In its next step towards carbon-free aluminum production, Hydro is testing emission-free plasma technology at its Sunndal aluminum smelter. The company wants to completely decarbonize its aluminum production. Hydro is addressing the challenges of high-temperature processes required to remelt aluminum into new products. Innovative plasma technology enables the electrification of this energy-intensive process, leveraging renewable energy sources that already power Hydro's primary smelters.
“Our goal is to transform aluminum production. Plasma technology is both high-tech and future-oriented. If we are successful with the pilot project in Sunndal, it will impact not only the aluminum industry but also other hard-to-reach industries worldwide,” said Eivind Kallevik, Executive Vice President of Hydro Aluminum Metal.
Financing the project
Hydro has secured low-interest financing from the Norwegian government for this project. Enova, a Norwegian government company that promotes the transition to a low-emission society, is supporting the project with NOK 39.6 million.
The pilot project in Sunndal, which is expected to smelt the first aluminum with near-zero emissions in the fourth quarter of 2025, is expected to result in a significant reduction of over 500 tonnes of carbon emissions per year. However, the global potential for reducing emissions in aluminum smelters is estimated at around 11 million tonnes of CO2.
Sunndal aluminum plant
Hydro's commitment to achieve zero emissions across the aluminum value chain by 2050 also includes initiatives at its Sunndal plant. Sunndal is the largest and most modern aluminum factory in Europe. The site serves as a test site for recording carbon emissions from existing electrolysis processes. In addition, Hydro has invested in a test facility in Porsgrunn to develop HalZero, a new process for the production of primary aluminum. HalZero aims to eliminate carbon emissions from both electrolysis and anode baking.
“We work closely with Europe’s most demanding customers to help them achieve their climate goals through the use of low-carbon and recycled aluminum. We are proud to offer aluminum that is based on renewable energy and has a 75 percent lower carbon footprint than the global average,” explains Kallevik.
Plasma technology, known as the “fourth state of matter,” reaches extremely high temperatures of over 5000°C by making gases electrically conductive. The plasma torch, which uses an electric arc, heats the metal in the furnace using radiation and convection.
In the pilot project in Sunndal, the current natural gas burner will be replaced by a plasma burner in an existing industrial furnace at the Sunndal test center. The test center deals with the development and testing of alloys and the further development of technologies.
