See how plasma is revolutionizing the foundry industry

Hydro recently announced that it is working on the implementation of plasma technologies to reduce its CO2 emissions at its smelting plant in Sunndal. The Norwegian government has granted funding to Hydro to carry out this project, which could have a significant impact globally, especially on industries that have difficulty reducing their emissions.

The process of recycling aluminum into new products requires very high temperatures, which is energy intensive and difficult to achieve without the use of fossil fuels such as natural gas. However, thanks to the new plasma technology, it will be possible to carry out this process using only renewable energies, the same energies that already power Hydro’s main smelters.

“Our goal is to change the rules of the game for aluminum production. Plasma technology is both high-tech and future-oriented. If we are successful with the pilot project in Sunndal, it will not only affect the aluminum industry, but also other hard-to-reduce industries around the world.”said Eivind Kallevik, executive vice president of the company.

Hydro aims to achieve the first near-zero-emission aluminum smelter at its Sunndal plant by the fourth quarter of 2025. Through a pilot project, it is expected to reduce more than 500 tons of carbon emissions per year, but the overall reduction potential across all aluminum smelters and recyclers is approximately 11 million tons per year. To support this project, Enova has granted a sum of NOK 39.6 million.

Hydro aims to achieve zero emissions throughout the aluminum production chain by 2050. To achieve this, they are using their largest and most advanced aluminum plant in Europe, Hydro Sunndal, as a test site to capture the carbon emissions generated by the electrolysis process. In addition, in the fall of 2023, the company has also decided to invest in a test facility in Porsgrunn to further develop HalZero, a revolutionary technology that will make it possible to produce primary aluminum without generating carbon emissions during electrolysis and anode firing.

Kallevik said they are working together with Europe’s most demanding customers to help them achieve their climate action goals by using recycled and low-carbon aluminum. “We are proud to offer aluminum based on renewable energy and with a carbon footprint 75 percent lower than the global average.” Kallevik concluded.