas with electricity can prove an important step to cutting carbon. While offering the simplicity of using a single carrier, it’s important to consider whether or not the grid offers sufficient local capacity for energy intensive operations and the possible cost implications as electricity is historically 2.5 times more expensive than gas in the UK and its distribution cost to customers even more so. Private wire options, such as on-site renewables (solar, wind, battery storage, etc.), can effectively navigate this barrier, but having sufficient space to house assets and the capital required to invest is critical November/December 2023

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to success. B. Option 2: Hydrogen There are two approaches to producing hydrogen: blue hydrogen (produced by splitting natural gas into hydrogen and carbon dioxide) and green hydrogen (produced by splitting water via electrolysis into hydrogen and oxygen). Green hydrogen requires a large energy input from a renewable source and blue hydrogen requires carbon capture infrastructure making use of large carbon stores in the North Sea. The UK government’s aim is to have 10GW blue and green Hydrogen production capacity installed by 2030. The application and operation of hydrogen is similar to natural gas, but with the added benefit of lower carbon intensity. This said, any business must consider its own readiness and viability. For example, plant equipment like turbines or boilers must be converted to be fully compatible to use hydrogen as an input fuel, while you’ll also need direct access to a hydrogen pipeline. C. Option 3: Carbon Capture and Storage (CCS) CCS is yet another attractive decarbonisation option for industrial businesses. The process sees CO2 captured and separated from flue gas, before being treated, processed, transported and injected deep underground where it can be safely stored in the North Sea depleted oil or gas reservoirs or aquifers. The opportunity for industrial offtakers is significant. What’s more, there is little change needed for plant equipment (just

amendments needed to flue processes). This said, however, businesses should be aware that impact and value is based on scale, while good carbon transportation links are needed. Opportunities for the future While the past 24 months have proven uncertain at best for industrial energy users, the system will continue to evolve between now and 2050, bringing with it changes in cost profiles, stringent regulation and the requirement to embrace new technology. It’s no longer an ‘if’ but a ‘when’ for industrial businesses to decarbonise their operations. Driving widespread energy efficiency across your business should be an immediate first step, while clear consideration should be given to initiatives such as electrification, hydrogen and CCS. For any industrial company looking to decarbonise, it’s essential to take a baseline of carbon intensity, equipment and cost and then undertake extensive due diligence to understand the cost and supply security implications of available solutions, as well as infrastructure availability and the adaptability of existing plant equipment. Shell Energy is perfectly placed to support users in their journey to net-zero. Our experienced team are here to help customers navigate the complexities of decarbonisation and achieve their longterm net-zero goals. To find out more about Shell Energy and its affordable, cleaner, simpler renewable energy solutions, visit www.shellenergy.co.uk/business. � Aluminium International Today

30/10/2023 11:11:23

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THE ALUMINA CHRONICLES 31

Two workers at Emirates Global Aluminium (EGA) reviewing information at the Al Taweelah Alumina Reﬁnery of EGA in the Khalifa Industrial Zone Abu Dhabi in the United Arab Emirates. (The photograph was provided courtesy of Emirates Global Aluminium.)

Aluminium industry in The United Arab Emirates By Richard McDonough*

Though relatively modest in size – both geographically and population-wise – the United Arab Emirates (UAE) is one the largest producers of aluminium and related products in the world. In its most recent report, the International Monetary Fund (IMF) indicated that the estimated population of the UAE was estimated to be about 10,060,000 in 2023. Geographically, the UAE includes approximately 83,600 km2 of territory, according to the World Bank. The IMF indicated that the economy of the UAE was the 31st largest globally in 2023. This international agency estimated the Gross Domestic Product (GDP) of the UAE to be about (US) $509,180,000,000 for 2023. This level of GDP is comparable to the estimated amounts in Thailand and Singapore. To put this into further perspective, the GDP of the UAE is estimated to be substantially higher than a number of countries with larger populations, such as Nigeria and Pakistan, as well as a number of nations within the European Union,

including such countries as Czechia, Denmark, and Romania. A significant portion of the economy of the UAE is based on the oil and gas industry. “The UAE is estimated to hold the seventh-largest proven oil and natural gas reserves globally,” according to a recent statement from the International Trade Administration of the United States of America (USA). “Approximately 30 percent of the country’s GDP is directly based on its oil and gas output, contributing to almost 13 percent of the value of its total exports.” Whilst petroleum-related products are a critical factors in the economy of the UAE, manufacturing of other products has been steadily increasing in recent years. The increased production of aluminium and related products is an important aspect of the growth in the UAE’s economy. Trade Of all nations, the UAE was ranked as the 6th largest exporter of aluminium and

related products in 2022. This was a jump from its status as the 7th largest exporting nation of these products in 2021 and the 9th largest exporter of aluminium and related products in 2020. The country ranked as the 7th largest exporter of these products in 2017, 2018, and 2019. These statistics are according to the International Trade Centre (ITC). Unless otherwise stated, statistics detailing imports and exports of aluminium and related products to and from the UAE are from reports issued by the ITC. In 2022, the UAE exported approximately (US) $10,210,365,000 of aluminium and related products. To put this amount into perspective, exports of these products from the UAE were slightly less than the Russian Federation (Russia) and slightly more than Italy in that year. Only China, Germany, the USA, Canada, and the Russia exported more aluminium and related products than the UAE in 2022. Please note that this number for exports in 2022 was tentative and was based on

*Do you have questions about the aluminium industry? Governmental regulations? Company operations? Your questions may be used in a future news column. Contact Richard McDonough at aluminachronicles@gmail.com © 2023 Richard McDonough Aluminium International Today

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November/December 2023

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32 THE ALUMINA CHRONICLES

IMPORTS

EXPORTS

Sources of aluminium and related products imported into the United Arab Emirates 2021. (US) $1,379,747,000

Destinations for aluminium and related products exported from the United Arab Emirates 2021. (US) $8,149,499,000

China

USA Japan The Netherlands Taiwan Italy Malaysia South Korea Thailand India Saudi Arabia Turkey Morocco Spain Oman UK Indonesia China Mexico All Other Nations

India Saudi Arabia Oman Thailand South Korea USA All Other Nations

Pic 1.(The image was created using data from the International Trade Centre, 2021.)

Pic 2. (The image was created using data from the International Trade Centre, 2021.)

Pic 3. Emirates Global Aluminium operates an aluminium smelter at Jebel Ali south of Dubai in the United Arab Emirates. (The photograph was provided courtesy of Emirates Global Aluminium.)

what the ITC called “mirror data.” This data was “reconstructed on the basis of data reported by partner countries… Mirror data is better than no data at all but it has a number of shortcomings… Hence comparisons over time using mirror data need to be interpreted with caution.” Statistics regarding exports and imports provided by the ITC for 2021 and years prior detailed in this news column are amounts reported to the ITC and are not based on mirror data. Imports of aluminium and related products into the UAE have been much more limited than the level of exports of these products. The nation has seen its ranking as an importer of aluminium and related products decrease in recent years. The UAE was ranked as the 38th largest importer of aluminium and related products in 2022 as well as in 2021. The country was ranked at number 35 in November/December 2023

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2020, at number 34 in 2019, at number 36 in 2018, and at number 33 in 2017. In 2022, the UAE imported about (US) $1,465,482,000 of aluminium and related products. As with the stats provided by the ITC for exports in 2022, the amount of imports for this year was based on mirror data. Imports Imports of aluminium and related products increased from 2017 to 2018, but then dipped in 2019 and 2020. The level of imports increased again in 2021. Overall, imports of these products into the UAE increased about 19.6% from 2017 to 2021. In 2017, imports of aluminium and related products amounted to approximately (US) $1,153,540,000; in 2018, (US) $1,176,099,000; in 2019, (US) $1,112,217,000; in 2020, (US)

$1,017,375,000; and in 2021, imports of these products were valued at (US) $1,379,747,000. The majority of the aluminium and related products imported into the UAE from 2017 through 2021 arrived from Asian nations. The only major source of these products from outside Asia was from the USA; the level of imports from that nation were only about 4% of the total imports of these products in 2017, and approximately less than 5% of all of the imports of aluminium and related products in 2021. As has been the case with many nations throughout the world, China was the largest source of aluminium and related products into the UAE in each year from 2017 through 2021. Its portion of this market increased during this five-year time period – from about 35.5% of all of the imported aluminium and related products in 2017 to approximately 39.1% of these imports into the UAE in 2021. The amount of these products imported from China increased each year from 2017 to 2021, with the exception of a decrease in 2020. The UAE imported about: (US) $409,815,000 in these products from China in 2017, (US) $461,401,000 in 2018, (US) $476,341,000 in 2019, (US) $417,017,000 in 2020, and (US) $539,777,000 in 2021. India was the second largest source of aluminium and related products imported into the UAE in 2021. The amount of these products imported in that year from India was about twice the amounts in each of Aluminium International Today

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THE ALUMINA CHRONICLES 33

the previous four years. In 2017, the UAE imported approximately (US) $76,814,000 of aluminium and related products from India, whilst that amount increased to about (US) $143,840,000 in 2021. Imports of these products from India represented approximately 6.7% of all such imports in 2017; that level increased to about 10.4% of imports of aluminium and related products in 2021. Saudi Arabia and Oman were the third and fourth largest sources, respectively, of aluminium and related products imported into the UAE in 2021. Their portion of this market varied from year-to-year from 2017 to 2021, but decreased in absolute terms as well as market share percentages during that five-year time period. Imports of these products from Saudi Arabia were about (US) $116,207,000 in 2017, (US) $107,609,000 in 2018, (US) $97,199,000 in 2019, (US) $86,230,000 in 2020, and (US) $106,183,000 in 2021. Imports of aluminium and related products from Oman were approximately (US) $112,717,000 in 2017, (US) $125,595,000 in 2018, (US) $97,209,000 in 2019, (US) $95,729,000 in 2020, and (US) $105,838,000 in 2021. The combined percentage share for imported aluminium and related products from Saudi Arabia and Oman into the UAE decreased from about 19.8% of the market in 2017 to approximately 15.4% of the market in 2021. Thailand, South Korea, and the USA ranked as the fifth through the seventh largest sources of aluminium and related products imported into the UAE in 2021. Together, the percentage of these products imported from the three countries

Pic 4. An aerial view of the Al Taweelah alumina reﬁnery of Emirates Global Aluminium. (The photograph was provided courtesy of Emirates Global Aluminium.)

amounted to about 10.3% in 2017; that percentage increased to approximately 16.7% in 2021. The bulk of the increase was from imports from Thailand. Aluminium and related products imported from Thailand were about (US) $21,305,000 in 2017 and (US) $99,061,000 in 2021; from South Korea, (US) $52,196,000 in 2017 and (US) $68,556,000 in 2021; and from the USA, (US) $45,019,000 in 2017 and (US) $62,804,000 in 2021. In total, imports from these seven nations represented about 72.3% of all aluminium and related products imported into the UAE in 2017. The level of imports into the UAE from the seven specific countries increased to approximately 81.6% for these types of products in 2021. Exports The UAE increased its exports of aluminium and related products by about 31.3% from 2017 to 2021. Whilst

Pic 5. Emirates Global Aluminium is a major industrial ﬁrm in the United Arab Emirates. (The photograph was provided courtesy of Emirates Global Aluminium.)

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there was an increase in exports of these products during this five-year time period, the amounts decreased in both 2019 and 2020 from the previous years. There was a substantial increase in 2021. Aluminium and related products exported from the UAE were valued at approximately (US) $6,206,409,000 in 2017 and (US) $8,149,499,000 in 2021. In the intervening years, the amounts were about (US) $6,379,975,000 in 2018, (US) $5,539,326,000 in 2019, and (US) $4,446,737,000 in 2021. Whilst a majority of the imports of these products into the UAE were from Asian countries, exports of aluminium and related products were to a wide variety of nations in Africa, Asia, Europe, and North America. The USA and Japan have been the second and third largest export markets, respectively, for aluminium and related products exported from the UAE for each year from 2017 through 2021. The share of the export market for these products held by the USA decreased from about 21.9% in 2017 to approximately 15.1% in 2021, whilst Japan’s share of the market for aluminium and related products exported from the UAE grew to approximately 13.6% in 2021 from about 11.3% in 2017. Exports of aluminium and related products from the UAE into the USA decreased each year from about (US) $1,359,655,000 in 2017 to approximately (US) $817,946,000 in 2020; the amount then increased to (US) $1,231,597,000 in 2021. For exports of these products to Japan from the UAE, the amounts increased each year from about (US) $702,691,000 in 2017 to (US) $747,324,000 in 2019, November/December 2023

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34 THE ALUMINA CHRONICLES

Pic 6. Guinea Alumina Corporation, a fully-owned subsidiary of Emirates Global Aluminium, produces bauxite from its mines in the Republic of Guinea. (The photograph was provided courtesy of Emirates Global Aluminium.)

then decreased to approximately (US) $504,014,000 in 2020. Exports of aluminium and related products from the UAE into Japan more than doubled to about (US) $1,110,997,000 in 2021. The Netherlands, the third largest destination for aluminium and related products exported from the UAE, has seen its portion of this market decrease from about 11.2% in 2017 to approximately 8.6% in 2021. Exports of these products from the UAE varied during the five-year time period, but increased only slightly in absolute terms from about (US) $695,296,000 in 2017 to approximately (US) $701,472,000 in 2021. About one-fifth (19.7%) of the export market for these products focused on Taiwan, Italy, Malaysia, and South Korea in 2021; that was an increase in the percentage of this export market from the approximate 17.3% share held by the four nations in 2017. Exports of aluminium and related products from the UAE to Taiwan amounted to about: (US) $302,289,000 in 2017, (US) $434,693,000 in 2021; to Italy, (US) $315,046,000 in 2017, (US) $399,143,000 in 2021; to Malaysia, (US) $218,897,000 in 2017, (US) $397,766,000 in 2021; and to South Korea, (US) $238,638,000 in 2017, (US) $377,133,000 in 2021. Five other nations that were also large export markets for these products manufactured in the UAE were Thailand, India, Saudi Arabia, Türkiye, and Morocco. The UAE exported aluminium and related products to Thailand in the approximate amounts of: (US) $353,103,000 in 2017 and (US) $371,945,000 in 2021; November/December 2023

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to India, (US) $280,722,000 in 2017 and (US) $343,704,000 in 2021; to Saudi Arabia, (US) $31,144,000 in 2017 and (US) $276,858,000 in 2021; to Türkiye, (US) $227,486,000 in 2017 and (US) $236,030,000 in 2021; and to Morocco, (US) $81,724,000 in 2017 and (US) $214,944,000 in 2021. Collectively, exports of these products from the UAE to these five countries increased from about 15.7% of the market in 2017 to approximately 17.7% of the market in 2021. Six other nations were also important destinations for aluminium and related products exported from the UAE: Spain, Oman, the United Kingdom (UK), Indonesia, China, and México. The market share for exports of these products from the UAE to these six nations increased two percentage points from about 8.3% in 2017 to approximately 10.3% in 2021.

Exports of aluminium and related products from the UAE to Spain amounted to about: (US) $100,769,000 in 2017, (US) $176,242,000 in 2021; to Oman, (US) $133,768,000 in 2017, (US) $142,538,000 in 2021; to the UK, (US) $91,233,000 in 2017, (US) $141,275,000 in 2021; to Indonesia, (US) $133,593,000 in 2017, (US) $135,693,000 in 2021; to China, (US) $43,259,000 in 2017, (US) $123,711,000 in 2021; and to México, (US) $15,404,000 in 2017, (US) $116,399,000 in 2021. Overall, exports to these 18 countries represented about 85.7% of all aluminium and related products exported from the UAE in 2017. Exports of these products from the UAE to these specific nations combined decreased slightly to approximately 85.1% in 2021. Emirates Global Aluminium Emirates Global Aluminium (EGA) is the largest business in the aluminium industry in the UAE. The firm operates smelters in Abu Dhabi and Dubai, an alumina refinery in Abu Dhabi, and a bauxite mine in the Republic of Guinea. “Since 1975, when it was founded as Dubai Aluminium by His Highness Sheikh Rashid bin Saeed Al Maktoum, Emirates Global Aluminium has been innovating aluminium to make modern life possible,” according to a statement from EGA. “Today EGA is the world’s biggest ‘premium aluminium’ producer and the largest industrial company in the United Arab Emirates outside the oil and gas industry. EGA is equally-owned by Mubadala Investment Company of Abu

Pic 7. Emirates Global Aluminium uses solar power to produce its CelestiAL brand of aluminium. (The photograph was provided courtesy of Emirates Global Aluminium.)

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36 THE ALUMINA CHRONICLES

Dhabi and the Investment Corporation of Dubai. It is the largest company jointly owned by the two Emirates.” A spokesperson for EGA said that the company sells its aluminium both locally and throughout the world. “We are globally-balanced in terms of customers, exporting to the Americas, Europe, Asia, and the MENA [Middle East – North Africa] region,” the spokesperson for EGA stated. “About 10% of our sales are local here in the UAE.” Sustainability is one of the goals for EGA. “We were the first company in the world to produce aluminium commercially using the power of the sun,” the EGA spokesperson said. “We call this product ‘CelestiAL.’ In 2022, we produced 57,000 tonnes of CelestiAL out of total sales of 2.72 million tonnes. BMW Group was the first and remains the biggest customer for CelestiAL. We have also announced supply agreements with Tier 1 suppliers of Mercedes-Benz and Nissan.” The solar power utilised by EGA to produce this brand of aluminium “…is supplied by Dubai Electricity and Water Authority, which operates the Mohammed bin Rashid Al Maktoum Solar Park in the desert outside Dubai, and by Emirates Electricity and Water Company from Noor Abu Dhabi at Sweihan,” according to a statement from EGA. EGA noted that “electricity generation accounts for around 60 per cent of the global aluminium industry’s greenhouse gas emissions. The use of solar power significantly reduces these emissions.” Gulf Extrusions is utilizing CelestiAL aluminium produced by EGA for a commercial satellite to be launched into space by the Mohammed Bin Rashid Space Centre (MBRSC) , according to a news statement from EGA issued on 17 May 2023. “EGA’s metal has been formed in Jebel Ali [in Dubai] into parts for MBRSC’s MBZ-SAT, the region’s most advanced commercial satellite in the field of highresolution satellite imagery, which is due to be launched in 2024,” the news statement detailed. “At MBRSC, our mission is not only to explore the vast potential of space but also to drive the diversification of the UAE’s economy,” stated His Excellency Salem Humaid AlMarri, Director General of the MBRSC. “We recognise the immense value of joining forces with diverse partners to leverage their unique expertise and capabilities. By forging strategic partnerships with innovative entities such as Emirates Global Aluminium and Gulf Extrusions, we are able to expand the horizons of the UAE’s space sector. Together, we are committed to pushing November/December 2023

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Pic 8. CelestiAL aluminium produced by Emirates Global Aluminium is being utilised by Gulf Extrusions for a commercial satellite to be launched into space by the Mohammed Bin Rashid Space Centre in 2024. Pictured here, from left, are Wafa Al Kaz, Senior Manager Metallurgy, Emirates Global Aluminium; Abdulla Bin Kalban, Senior Manager, Casthouse, Emirates Global Aluminium; His Excellency Salem Humaid AlMarri, Director General, Mohammed Bin Rashid Space Centre; and a representative of the Mohammed Bin Rashid Space Centre. (The photograph was provided courtesy of Emirates Global Aluminium.)

the boundaries of innovation and fuelling the growth of this vital industry.” Abdulnasser Bin Kalban, Chief Executive Officer of EGA, said that “we are proud to now provide CelestiAL solar aluminium, together with Gulf Extrusions, to another UAE champion which will use it to reach beyond the sky on behalf of our nation. Aluminium is an essential material for modern life, including space travel, and the UAE’s production through EGA is a global contribution to human progress.” These efforts of EGA and Gulf Extrusions to bring UAE-produced aluminium into outer space continue a tradition of the working relationship between the two companies. “Our parts, made in the UAE with EGA’s aluminium, are already found in everything from cars to skyscrapers around the world,” stated Omar Shegem, Chief Executive Officer of Gulf Extrusions. “We are now honoured that our work will leave the Earth’s atmosphere for the first time as part of MBZ-SAT. Together we are making it in the Emirates for the world and beyond.” The news statement from EGA noted that Gulf Extrusions is a subsidiary of Al Ghurair Group and is one of 26 UAE customers of EGA. Aluminium produced by EGA, according to the firm, is utilised by these businesses to make products for local markets in the UAE as well as for export throughout the world. EGA is planning for growth for the company for the years ahead.

In a joint news statement issued by EGA and Alcoa on 15 May 2023, both companies announced that they signed a long-term alumina supply agreement. “Over the life of the 8-year agreement, which commences in 2024, volume options will allow EGA to procure as much as 15.6 million metric tonnes of alumina from [Alcoa’s production in] Western Australia,” according to the news statement. “The supply agreement will represent a significant portion of Alcoa’s annual third-party alumina sales. The supply agreement will make Alcoa EGA’s largest third-party supplier of alumina. EGA’s Al Taweelah alumina refinery in Abu Dhabi met 47 percent of EGA’s total alumina needs in 2022.” Mr. Roy Harvey, President and Chief Executive Officer of Alcoa, said that “Alcoa operates the world’s largest third-party alumina business with lowcarbon processes, and we’re proud to be recognised with this significant additional volume from EGA as a leading global producer. The agreement is the largest alumina supply contract ever signed between Alcoa and EGA, and it will strengthen the long-term supply relationship between our two companies.” “Most of our alumina needs into the next decade are now secured by our own production and a long-term supplier in Alcoa that is aligned with our sustainability goals,” stated Mr. Bin Kalban of EGA. “This agreement will further strengthen EGA’s platform for future growth.” � Aluminium International Today

30/10/2023 15:19:58

38 AUTOMOTIVE

Why aluminum is the material of the future for automakers Global association launches new white paper entitled: When it Comes to Aluminum, Less is More One of the most important reasons the use of aluminum is rapidly gaining traction in the automotive industry is because aluminum has one-third the density of steel, according to Alumobility’s recent white paper: When it Comes to Aluminum, Less is More. When comparing two identical vehicles with equal stiffness and load-carrying capacity – one made of aluminum, the other of steel – the aluminum vehicle body will be up to 45% lighter, which provides many advantages that will affect the future of the automotive industry. Professor Mark White* outlines the Top 8 Reasons Why When it Comes to Aluminum, Less is More, which are highlighted in Alumobility’s newly published white paper of the same name. 1. LESS WEIGHT = MORE EFFICENCY: There are efficiency advantages of aluminum lightweighting in Battery Electric Vehicles (BEVs) as well as Internal Combustion Engine (ICE) vehicles. ICE vehicles manufactured from aluminum have better mileage, consume less fuel and produce less emissions. BEV’s do not run on fossil fuels but still require energy to move so the lighter weight of an Aluminum Intensive Vehicle (AIV) improves range capability. Because electric vehicle batteries can weigh as much as 2000 pounds, automakers are embracing the lightweighting benefits of aluminum as the market shifts to electrification. 2. LESS WEIGHT = MORE SECONDARY SAVINGS: A lighter aluminum body means a car can use smaller parts, including brakes, suspension parts, batteries, motors, yet achieve the same acceleration, performance and range with less emissions. In BEV’s, smaller batteries translate not only to greater range in traveling but also less extraction of raw materials and chemicals for manufacturing, which helps to protect the earth’s resources. The overall manufacturing of AIVs versus steel is more efficient in terms of materials and labor. This means that in addition to primary weight savings of, for example, 160 kg which is achieved by replacing 400 kg of steel with 240 kg of aluminum, the vehicle will also have another 40 to 60 kg savings in the weight of other materials savings. 3. LESS WEIGHT = MORE SAFETY: It is a common misconception that heavy cars are safer than light ones, but lighter weight AIVs are safer than those made of steel. Aluminum absorbs more energy that steel per Kg (lb), so a lightweight aluminum vehicle can even be safer for the occupant than a comparable steel-based vehicle. When kinetic energy is absorbed in a controlled manner, vehicle occupants will be better protected from intrusion into the safety cell. In addition to being safer for vehicle occupants, an AIV is safer for everyone else-occupants of other vehicles, cyclists and pedestrians, as it carries less mass into any accident, therefore less energy to be absorbed.

4. LESS WEIGHT = MORE DURABILITY: Since aluminum vehicles are lighter, they create less friction on key components such as tires and brakes. Less friction means that materials such as rubber and plastic emit fewer particle emissions and with less wear and tear, are expected to have a longer vehicle lifespan.

*Alumobility’s Technical Director November/December 2023

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AUTOMOTIVE 39

7. LESS COMPLEXITY = MORE EFFICIENCY IN MANUFACTURING: Compared to a steel-intensive vehicle, the process to manufacture an AIV requires fewer parts, translating to less complexity. AIVs require less of the following: tools, robots, joints, energy, factory emissions, less inventory, capital and sealers. These parts will be made from fewer alloys, allowing for simpler end-of-life recycling. More than 90% of a vehicle’s aluminum can be recovered and recycled--so an aluminum-intensive car at the end of its life can be recycled and practically made into another car body.

5. LESS CORROSION = MORE YEARS IN SERVICE: Automotive grades of aluminum alloys are less prone to corrosion due to the self-healing, protective barrier that forms in milliseconds when cracked, dented, or deformed. Unlike automotive steel grades, which are inherently susceptible to rust and rely on protective systems for durability, aluminum does not need a protective coating, even in severe environments. 6. LESS WEIGHT = MORE PAYLOAD AND TOWING CAPACITY: Pick-up trucks, SUVs and last mile delivery vehicles manufactured from aluminum can carry more cargo and/or have the potential for overall weight reduction compared to a steel reference vehicle. The lighter weight vehicles made of aluminum have a reduced impact on the roads, protecting an older infrastructure from extra wear and costly repairs. The light weight aluminum body and chassis can enable secondary weights savings and result in lower cost per mile in running costs.

8. LESS WASTE = MORE CIRCULARITY: More sustainable than steel, aluminum is infinitely recyclable without a loss in its qualities, including lightness, durability and formability. Recycling aluminum scrap in a closed loop process allows vehicle manufacturers to reduce their carbon emissions immediately while endof-life recycling offers an opportunity for future reductions. Steel is recyclable but it is important to know that it melts at 1400 degrees centigrade whereas aluminum melts at less than half that temperature, at 650 degrees. Since vehicles are manufactured with 600 kg or less of aluminum for every metric ton of steel, the energy savings of aluminum are noteworthy.

In conclusion, there are numerous benefits for accelerating aluminum use in motor vehicles. As outlined, infinitely recyclable, lightweight aluminum provides clearly defined advantages demonstrating its superiority as the material of the future for mobility. �

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40 DIE CASTING

Enhancing fluids and equipment for consistent die casting performance

To achieve consistent product quality and maintain process performance in die casting, controlled, stable die release lubricant application to the die face is essential. Yet, many manufacturers struggle to achieve this level of consistency. Examining the challenges and exploring effective solutions is crucial to ensure quality and optimize performance. Dr. Mark Cross* delves into these matters. Die release agents, also known as die lubricants, are essential in the die casting process. Many solutions have been developed to cater to diverse industry applications. These encompass water-based options, water-based MQL (Minimum Quantity Lubrication), oil-based MQL, and electrostatic-based lubricants. Each solution is meticulously designed for precise and consistent application, contributing to improved process efficiency and component quality. Achieving controlled and repeatable application is paramount for optimal performance. Accurate and consistent dilution is an additional consideration when working with water-based products. Failing to optimize these aspects can lead to challenges, including porosity, staining, and soldering, where components adhere to the die. Such issues can compromise product quality in the short term and, if not addressed, may result in downstream consequences such as production inefficiency, reduced equipment lifespan, or even equipment downtime. So, what obstacles prevent the consistent, accurate, and repeatable application of die lubricants?

The causes of inconsistency - waterbased release agents For water-based release agents specifically, mixing and bacteria can present significant challenges. Most water-based die lubricants are purchased in concentrated form and mixed to the desired concentration. Poor control of dilution concentration will lead to inconsistencies in the process. For this type of lubricant, it’s common to use large central stores of diluted lubricant to feed the casting lines, which inevitably leads to fungal and bacterial growth which, left unchecked, can clog lines, affect flow rates, and pose both process problems and potential health hazards. While this can be treated with heavily regulated biocides, it adds an additional layer of complexity. However, for water-based and other lubricants, the critical barrier to the consistent, repeatable delivery of die lubricant dosing is inadequate or incorrectly specified equipment that fails to offer the required level of controlled lubricant dilution and/or spray volume.

A case for universal consistency Accuracy, repeatability, and consistency: These are what matter in the application of die lubricants. Only then can constant flow rates, volumes, and pressures be achieved, ensuring the desired result, regardless of the number of machines used or the scale of the wider operation. All of this emphasizes the quality of the die release lubricant delivery equipment – itself a complex and multifaceted part of the overall process. Equipped for the task Each lubricant has different properties. Equally, each application is unique. The solution, therefore, needs to be fully customized to each challenge. One obvious way to build quality assurance into even the most intricate parts of the die casting process is to invest in equipment that accurately mixes concentrated die lubricants to predetermined levels and delivers consistent, repeatable quantities to the die face. There is a wide range of requirements, from operations with mixed schedules that require agile or mobile solutions to fixed central systems capable of

*Global Business Development Director for Die Casting at Quaker Houghton November/December 2023

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DIE CASTING 41

supporting various lines. While some operations require water-based agents, others involve new water-free (oil-based) Minimum Quantity Lubrication (MQLs) or hybrid systems. Technology exists to meet these varied needs, including Quaker Houghton’s QH FLUIDCAST™ range, designed to deliver on-demand, eliminating the need for large central stores of lubricants and, as a result, the risk of bacterial/fungal contamination. With the addition of QH FLUIDCAST™ E-STATIC, the range accommodates water-free electrostatic lubricants. It can be further enhanced by plunger technology – such as the PLA 100 system, which delivers neat, oil and water-based lubricants to extremely high tolerances, minimizing risk, improving part quality, and enhancing plunger tip life. But whatever the configuration of equipment and delivery system, there’s one area where both meet to deliver exceptional advantage - digital. Digitalization – the future for ﬂuids The arrival of Industry 4.0 has changed manufacturing forever, giving even greater control and data and putting users firmly in command of their operations. Digital

has obvious applications in the die casting industry, helping automate complex functions while using sensors and other technologies (including thermal cameras to identify hotspots, for example) to monitor performance and efficiency. Gathering live, real-world information from equipment and relaying instructions back to the hardware enables system managers to fine-tune improvements on live die casting lines while also gathering actionable insights that will allow businesses to use lubricants and die casting fluids more effectively. By optimizing the use of time, labor and resources, the benefits include improved processes, productivity, and machine performance, along with reduced cost, cycle times, and downtime. This technology is already in action. For example, all products within the QH FLUIDCAST™ range are programmable logic-controlled (PLC) and enabled by human-machine interface (HMI). Importantly, they also connect to QH FLUID INTELLIGENCE™, an ecosystem of process fluids, application expertise, equipment, and software that enables customers to Measure, Control, and Optimize their production processes. Helping our

customers operate safely, sustainably, and at the optimized total cost of ownership. Consistency through consultancy Consistency is the key to protecting the quality and integrity of any given die casting operation, and it is something that can be designed and engineered. However, balancing the different commercial and technical needs requires a detailed understanding of objectives, a thorough evaluation of operating conditions, and a considered recommendation. In arriving at the optimal solution, equipment and lubricant are key. But there’s one final piece of the puzzle that’s missioncritical: namely, expertise. Therefore, it’s advisable to seek advice from a specialist such as Quaker Houghton, who can configure a complete, turnkey package of equipment and lubricants, hardware, and software to ensure that desired outcomes can be replicated repeatedly. Accurately. Repeatably. Consistently. �

Contact https://home.quakerhoughton.com/product-lines/ die-casting/

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42 PROFILE

Storvik’s Vision: A sustainable future in the Middle East By Siri Sande* We are delighted to share our latest milestone, a significant chapter in our journey that fills us with immense pride and excitement. At Storvik, our dedication to pioneering sustainable solutions for the process industry has always been the core of our mission. Over the years, our innovations and services have positioned Norway and our clients in the process industry on the cutting edge, making them not only cost-effective but also leading the way towards a net-zero industry. While our technology has been exported more than 40 countries, it wasn’t until 2022 that we opened our first office outside Europa, in the USA. Today, we proudly announce our focus on the Middle Eastern market, a region ripe with potential and opportunities for innovation. In this exciting phase, we aim to leverage our expertise within the aluminum industry and establish our second international presence outside Europe in the Middle East by 2024.

Fostering Sustainable Solutions Sustainability isn’t merely a buzzword at Storvik; it’s our guiding principle. Our dedicated team has worked tirelessly to develop cutting-edge, sustainable solutions tailored for the process industry. With a blend of advanced technology and a deep understanding of industry intricacies, we are driving meaningful change. Our sustainable solutions not only meet industry needs but also significantly reduce our environmental footprint. By 2024, we will proudly present our carbon footprint, ready to integrate into your supply chain efforts, aiding in lowering emissions and achieving net-zero targets. This showcases how our cutting-edge casting technology expedites the journey to sustainability. Metal Transfer Equipment Redefined Navigating the intricate challenges of metal transfer to achieve net-zero status demands precision and innovation. At Storvik, we have redefined tapping

pipes for decades, continually enhancing efficiency. Our metal transfer equipment are not mere products; they represent pathways to enhanced efficiency, safety, and productivity in transferring metal from primary production to your casthouse. Our tools not only boast the lowest carbon footprint available but also come at significantly lower operating costs than those offered by our competitors. We take immense pride in the high service marks granted to this business unit by our clients, a testament to our product quality, sustainability, and service excellence. Revolutionizing the Aluminum Industry In addition to our expertise in cast tools and equipment, we introduce innovative products tailored for the aluminum industry. We continuously strive to maintain and improve, offering solutions in areas such as Rodding shops with innovative solutions for timble press, rod repair, stem straightening, and industry

*Marketing Manager, Storvik November/December 2023

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SUSTAINABLE SOLUTIONS SINCE 1913

Middle East contact Maarten Gerhard Meijer, Senior Business Developer

44 PROFILE

4.0 vision integration. Our in-line rod repair system introduced in 2018, along with the commissioned timble press in 2023 and the latest developments in vibro compactors, demonstrates our engineering ability. This unique blend of innovation, robust engineering, and firsthand experience positions us as leaders in this field. Moreover, our in-line rod repair solutions redefine industry standards, providing seamless, on-the-go repair capabilities, maximizing productivity, minimizing downtime, and reducing safety risks. This combination of skills and talents has catapulted us into becoming one of the fastest-growing engineering services companies in Norway. A Strategic Presence in the Middle East Our decision to focus on the Middle Eastern market signifies our belief in the region’s growth and innovation potential. The Middle East is not just a market for us; it’s a vibrant region of opportunities. Establishing ourselves in the Middle East draws on many parallels to our home market, sharing similar beliefs in technical support for the process industry. By

establishing our presence in the Middle East, we aim to foster collaborations, exchange knowledge, and contribute to the region’s industrial progress, mirroring our successes in Norway, Europe, and the USA. ARABAL 2023: A Platform for Innovation One of the milestones in our Middle East journey is our participation in ARABAL 2023. This event represents more than just a platform; it’s a hub of innovation and ideas that enable the Middle East to ﬂourish and claim its international position as a strategic business partner. We are thrilled to showcase our casted solutions, introduce our unique products enhancing anode production, rodding shops, electrolyses, recycling, and casthouses. Engaging in meaningful discussions and collaborating with industry leaders,

ARABAL 2023 stands as a testament to our commitment to driving progress through dialogue and collaboration in the Middle East. Looking Ahead: A Bright Future As we embark on this new chapter, we do so with a profound sense of purpose and optimism. Our venture into the Middle East is not just a business expansion; it signiﬁes our belief in the transformative power of innovation and sustainable practices. We are not merely pioneers; we are your improvement partners, blending the best elements of the Middle East and Storvik to create a winning blend of business opportunities for our partners and clients. Together, we are shaping a better future, one innovation at a time. � Contact: www.storvikgroup.com

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November/December 2023

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EVENTS 45

UK aluminium industry and opportunities for growth � Recognising the significance of advanced manufacturing in the UK’s aluminium flat rolled products market, Primetals Technologies partnered with ALFED to host a celebration event. � Insightful presentations, engaging panel discussions and a workshop tour highlighted key growth opportunities for the aluminium flat rolled products market in the UK, specifically in beverage cans and foils for electric vehicle battery production. � UK Aluminium producers, industry experts, suppliers and trade press were in attendance. � Celebrated 50 years of aluminium strip shape measurement technology and production of the 1000th Air Bearing ShapeMeter roll in the UK.

On a gloriously sunny day in September Primetals Technologies celebrated 50 years since the launch of their class leading aluminium shape measurement technology – the Air Bearing ShapeMeter (ABSM). To mark this achievement they partnered with ALFED (UK Aluminium Federation), to host a landmark event. The day recognised the significance of advanced manufacturing in the UK with a spotlight on the aluminium flat rolled products market and its role in fostering a circular economy. Leading industry insight The event programme explored important topics relating to key growth markets for aluminium flat rolled products. Paul Williams, Head of Aluminium at CRU kicked the session off with a highly insightful and informative presentation Aluminium International Today

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on the growing market for electric vehicle batteries. With two new gigafactories coming online in the UK and potential for another two there will be an increased demand for battery foil. With the UK currently fully reliant on imports of foil material (primarily from Europe and China) this poses a great opportuinity for local investment in foil production – which would positively support a UK circular economy. Nick Saunders, Senior Sales Manager took to the stage to highlight the importance of flat rolled aluminium in the decarbonisation of the beverage packaging market. There is a global expectation that demand for aluminium beverage cans will continue to accelerate as we see a shift from plastic to cans. With the UK a major manufacturer and exporter of beverage cans there is a significant

opportunity and justification to persue a circular economy for UK can production. But as an importer of can body, lid and tab material investment in aluminium flat rolling production is needed. There was also a very lively and engaging panel discussion with key participants including Jan Lukaszewski, Technical Manager at ALFED, Mike Brammer, Director and David Parkin, Head of Projects and Engineering both at Primetals Technologies. The theme of the discussion was ‘maximising productivity using new vs. old equipment in the aluminium industry’. Key highlights included details of how older aluminium rolling plants can be modernised to achieve current and future quality standards. Some of the roadblocks for expansion of existing UK rolling plants including the high cost of investment, labor shortages in the November/December 2023

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46 EVENTS

manufacturing sector and competition from overseas were discussed as well as some of the opportunities. These opportunities included the growing demand for aluminium, the localisation of manufacturing to decarbonise the industry, government support, and the introduction of new technologies. The event concluded on an optimistic note with a tour of the Christchurch workshop facility. This facility is responsible for designing, developing and precision manufacturing innovative aluminium flatness measurement and error correction technologies, including the ABSM and Integral Solenoid Valves (ISV). �

“It was nice to see the evolution of the technology, some of which I was involved with more than 35 years ago. I worked for Davy from 1987 to 1996. Back in 1988, I was a Mechanical Design Engineer for the Automation Department. We were responsible for the Engineering of the ISV valves and Spraybars as well as the Air Bearing ShapeMeter. Its impressive to see how Primetals Technologies continues to push theboundaries

”

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EVENT REVIEW: ALUMINUM USA 47

ALUMINUM USA: Event Review By Zahra Awan*

The United States has a detailed history of aluminium and music. In the 1930s, Alcoa collaborated Dr. Joseph Maddy, a music teacher and director, in providing 435 aluminium violins and around aluminium 500 double bass instruments to other dealers. [1] The Nashville Hall of Fame pays tribute to numerous influential artists, such as; Johnny Cash (1932-2003), Kitty Wells (1919-2012), Chet Atkins (1924-2001). Tennessee could be considered a museum

of music, however, upcoming new artists, such as; Miley Cyrus, Kings of Leon, Taylor Swift, and Kesha represent a new generation. Aluminium is similar to this new generation. Bridging the gap between old and new, the metal presents an opportunity for multiple industries to innovate their products at a better, more sustainable level, whilst simultaneously enhancing their prospects for future innovation.

The ALUMINUM USA event opened its doors on the 25th October. The twoday event looked at the possibilities for aluminium in the US and Global market. With current global geopolitics, the event provided an opportunity for the industry to catch up and anticipate 2024. “Let’s show the world what the aluminium industry has to offer.” - Reed Exhibitions

THE CONFERENCE Opening the conference, Stephen Williams, CRU welcomed Charles Johnson President & CEO, The Aluminium Association. Mr Johnson provided an overview on the US Aluminum market during and following the COVID years, as well as provided a 12-year outlook for the industry. He noted that the automotive, aerospace, and transport sectors are predicted for growth, but surprisingly it is the “container and packaging sector which is most optimistic.” He went on to emphasise the need for the industry to “race to improve aluminium recycling rates.” “There has been a big divot in the demand for aluminium, but we have seen

demand come roaring back” – Charles Johnson The need for recycling was revisited by Matt Meenan, Vice President, External Affairs, The Aluminum Association, in his presentation ‘The Coming U.S. Recycling Crunch: Why We Need Recycling Refunds’. He summarised the topic as a “long process, a bit of a slog, but it will happen … and benefit us all!” Mr Meenan stressed the importance of having commercial Deposit Return Schemes and noted that industry and manufacturing sectors have developed systems which enforce high recycling processes. However, on a commercial level, recycling is left up to the consumer.

With the decision of can recycling left to a consumer, it was noted that it is the industries responsibility to educate, push and enforce consumers to make the right choice. He stated: “The US could save around $800 million each year from recycling aluminium cans.” Moving onto the next steps for can recycling implementation in the US, he noted that whatever the plan, it will have to be addressed “State by State.” Providing figures, Oregon came up on top with the highest can recycling rates. Oregon has a well-known DPS scheme. In contrast, many mid and southern states had recycling levels below 20%. These states did not have can recycling schemes in place. It was apparent that DPS play a part

*Assistant editor Aluminium International Today

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48 EVENT REVIEW: ALUMINUM USA

in encouraging can recycling. However, implementing DRS may not be a national solution, as discussed in the exclusive editorial with Ball Cooperation on page 16. With 9.834 million km² of land, America houses all five of the major biomes: aquatic, grassland, forest, desert, and tundra. The biome variations seen State to State mean investors and companies have to consider the pros and cons to developing in an area. For example, Aluminium needs access to water; this excludes states in the desert biomes; Great Basin, Mohave, Chihuahuan and Sonora. Looking into this topic was Stephen Williamson, Research Manager, Aluminium, CRU, who hosted a panel session with: Bryan Farlow, Regional Director Economic Development & Site Selection; Thomas & Hutton; and Bill Shannon, SVP, Global Battery Foil Program, Granges Group. “Every two minutes, the energy reaching the earth from he sun is equal to the amount of energy we need to power our activities on earth for a year” – Bill Shannon The panel session also went onto discuss the issues associated with workforce. They concluded that a state-to-state analysis on enhancing and encouraging a specialised workforce for the automotive industry is

necessary for industry success. “We have the infrastructure and have overcome the locations, what is lacking is the people.” – Panel Session. To be more specific, the workforce that the panel wished to develop is a high skilled, technology experienced workforce. They agreed that the industry needs personnel who are able to adapt and grow with innovative technology. Moving away from the topic of recycling, and the US, Marius Baader, Managing Director; Aluminium Association, Germany Discussed the ‘European Green Deal and its Sub-plans – Consequences for the Aluminum Industry’. He provided a European outlook and commented on Carbon Border Adjustment Mechanism (CBAM). The “European Dream”, to become carbon neutral by 2050 and reduce emissions by 55% by 2030, is an ambitious goal. Mr Baader presented the realistic solutions that need to be implemented for these goals to be met. He also commented on the loopholes and issues that the EU have seen regarding the CBAM, and more positively, discussed the listing of aluminium on the Critical Raw Materials Act. “Sometimes the European Commission don’t think things though enough… it is our responsibility to get behind and encourage people to look at aluminium

and support the aluminium industry.” – Marius Baader Discussing the EU and North America, both Marius Baader and Charles Johnson commented on the complex relationship the two have with one another. Mr Baader noted that the European Aluminium Industry are envious of the US industry, whilst the European commission don’t approve of US policies. Charles visited this topic in his opening, discussing Global agreements and Aluminum Import Monitoring (AIM). He also addressed the tensions felt with regards to the US and EU disagreement on tariffs, after they could not come to an agreement. Day Two saw presenters from across the industry. Speakers from; Aluminium Extruders Council, Pyrogenesis, Tecnar, DTE Analyzers, Fives Group, Steinert, Stirweld and Primetals spoke about the latest developments and innovations. In these presentations, speakers offered their latest finds, developments, innovations, and technology to the industry. Presenting alternative Industry 4.0 transition technology, automated designs too improve safety, and announcing pilot project case studies, the industry was able to show off its potential for the highest level of performance.

THE EXHIBITION FLOOR The conference was just one aspect of the multifaceted event. On the Exhibition floor, ALUMINUM USA saw numerous booths from across the world, come together. What are MQPs ambitions, anticipations for 2024, in the US? I was fairly bullish actually for 2024, but there’s so much bad stuff going in the world, it certainly isn’t helping sentimentally. But I think some of the leading financial experts still expect the stock markets to rebound in the next 12 months and predict the formation of another bull cycle. So, we can anticipate economies improving providing that nothing goes seriously wrong with current political affairs. At the moment, the biggest threat is the situation in the Middle East. If that turned into a wider conflict, that would be a problem. . John Courtenay, Chairman and owner, MQP Limited

What are August Mossners ambitions, anticipations for 2024, in the US? We have several plans going into 2024. We will be focusing more on the American and Canadian market since we have seen some good business this year and last year. Simon Lojewski, Sales Engineer, August Mossner

What are Glamas ambitions, anticipations for 2024, in the US? We’re growing rapidly here in the US; it is a very good market for us. That being said, we also aim to expand our business in other parts of the globe too. We want to push our presence into markets where we are not yet present, for example in Middle East. We expect good things for 2024. Paul Hibbe, Sales Manager, Glama

What are American Buffalo Metals’ ambitions, anticipations for 2024? We only started two months ago; we just built a new plant, new equipment, it was an enormous investment. We’re looking to sell that out. It’s a good time to be in the aluminium business. So, we are optimistic about 2024, unless some crazy geopolitical thing happens. Drew Heideloff, President, American Buffalo Metals

What are Primetals ambitions, anticipations for 2024, in the US? We have some big projects on the horizon for the US market. The market itself is, is not got, it’s not bad. We will just have to see. Going into 2026, 2027, a lot of new supply will be going online, and the dynamics with new technology coming in, will change the market dramatically. But these changes are 18 months - two years away. So, we will have to see what 2024 has in store for us. Grant Shoebridge, General Manager, Head of Downstream UK, Primetals Technologies November/December 2023

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