UK’s first industrial-scale hydrogen fuel switching in the aluminium industry
Technical feasibility has been confirmed in a hydrogen trial for aluminium recycling.
The work at Novelis' Latchford site in Warrington has earned the firm recognition for innovation in hard-to-decarbonise sectors at the IEA Hydrogen TCP Awards of Excellence 2025.
The two-week trial, funded by the UK Department for Energy Security and Net-Zero under the Industrial Fuel Switching Competition, involved converting a natural gas furnace to operate flexibly on hydrogen.
Novelis says the demonstration confirms that hydrogen can be safely delivered and combusted in aluminium recycling furnaces.
Existing infrastructure was reportedly successfully adapted, product quality remained consistent and dual-fuel burners allowed for operational flexibility.
The execution of this programme gives Novelis the technical confidence to eliminate up to 45,000t of direct CO₂ emissions annually at the Latchford site, contingent on hydrogen availability.
Future deployment depends on connection to the HyNet hydrogen network, expected from 2031, or on-site electrolytic production.
Novelis partnered with Progressive Energy to deliver the project over a two-year period.
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