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Novelis Inc., a leading sustainable aluminium solutions provider and world leader in aluminium rolling and recycling, today announced that it has successfully tested using hydrogen fuel to power a recycling furnace at its UK plant in Latchford, Warrington. 

The tests were carried out as part of a UK government decarbonization programme and in collaboration with Progressive Energy, an independent UK energy company, and required the installation of new burners, regenerators, and furnace lining material. Using hydrogen instead of the same amount of natural gas when operating a melting furnace can reduce CO2e emissions by up to 90%. 

Exploring renewable energy sources, such as hydrogen, making first mover investments, and reducing energy intensity are part of our 3x30 vision to advance aluminium as the material of choice with circular solutions.With the significant expansion of our local recycling capacity, we are transforming the Latchford site into a prototype for high-recycled content and decarbonized aluminium production.

Emilio Braghi, Executive Vice President, Novelis Inc., and President, Novelis Europe

The use of hydrogen is not common in the aluminium industry today and we are very proud to be one of the pioneers to have tested this new fuel at an industrial scale and in a real-world environment. The results from Latchford will drive further research into the potential deployment of hydrogen in our recycling operations worldwide.

Allan Sweeney, Plant Manager, Novelis Latchford
Team Novelis Latchford with the first Hynet Hydrogen Ingot

With safety as the top priority of the hydrogen pilot project, several series of tests were conducted by blending different percentages of hydrogen with natural gas (30%-100%) to evaluate the impact on existing infrastructure, and equipment compatibility. During the trial campaign, several hundred tonnes of 3000 series scrap aluminium alloy were remelted and cast into sheet ingots. In addition, all relevant parameters were measured to assess any impact on the product, process, operating environment, and environmental emissions. 

Further downstream processing, including rolling and finishing, will be now completed at other Novelis plants in Europe to establish the real ‘end-to-end’ parameters of a hydrogen-based, recycled alloy production process. Following the full post-trial evaluation and assessments, a report will be released as part of the UK government’s Industrial Fuel Switching programme later this year. 

The demonstration project at Novelis Latchford is part of the UK government’s Industrial Fuel Switching Competition programme. Supported with a grant of £4.6 million, as part of the £1 billion Net Zero Innovation Portfolio and the wider regional HyNet project, the programme is designed to support industry to decarbonise their operations through a switch from natural gas to low carbon hydrogen. As the UK’s leading industrial decarbonisation cluster, HyNet will decarbonise industry across the North West and North Wales through the production, transportation and storage of low-carbon hydrogen, and through capturing industry’s carbon dioxide emissions through Carbon Capture Solutions. Novelis has been a partner in the HyNet project since 2017 and is supporting the development of the regional infrastructure project.   

Novelis is also conducting its own technical feasibility studies into the use of hydrogen as a direct replacement for natural gas, and more generally, Novelis research and development teams worldwide continue to investigate the possibility of using plasma and electricity to supply energy to its production plants.  

As announced in July 2024, Novelis is investing approximately $90 million to double the recycling capacity for used beverage cans (UBCs) at its plant in Latchford. The project will increase the facility’s UBC recycling capacity by 85 kilotonnes per year and decrease Novelis Europe’s CO2e by more than 350,000 tonnes annually. The project is expected to begin commissioning in December 2026. 

Furthermore, as part of its new Novelis 3×30 vision, the company has set new ambitious sustainability targets to achieve by the end of 2030, including increasing recycled content to 75% from today’s 63%, reducing carbon emissions to less than 3 tonnes CO2e per tonne aluminium shipped, and continuing to lead the industry to circularity through first-mover investments. These are in addition to the company’s goal to be carbon neutral by 2050 or sooner. Along with using higher amounts of recycled content, decarbonization of the company’s melting processes and energy sources are important levers to delivering lower-carbon, highly sustainable aluminium solutions.  

A thought leadership piece by Daniel Kern, Vice President, Global Automotive Development, Novelis  

Traditionally, aluminum was reserved for luxury and high-performance vehicles. However, advancements in material science, recycling capabilities, and design innovation have transformed aluminum into a cost-effective and sustainable choice for all vehicle categories—from compact cars to SUVs and trucks. 

Novelis is proud to be featured in a recent World Economic Forum article highlighting the impact of the First Movers Coalition (FMC), which has mobilized over $16 billion to accelerate the adoption of emerging decarbonization technologies in hard-to-abate industries. The FMC aims to drive demand for low-carbon solutions in sectors such as aluminum, aviation, and shipping—sectors that are critical to achieving a net-zero future but face significant technological and economic challenges. 

Novelis, in collaboration with Ball Corporation and Alcoa, has played a key role in developing an innovative aluminum cup made with 90% recycled aluminum and 10% ELYSIS-produced aluminum, manufactured using carbon-free smelting technology. This initiative, featured in the article, exemplifies how strategic partnerships and technological advancements can lead to more sustainable solutions and further advance aluminum’s role in the circular economy. 

As an initial signatory and committed FMC member, Novelis plays a crucial role in supporting the coalition’s mission to accelerate the transition to clean energy solutions and reduce emissions from aluminum production. The FMC, launched during the 26th United Nations Climate Change Conference (COP26) in October 2021, in collaboration with the World Economic Forum and the U.S. Department of State, brings together leading global companies to leverage their collective purchasing power and supply chains to create early markets for innovative technologies that will be essential in reaching net-zero emissions by 2050. 

Novelis has pledged that by 2030, 10% of its primary aluminum purchases will be near-zero carbon, emitting less than 3 tonnes of CO2 per ton. Additionally, the company has committed to ensuring that at least 50% of all aluminum used comes from recycled sources. Novelis has already exceeded this goal, achieving a 63% average recycled content rate in its products as of fiscal year 2024, further solidifying its leadership in sustainable aluminum production. 

Novelis’ participation in the FMC aligns closely with our ambitious Novelis 3×30 goals, which aim to increase recycled content to 75%, reduce emissions to less than 3 tonnes of CO2e per tonne of flat-rolled product (FRP) shipped and lead the industry with first-mover investments to drive circularity by 2030. 

Through our involvement in FMC, Novelis continues to lead the way in delivering low-carbon aluminum solutions that support the global transition to a net-zero economy. By investing in innovative recycling technologies, expanding closed-loop systems, and forming strategic partnerships, Novelis remains at the forefront of the industry’s sustainability transformation. 

Read the full article here: Over $16bn: First Movers Coalition sends world’s largest demand signal for emerging decarbonization technologies | World Economic Forum 

Electric vehicles (EVs) are transforming the automotive industry, but their significantly heavier weight—up to 500kg more than comparable internal combustion engine (ICE) models—poses unique challenges. Reducing weight is critical for improving performance, safety, and sustainability while meeting the evolving demands of consumers and regulators. 

Novelis recently participated in an insightful panel discussion hosted by Automotive World, alongside industry experts from Ricardo and Cranfield University, on ways to address these challenges. Moderated by Megan Lampinen, Editor-at-Large for Automotive World, the webinar explored: 

Dr. Daniel Kern, Vice President of Global Automotive Development at Novelis, shared Novelis’ lightweighting strategies for EVs and insights into the future of sustainable mobility. 

The recording of this engaging webinar is now available! Watch it here. 

Join the conversation and discover how Novelis is driving the future of sustainable automotive solutions here: Automotive – Novelis. 

Strategic collaboration to provide advanced aluminium solutions to the Aerospace industry 

thyssenkrupp Aerospace, one of the world’s leading supply chain management and third-party logistics service providers for the commercial Aerospace industry, and Novelis, a leading sustainable aluminium solutions provider and the world leader in aluminium rolling and recycling, have renewed their strategic partnership through a multi-year agreement. 

Under the agreement, Novelis will supply specialized, aerospace-grade aluminium from its facilities in Koblenz, Germany, and Zhenjiang, China, to several thyssenkrupp Aerospace key markets in Europe and Asia. The contract provides for the ongoing supply of premium, aircraft-grade aluminium plates and sheets from Novelis to thyssenkrupp Aerospace, reinforcing Novelis’ strategic importance as a supplier of innovative aluminium products for the aerospace sector. 

We are very pleased that our global Aerospace unit is prolonging our partnership with Novelis. Securing a reliable, long-term supply of high-quality aluminium is critical to ensuring that we can consistently meet the needs of our customers. This agreement reinforces our commitment to delivering excellence by ensuring material availability and reliability for our customers’ supply chains, an important part of our Materials-as-a-Service strategy. We look forward to continuing this successful collaboration

Patrick Marous, CEO of Business Unit Solutions at thyssenkrupp Materials Services and responsible for the Aerospace business field

Since the first contract was signed in 2014, our collaboration with thyssenkrupp Aerospace has flourished. We look forward to building on this successful relationship, underlining Novelis’ role as a preferred supplier and continuing to deliver high-quality products that meet the evolving needs of the aerospace industry.

Johan Petry, Vice President of Sales & Marketing, Global Aerospace, at Novelis
f.l.t.r.: Andreas Delis, Director Aerospace Novelis Europe; Emilio Braghi, Executive Vice President Novelis Inc., and President Novelis Europe; Patrick Marous, CEO of Business Unit Solutions at thyssenkrupp Materials Services and responsible for the Aerospace business field; Johan Petry, Vice President, Sales & Marketing, Global Aerospace Novelis and Julian Koch, Key Account Manager Aerospace Sales Novelis Europe.

This long-standing collaboration is an important step in maintaining the well-established relationship between Novelis and thyssenkrupp Aerospace. It strengthens the position of both companies in the global aerospace market, while reflecting their continued commitment to innovation and the provision of high-performance materials to the aerospace industry on a global scale. 

Patrick Marous, CEO of Business Unit Solutions at thyssenkrupp Materials Services and responsible for the Aerospace business field; Johan Petry, Vice President, Sales & Marketing, Global Aerospace Novelis

This year marks a remarkable milestone for Novelis: 20 years of innovation, sustainability, and leadership. Since we began in January 2005, we have transformed the aluminum industry through groundbreaking achievements and a steadfast commitment to our company’s Purpose of Shaping a Sustainable World Together.

Over the past 20 years, Novelis has redefined what’s possible in the aluminum industry. Take a look at some highlights from our incredible journey:

On January 6, 2005, Novelis launched as a biproduct of Alcan. Just two years later, in May 2007, we joined the Aditya Birla Group (ABG) under Hindalco, opening doors to global growth and new possibilities.

In July 2011, we began a new chapter in North America by investing in the Oswego Plant, paving the way for automotive as a key value stream in the region. By November 2011, we solidified our presence in Asia by acquiring full ownership of Novelis Korea, previously a joint venture.

Growth continued in April 2012 as we entered China with a single CASH line for automotive in Changzhou, followed closely by the opening of the Yeongju Recycling Center in October 2012. These milestones underscored our leadership in sustainable innovation.

By July 2013, we expanded Pinda’s capacity in Brazil by 50%, strengthening our South American operations. Shortly after, in October 2013, we increased production capacity in South Korea by 50%.

Sustainability remained our focus and in September 2014, Novelis achieved 50% recycled content, a bold milestone that set an industry benchmark. This was followed by completing the Nachterstedt Recycling Center in February 2015, cementing our commitment to world-class recycling.

The acquisition of Aleris in April 2020 transformed Novelis, expanding our reach with entry into aerospace. By December 2020, the Guthrie automotive line was operational, meeting growing automotive market demands in North America.

Our focus on carbon neutrality led to the creation of the Net Zero Lab Valais in February 2022. That same year, we broke ground on the Guthrie Recycling Facility in May 2022, invested in Sortera’s recycling technology in July 2022, and launched construction of facilities in Bay Minette and Ulsan in late 2022.

In May 2024, we reached an incredible milestone: 63% recycled content. Also in 2024, we set a new path forward, introducing Novelis 3×30, our bold roadmap to “Advance Aluminum as the Material of Choice with Circular Solutions” by achieving three critical objectives by 2030.

We’re proud of these achievements and look forward to an even more sustainable future ahead!

16th January 2025 | 4 PM CET | 7 AM PDT | 10 AM EDT

Electric vehicles (EVs) are the future of mobility, but their weight—up to 500kg more than comparable internal combustion engine (ICE) models—presents significant challenges for manufacturers, like the need for larger batteries, to achieve acceptable driving ranges, which further increases vehicle weight and cost.  

How can automakers address the critical weight issue while balancing cost, safety, and environmental impact? 

Join us for an engaging 60-minute webinar featuring leading experts in EV lightweighting as they explore innovative strategies to reduce vehicle weight and drive the development of more efficient and sustainable EVs. 

What You’ll Learn: 

Meet the Panelists: 

Don’t miss this opportunity to gain critical insights into the future of EV lightweighting! 

Register Now Microsoft Virtual Events Powered by Teams 

As the automotive industry navigates the crossroads of electrification, sustainability, and consumer preferences for vehicles that are more efficient, safer, and environmentally friendly, one thing is clear: the future of mobility requires a new approach to vehicle design. At Novelis, we believe that aluminum is the key to unlocking a lighter, greener, simpler, and safer future for automakers and their customers.

Aluminum recycling is more than a sustainable practice—it’s a powerful driver of economic growth, supply chain resiliency, and environmental stewardship. In his latest thought leadership piece, Chris Cerone, Novelis’ Vice President of Public Affairs & Communications, explores the significant impact of aluminum recycling on job creation, economic activity, and sustainability. 

Discover how Novelis is harnessing the power of aluminum recycling, from reducing greenhouse gas emissions to boosting the circular economy.  

Novelis, in collaboration with Sourced Economics, is advancing the conversation on sustainability in the automotive industry. In a recent article published in Inbound Logistics, Novelis experts Mario Greco, Global Technology Director of Automotive, and Kashif Solaija, Senior Manager Sustainability and Commercial Excellence, Global Automotive, joined Sourced Economics CEO John Frechette to explore how businesses can pinpoint and quantify the commercial value of green initiatives. 

The article outlines innovative modeling techniques to integrate environmental performance into product design and business strategy. It highlights research on consumer willingness to pay for sustainable features and provides actionable insights into prioritizing sustainability investments for maximum impact. 

This collaboration underscores Novelis’ commitment to driving data-driven sustainability solutions and fulfilling our purpose of Shaping a Sustainable World Together. 

Read the full article in Inbound Logistics