Novelis Inc., a global leader in sustainable aluminium solutions, has successfully completed the UK’s first full-scale hydrogen fuel-switching trial in the aluminium recycling industry. The demonstration, carried out at the company’s Latchford plant, marks a significant milestone in industrial decarbonization and has earned Novelis top global recognition at the IEA Hydrogen TCP Awards of Excellence 2025.
The two-week trial, funded by the UK Department for Energy Security & Net Zero (DESNZ) through its £1 billion Net Zero Innovation Portfolio (NZIP) Industrial Fuel Switching Competition, converted a natural gas furnace to run flexibly on hydrogen. The project was delivered in partnership with Progressive Energy following a two-year development program.
“All involved can be proud of this achievement,” said Allan Sweeny, Plant Manager at Novelis Latchford. “We proved that hydrogen can be safely integrated into aluminium recycling without compromising safety, quality, or furnace performance. It’s a practical step toward cutting our carbon footprint and preparing for a low-carbon future.”
Technical success and global recognition
The trial confirmed that hydrogen can be safely delivered and combusted in aluminium furnaces, with existing infrastructure adapted for dual-fuel burners to ensure operational flexibility. Product quality was maintained throughout the process.
In recognition of this achievement, the project received the IEA Hydrogen TCP Award of Excellence 2025, presented in Busan, South Korea, during the Clean Energy Ministerial (CEM). Novelis was selected as the first winner among 13 global entries, highlighting innovations in hydrogen technology for hard-to-decarbonize sectors. The award ceremony was attended by energy leaders and officials from over 24 countries, including the US, UK, Germany, China, Brazil, South Korea, and the European Commission.
Pathway to large-scale decarbonization
If connected to the planned HyNet hydrogen network (expected by 2031) or supported by on-site hydrogen production, the Latchford site could reduce direct CO₂ emissions by up to 45,000 tonnes annually. The trial also underscored the need for robust hydrogen transport and storage infrastructure, with mechanisms like the UK’s Low Carbon Hydrogen Agreement (LCHA) providing an important foundation.
Investing in circularity
In parallel with hydrogen integration, Novelis is investing around $90 million to double its used beverage can (UBC) recycling capacity at Latchford. The expansion will add 85 kilotonnes of capacity per year and reduce Novelis Europe’s emissions by more than 350,000 tonnes of CO₂e annually.
The trial and investment support Novelis’ broader 3×30 vision, which includes:
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Increasing recycled content to 75% (from 63% today)
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Reducing carbon emissions to below 3 tonnes CO₂e per tonne of aluminium shipped by 2030
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Achieving carbon neutrality by 2050 or sooner
