Aluminium International Today January February 2024

INDUSTRY NEWS

EXCLUSIVE INTERVIEW

DECARBONISATION

HEALTH AND SAFETY

www.aluminiumtoday.com January/February —Vol.37 No.1

THE JOURNAL OF ALUMINIUM PRODUCTION AND PROCESSING

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CONTENTS 1

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Volume 37 No. 1 – January/February 2024 Editorial Editor: Nadine Bloxsome Tel: +44 (0) 1737 855115 nadinebloxsome@quartzltd.com

COVER

Assistant Editor: Zahra Awan Tel: +44 (0) 1737 855038 zahraawan@quartzltd.com

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LEADER

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NEWS

Production Editor: Annie Baker

EXCLUSIVE INTERVIEW

Sales Commercial Sales Director: Nathan Jupp nathanjupp@quartzltd.com Tel: +44 (0)1737 855027

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Sales Director: Ken Clark kenclark@quartzltd.com Tel: +44 (0)1737 855117

GLASSPOINT: Unveiling the power of the sun

THE ALUMINA CHRONICLES

Advertisement Production

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Production Executive: Martin Lawrence

Aluminium trade between the USA and Europe and beyond

Managing Director: Tony Crinion CEO: Steve Diprose

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Aluminium in the USA

HEALTH & SAFETY

Supporters of Aluminium International Today

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Quick to forget

DECARBONISATION 30

ASI launches 1.5 degree method

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Decarbonisation - using oxygen now to reduce carbon emissions

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RECYCLING 38

2023 in review: Every can counts reflects on its UK highlights

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2 COMMENT

TOP STORIES

Hydro completes sale to Glencore

LOOKING FORWARD

There was an overwhelming feeling from a number of people I spoke with towards the end of last year that 2023 was a lot!

We were thrown back into a fast paced world and still trying to find our feet and way after the pandemic, while daily lives were impacted by huge increases in the cost of living.

This feeling was echoed across the aluminium sector, with companies across the supply chain traversing a landscape marked by resilience and adaptation. Despite these challenges, the industry has continued to embrace innovation and sustainability, the two of which will go hand in hand at the next Future Aluminium Forum, due to take place in Istanbul from the 21st - 23rd May, 2024.

The Future Aluminium Forum was originally developed to explore the transformational impact of digital technologies in the aluminium manufacturing processes. By hosting this next edition in Istanbul, we will be looking to uncover the potential to revolutionise the industry in Turkey and the surrounding regions.

By bringing together major aluminium manufacturers, suppliers of digital and sustainable technologies, and industry experts, the Forum aims to foster collaboration and knowledge-sharing, paving the way for a more efficient, sustainable, and competitive aluminium sector. You can find out more about this event in this issue and we hope to see many of you there!

This issue continues on the theme of innovation and sustainability with an exclusive feature on the largest solar thermal project in history and more information from the ASI on launching the 1.5 Degree Aligned Target Setting Method. Enjoy! nadinebloxsome@quartzltd.com

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Hydro has completed the USD 1.11 billion transaction for the sale of 30 percent indirectly held interests in the Brazilian alumina refinery Hydro Alunorte and Hydro’s 5 percent interest in the bauxite producer Mineracão Rio do Norte (MRN), together with Vale’s 40 percent stake in MRN. “We are looking forward to work with Glencore to further develop Alunorte. Glencore has broad industrial experience within metals and mining, which adds to the significant progress our bauxite and alumina area has made to bring down the footprint of alumina production. This enables Hydro to strengthen our position in low-carbon aluminium,” says President and CEO, Hilde Merete Aasheim.

Hydro and Glencore will continue efforts to reduce carbon emissions from Alunorte through the fuel switch project that aims to substitute fuel oil with LNG, and the electrification of boilers.

This will bring Alunorte to the first decile on the global carbon curve already in 2025, positioning Alunorte as a leading supplier of low-carbon alumina. The partners are committed to continuing the development of social projects to improve the lives and livelihoods of nearby communities.

“This transaction is an important step to deliver on Hydro’s strategy. Alunorte remains a core strategic asset for Hydro and is a key source of low-carbon alumina supply to our primary aluminum smelters,” says Aasheim.

The total enterprise value for

the transaction is USD 1.11 billion, which was adjusted by USD 244 million for 30 percent of Alunorte’s net debt, and a deviation from normalized working capital and financial items as of June 30, 2023. The enterprise value and net debt exclude asset retirement obligations of USD 40 million on a 30 percent basis. The parties have agreed to a post-closing price adjustment based on the financial performance of Alunorte and Hydro expects to pay the full capped amount of USD 55 million in Q1 2024.

Aluminium included on Australia’s Strategic Materials List The Australian Aluminium Council welcomes the recognition that aluminium is, and will continue to be, one of the most widely used commodities in the global net zero transition, with its inclusion in the newly announced Strategic Materials List.

This important recognition helps align Australia with our peers including Canada, USA, and Europe, who have also identified bauxite (aluminium ore) and aluminium as critical. Aluminium

is also recognised by the World Bank and the International Energy Agency as one of the commodities most needed for both clean energy technologies; including solar, batteries and electric vehicles; and the construction of electricity networks; as well as in broad strategic applications.

Responding to the new list, the Council’s CEO, Marghanita Johnson, said “The Council is pleased that the Australian Government has recognised that Australia’s

EU sanctions against Russian aluminium imports European Aluminum welcomed the European Commission’s proposed 12th package of sanctions against Russia, which includes a ban on the importation of certain aluminium products, such wires, tubes and pipes, as well as aluminium foil.

While European Aluminium welcomes this initial signal of intent, the association urges the

EU to adopt a much more rapid and expansive approach to the restriction of Russian aluminium imports. The proposed list included in the package covers only 12% of EU imports of aluminium products (HS 76) from Russia, not nearly enough to have a meaningful impact in practice. Furthermore, future sanctions must be accompanied by strong anti-circumvention

integrated aluminium value chain is important - not only to our domestic needs, but also to meet global demand for aluminium.”

measures to ensure an effective mechanism to prevent the circumvention of sanctions through imports of (semi-) final aluminium products from third countries.

“These sanctions are a small first step, but we strongly encourage the European Union to accelerate its efforts and broaden their scope to cover all major product categories, including ingots, slabs, and billets, which constitute over 85% of the EU’s imports from Russia,” notes Paul Voss, Director General.

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NEWS 3

EGA begins construction of UAE’s largest aluminium recycling plant Emirates Global Aluminium, have announced the start of construction of the United Arab Emirates’ largest aluminium recycling plant.

The 170 thousand tonnes per year facility is being built next to EGA’s existing smelter in Al Taweelah. The plant will process post-consumer aluminium scrap such as used window frames, as well as pre-consumer aluminium scrap from extrusion production, into low-carbon, high quality premium aluminium billets.

The new facility will supply local and global markets with low carbon metal under the product name RevivAL. Construction is expected to be complete within three years.

Most of the aluminium scrap generated in the UAE is currently

exported for processing outside the country, and is lost to the national economy. Once the recycling plant is complete, EGA expects to become the largest consumer of aluminium scrap in the UAE.

Market analysts expect global demand for recycled aluminium to grow from some 27 million tonnes per year in 2022 to 57 mil-

lion tonnes in 2040. Recycled aluminium is expected to account for around 60 per cent of the growth in global aluminium supply between now and 2030, and around 70 per cent of supply growth between 2030 and 2040.

Aluminium is infinitely-recyclable. Recycling aluminium requires 95 per cent less energy than making new metal, and results in a fraction of the greenhouse gas emissions of primary aluminium production.

Abdulnasser Bin Kalban, Chief Executive Officer of Emirates Global Aluminium, said: “Aluminium recycling is key to our metal achieving its enormous potential to contribute to decarbonisation while improving global living standards.”

Hydro opens new aluminium recycling plant in Michigan, USA On November 16, Hydro opened the Cassopolis plant in the U.S., 18 months after breaking ground at the site. The USD 150 million Michigan plant will produce 120,000 metric tonnes of recycled aluminium annually. Hydro is now producing aluminium with the lowest carbon footprint in North America.

“With the U.S. experiencing a manufacturing renaissance, this is a great day for Cassopolis, Michigan and for Hydro. This project is a

key part of our strategy to double the production of our market leading recycled products and to bring more low-carbon aluminium to our American partners,” says President and CEO, Hilde Merete Aasheim.

Hydro expects to produce 120,000 metric tonnes of aluminium extrusion ingot per year at the site. It is the third greenfield recycling plant the company has built in the United States, but the first designed to produce Hydro CIR-

CAL. “The demand for sustainably produced aluminium has been growing rapidly within virtually all of our market segments, and among carmakers in particular, so we see this as a perfect time to introduce Hydro CIRCAL in larger volumes than before. And it is only the beginning,” says Eivind Kallevik, Executive Vice President for Hydro Aluminium Metal.

Alba breaks production record Aluminium Bahrain B.S.C. (Alba), has set a new record-breaking production of 1,620,665 metric tonnes (MT) in 2023, an increase of 20,554 MT, versus 1,600,111 metric tonnes (MT) in 2022 (+1.3% Year-on-Year).

Commenting on this milestone, Alba’s Chief Executive Officer, Ali Al Baqali stated: “We are proud to have once again exceeded our own production target for the year. Today, we celebrate not just numbers but the human capital behind such Aluminium International Today

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achievement.

I also take the opportunity to thank the Chairman of the Board Khalid Al Rumaihi for his leader-

ship and guidance as well as the Members of the Board for their support throughout 2023.”

NEWS IN BRIEF ALFED announces new President

The Aluminium Federation (ALFED) announced the appointment of its new president, Mark Allen at the Annual Business Briefing in November. Replacing outgoing president of two years Mike Dines, Allen is sales director at Mechatherm International, Britain’s largest global aluminium furnace supplier, and boasts over 25 years’ experience in the aluminium industry.

AMAG appointments

The Supervisory Board of AMAG Austria Metall AG has appointed Dr. Helmut Kaufmann (60) as Chief Executive Officer (CEO) from January 1, 2024, in addition to his function as COO. Helmut Kaufmann will thereby assume the position of the current CEO Gerald Mayer.

Ma’aden Aluminum extends relationship with JLR Ma’aden Rolling Company’s aluminium rolling mill has supplied JLR with aluminium sheets since 2016.

This relationship has been strengthened over the years and is set to continue for the future, having exported more than 100,000 tons of highquality aluminium sheet to date with various specifications and dimensions used in JLR luxury cars.

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GREEN NEWS

www.aluminiumtoday.com

2024 DIARY MARCH

10 years of renewable energy Aludium has entered into a longterm Power Purchase Agreement (PPA) with the Norwegian company Statkraft, Europe’s largest renewable energy generator. This agreement has been signed within the framework of the relationship between Statkraft and Fortia Energía, the largest independent supplier in the Iberian electricity market. The contract, valid for 10 years, will come into effect on July 1, 2024.

As a result of this strategic alliance, Aludium claims it will se-

cure more than a third of its annual electricity consumption with renewable energy. Reducing the total carbon emissions intensity to less than 4.5 t CO2/t Al (cradleto-gate), using renewable energy for electricity supply, creating certified low-carbon emission products, increasing the recycling of aluminium scrap, and maintaining the highest industry standards in environmental management certifications are some of the sustainability goals set for 2025 to drive the climate transition.

The agreement represents a significant step in accelerating the decarbonisation of its industrial activities and promoting renewable and clean electricity within the company. “With the signing of this agreement, we are taking a significant step towards achieving our goal of having an electricity consumption based solely on renewable energy. This marks a notable milestone in our roadmap to meet the sustainability objectives set for 2025” says Lionel Chapis, CEO of Aludium.

SMS group supplies energy and sustainability management system to ElvalHalcor The aluminium rolling division of ElvalHalcor S.A., Elval, has placed an order with SMS group for the delivery of its Viridis Energy & Sustainability Suite for its flat-rolled aluminium manufacturing plant based in Oinofyta, Greece.

This milestone marks a significant step forward in enhancing Elval’s sustainability initiatives and energy management capabilities.

ElvalHalcor is one of the leading flat rolled aluminium manufacturers worldwide. With an annual capacity of 450,000 tons, the project will make a significant contribution to the company´s goal to reduce carbon emissions and optimise overall production processes.

The partnership between SMS and Elval exemplifies a shared vision of

sustainable and responsible industrial practices. With the installation of two modules of the Viridis Energy and Sustainability Suite, Viridis Performance and Viridis Grids, Elval will be equipped to meet the ever-increasing demands for responsible and energy-efficient management in the aluminium industry.

European Aluminium unveils sciencebased decarbonisation pathways European Aluminium launched its report, Net-Zero by 2050: Science-based Decarbonisation Pathways for the European Aluminium Industry, during a high-level event with Kerstin Jorna, Director-General at the European Commission’s DG Grow. The report offers a com-

prehensive, realistic framework for achieving net-zero emissions across the entire aluminium value chain, from primary production and semi-fabrication to recycling.

As an energy-intensive, though highly electrified, and hard-toabate industry, the European aluminium industry is responsible for approximately 24 million tonnes of CO2 equivalent emissions annually. At the same time, aluminium is an essential material in the transition to a fully decarbonised economy, supporting countless clean technologies, including solar PV, wind power, heat pumps, and electric vehicles. As the European

demand for aluminum is expected to increase by 30% by 2040, and with the EU aiming to satisfy 40% of its annual consumption using domestically sourced raw materials for processing, the European aluminium industry is committed to ensuring that this growth is sustainable and does not contribute to a spike in global emissions.

Paul Voss, Director General of European Aluminium, stated: “It’s abundantly clear that our operations must align with the environmental limits set by our planet.

Achieving net-zero isn’t a distant aspiration; it’s an imperative that demands our immediate action.”

3rd - 7th TMS Annual Meeting & Exhibition The TMS Annual Meeting & Exhibition brings together more than 4,000 engineers, scientists, business leaders, and other professionals in the minerals, metals, and materials fields for a comprehensive, cross-disciplinary exchange of technical knowledge.

Held in Florida, USA www.tms.org/ AnnualMeeting/TMS2024

MAY 14th - 16th CRU: 30th World Aluminium Conference The 30th World Aluminium Conference will return to the St Pancras Renaissance Hotel, London, co-hosted by the International Aluminium Institute (IAI) and the Aluminium Stewardship Initiative (ASI). www.events.crugroup. com/aluminium/home 21st - 23rd Future Aluminium Forum The Future Aluminium Forum was originally developed to explore the transformational impact of digital technologies in the aluminium manufacturing processes. By hosting this next edition in Istanbul, we will be looking to uncover the potential to revolutionise the industry in Turkey and the surrounding regions. www. futurealuminiumforum. com/turkey/ 29th - 31st NorCast NorCast presents highprofile executive leaders as Distinguished Guest Speakers, along with an international line-up of presenters, to cover important aspects of the aluminium industry.

Held in Arendal, Norway www.norcast-seminar.com For a full listing visit www.aluminiumtoday.com/ events Aluminium International Today

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08/01/2024 09:24:33

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EXCLUSIVE INTERVIEW 7

Unveiling the power of the sun BIOGRAPHY: ROD MCGREGOR Rod is the founder and CEO of GlassPoint.

Under his leadership, GlassPoint has created the only solution proven at scale to reduce carbon emissions from industrial process heat and has built more than half of global industrial solar steam capacity. He is committed to helping industrial leaders across the mining and the aluminum industries – as well as many other industries–costeffectively decarbonize to meet pressing net-zero commitments.

For more than three decades, Rod has led global companies across the United States, Europe, China and the Middle East. Rod’s companies have partnered with a range of multinational corporations in the energy and technologies industries, including Royal Dutch Shell, AT&T, Intel and Volkswagen.

His first company received the Queen of England’s award for technical achievement and the Queen’s award for export achievement, and subsequently went public on NASDAQ. He’s also a five-time founder.

1. Congratulations on Glasspoint’s monumental MOU signing with Ma’aden Aluminium Company for the largest solar thermal project in history! Can you share more details about the scale and scope of this project and how it will contribute to decarbonizing the aluminium supply chain? a. GlassPoint has partnered with Ma’aden to develop the largest industrial solar thermal project in the world, Ma’aden Solar 1. The solar steam facility will replace steam made by fossil fuels at a bauxite refinery located in Ras al Khair, which in turn is converted into aluminium. The solar steam project will span six square kilometers and will generate 14,000 tons of solar steam daily. Ultimately, the facility will reduce gas use by 12 million MMBTUs and reduce Ma’aden’s carbon emissions by over 600,000 tons annually – the equivalent of taking 130,000 cars off the road.

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8 EXCLUSIVE INTERVIEW

2. The Kingdom of Saudi Arabia has outlined aggressive climate goals through Vision 2030 and the Saudi Green Initiative. How does Glasspoint’s collaboration align with these initiatives, and what role do you envision it playing in supporting the Kingdom’s sustainability objectives? a. The Kingdom of Saudi Arabia has set a goal to generate 50% of its power from renewable sources by 2030 and achieve net-zero by 2060. We’ve recently announced a partnership with the Ministry of Investment of Saudi Arabia to build a manufacturing facility in the Eastern Province, which will help deploy solar thermal capabilities for Ma’aden and beyond to help meet these commitments. This represents major progress toward decarbonizing Saudi industry, while improving the climate impact of hard-toabate industries across the region and helping to meet rising demand for low-carbon materials. Additionally, the manufacturing facility will support technology exports through the region, diversify the Kingdom’s economy, and expand Saudi Arabia’s leadership as a technology export hub.

3. What specific impact do you foresee this solar thermal project having on the aluminium industry in terms of reducing carbon emissions and fostering sustainable practices across the supply chain? a. We expect that our project will help many leaders up and down the aluminium supply chain gain confidence in our solution as a proven way to not only deliver lowcarbon aluminium, but also boost the bottom line. There IS a proven way to go green, improve business performance and ensure reliability, and the more trust in our solutions we can build the faster we’ll see sustainability practices deepen across the industry. The good news is that many aluminium leaders like Alcoa have already adopted net-zero goals; our job is to help them get going at the scale they need.

4. As the industry moves towards net-zero goals, what trends or shifts are you observing across the sector, especially in the context of decarbonization efforts? Are there emerging strategies or technologies that are gaining traction among industry players?

5. There’s a growing narrative around “electrify everything” as a means to decarbonize various industries. Why do you believe this approach might not be the most effective when it comes to decarbonizing mining and metals production, and how does Glasspoint’s solar thermal solution offer a more viable alternative? a. When you look at industrial heat, electrification dramatically raises costs and worsens a company’s environmental profile. Plugging into the grid to generate heat costs six to ten times more than what industrial leaders are doing now – buying fuel to burn in a boiler. b. Also – and this one’s somewhat counterintuitive – electrification makes emissions worse. Most grids generate 400 grams of CO2 per kWh of electricity generated. However, what many industrial operations are doing today – burning gas to create steam – generates half as much emissions. That means using grid electricity for industrial process steam doubles emissions right out of the gate. c. The carbon intensity of electricity should improve in the years to come, but in the meantime electrification will make emissions worse. Industry needs a cost effective solution that decarbonizes steam production today, not decades in the future. With our storage system to provide around-the-clock solar steam, we can immediately reduce emissions by up to 80%--a dramatic improvement.

a. Many have considered electrifying heat, but are learning that it doesn’t pencil out economically or even reduce emissions – which has directly driven greater interest in GlassPoint. Industry players also prioritize the proven ability to deliver and improve financial results, while of course helping to achieve sustainability goals. We’ve designed our solution to tick the box in each area. b. Today, GlassPoint stands out as the only proven solution at scale to decarbonize the industrial process heat market. It’s a $444B market and we can’t do it alone, so we hope our success inspires more solutions to cross the chasm to help industries decarbonize without increasing costs.

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EXCLUSIVE INTERVIEW 9

6. Could you shed light on the challenges and opportunities faced in implementing large-scale solar thermal projects within the mining and metals sector? How does Glasspoint address these challenges to ensure the success of such ventures?

7. In the context of the aluminium supply chain, how do you anticipate the integration of solar thermal solutions to impact energy consumption, cost-efficiency, and overall environmental sustainability?

a. Land is a common constraint for largescale thermal projects. Steam isn’t very portable, so our solutions must be sited close to the metals and mining facility.

Our facilities are typically many square kilometers, so we need a good amount of space in the right place. Fortunately, this is an easy variable to vet for quickly.

b. We’re seeing low-carbon aluminium commands a premium, helping to boost profits for products from cars to phones where solar thermal solutions directly improve sustainability.

b. It’s also essential that our systems and the inherent intermittency associated with solar power do not disrupt ongoing operations. That’s why we’ve designed our system to integrate all the available sources of energy, enabling mining and metals facilities to ramp up renewables and complement existing fuel sources to avoid any interruptions, with around the clock support.

a. Low-carbon aluminium – enabled by solar thermal technology – will unite cost efficiency and sustainability to make a real impact on the bottom line.

c. For example, GlassPoint’s project with Ma’aden will decarbonize the production of bauxite, which in turn is used to make aluminium, which ultimately goes into cars, microchips, phones, computers, and more – giving those manufacturers a real competitive advantage while helping them achieve net-zero commitments. As I’ve outlined above, our costs are far more compelling than electrification or PV, and competitive with fossil fuels as well. d. Also, the EU will now tax high-carbon aluminium imports via their carbon border adjustment mechanism, making low-carbon aluminium enabled by solar thermal solutions even more appealing.

8. Glasspoint has been a pioneer in harnessing solar energy for industrial processes. What future advancements or innovations do you foresee in this field, particularly in relation to enhancing the efficiency and scalability of solar solutions for large-scale industrial applications? a. We’ve just unveiled a range of technology advances that drive a 30% reduction in the cost of solar steam – essential to de-risk adoption even farther.

The centerpiece is a solar thermal storage system which uses direct heat and ternary molten salts to provide around-the-clock steam for industry, eliminating the need for costly heat exchangers and reducing capital expenses. b. We’ve also reimagined our solar enclosure to feature lighter materials which boost solar efficiency and notably reduce weight, materials, carbon intensity, shading and the levelized cost of energy. c. I expect to see ongoing innovations that improve reliability and continue reducing costs in the years ahead, making industrial solar thermal solutions an even more compelling solution.

9. How do you perceive the role of collaboration and partnerships within the industry in achieving collective sustainability goals? Are there specific opportunities for further collaboration to advance the cause of decarbonization in mining and metals? a. To reduce emissions along every aspect of vast, complex supply chains to deliver lowcarbon products and hit decarbonization goals, it’s clear we’ll have to work together.

Public-private partnerships can also have an important role to play in developing thoughtful incentives, validating new solutions, raising awareness and creating mechanisms to de-risk adoption and reduce upfront costs. b. For instance, new agreements from the COP28 climate conference made headlines with more than 190 governments agreeing to transition away from fossil fuels while tripling renewables by 2030. That groundswell of momentum makes a real difference spurring industries to embrace climate tech like ours.

10.

Finally, looking ahead, what milestones or developments can we anticipate from Glasspoint in the near future, considering the company’s commitment to revolutionizing clean energy solutions for industrial applications? a. GlassPoint currently has 42 projects in our pipeline around the world – representing around $12B of CapEx. As the only proven solution at a scale to decarbonize industrial process heat, we look forward to sharing updates relating to our technology, as well as new project announcements in a range of industries, in the future.

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THE ALUMINA CHRONICLES 11

Aluminium trade between The USA and Europe and beyond

By Richard McDonough* The New Year began with renewed hope that trade relations between the United States of America (USA) and the European Union (EU) will continue to benefit the two major trading partners.

Leaders from business, government, and labour within both the USA and the EU expressed confidence that more permanent long-term arrangements will eventually be implemented regarding trade in aluminium and steel. Image 1 During the latter part of December of 2023, major announcements regarding trade in aluminium were made by leaders in Europe and North America.

The EU extended the suspension of its rebalancing tariffs on USA aluminium and steel products until 31 March 2025. The USA extended its Tariff-Rate Quota (TRQ) system until 31 December 2025.

These announcements came after many months of negotiations by governmental leaders.

Officials of the USA and the EU held a joint summit in Washington, District of Columbia, in the USA on 20 October 2023. Among those that attended this summit were Joseph Biden, Jr., President of the United States of America; Charles Michel, President of the European Council; and Ursula Von Der Leyen, President of the European Commission.

A variety of issues were discussed at this summit. Among those topics was the subject of trade in steel and aluminium between these two economic powerhouses. At that time, the public statements indicated that the USA and the EU were still moving forward with plans to come to a formal trade agreement by 31 December 2023.

“On 31 October 2021, we announced that we would negotiate within two years an arrangement – known as the Global Arrangement on Sustainable Steel and Aluminum (Global Arrangement) – to address non-market excess capacity and emissions intensity of the steel and aluminium industries, including to foster

Image 1. Issues dealing with trade in aluminium between the United States of America and the European Union were among the many topics of discussion at the United States – European Union Summit on 20 October 2023. Key leaders attended this summit, including, from left, Charles Michel, President of the European Council; Joseph Biden, Jr., President of the United States of America; and Ursula Von Der Leyen, President of the European Commission.

(The photograph was provided courtesy of The White House, 20 October 2023.)

undistorted transatlantic trade,” noted the leaders in a joint statement issued by the USA and the EU. “Throughout these two years, we have made substantial progress to identify the sources of nonmarket excess capacity. We have also achieved a better understanding of the tools to address the emissions intensity of the steel and aluminium industries.

We look forward to continuing to make progress on these important objectives in the next two months.”

That progress led to a decision announced by the EU on 19 December 2023: The EU decided to extend the suspension of its rebalancing tariffs on USA aluminium and steel products until 31 March 2025.

“This extension is the result of an

agreement reached with the USA,” the statement from the EU detailed. “The EU prolongs the suspension of rebalancing tariffs in return for the USA extending the suspension of its tariffs for historical trade volumes that are reflected in the TRQ system established in January 2022.

In addition, the USA agreed to provide for further exclusions from the tariffs for EU exporters.”

According to this statement, EU steel and aluminium exporters will save approximately €1.5 billion in tariffs annually.“This prolonged suspension of tariffs gives businesses on both sides of the Atlantic certainty, facilitating the smooth flow of trade,” the EU statement continued. “The mutual prolongation of tariff suspensions provides the necessary

Do you have questions about the aluminium industry? Governmental regulations? Company operations? Your questions may be used in a future news column. Contact Richard McDonough at aluminachronicles@gmail.com. © 2024 Richard McDonough Aluminium International Today

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12 THE ALUMINA CHRONICLES

time and policy space to find agreement on the remaining GSA [Global Arrangement on Sustainable Steel and Aluminium] issues.”

“This important extension is the outcome of intensive engagement with the USA and serves two key EU objectives: first, we are giving our importers and exporters the market stability and business confidence to continue to trade smoothly,” said Valdis Dombrovskis, Executive Vice-President and Commissioner for Trade of the European Commission, on 18 December 2023.

“Second, it provides us with the necessary space to continue pursuing the full and permanent removal of 232 tariffs on EU exports, as well as working on addressing global overcapacity and decarbonisation of steel and aluminium industries. We are committed to ensuring that transatlantic trade in steel and aluminium is undistorted and that our exporters are treated fairly.”

Image 2 On 28 December 2023, President Biden issued a proclamation regarding the importation of aluminium into the USA. In this proclamation, President Biden declared that the USA was extending its TRQs until 31 December 2025.

“During the past two years, the USA and the EU have made substantial progress to identify the sources of non‑market excess capacity and the actions needed to address distortions resulting from that non-market excess capacity,” stated President Biden. “The USA and the EU are continuing their discussions on global steel and aluminium arrangements to restore market-oriented conditions in their steel and aluminium sectors and support the reduction of the greenhouse gas emissions intensity of steel and aluminium across all modes of production. These discussions are anticipated to include alternative measures to prevent imports of aluminium from the EU from threatening the national security of the United States.”

“In light of the ongoing discussions and joint actions taken pursuant to the agreement described in Proclamation 10327 [the proclamation issued by President Biden on 27 December 2021 that detailed adjustments to imports of aluminium into the USA], I have determined that specified volumes of eligible aluminium articles imports from the EU will no longer threaten to impair the national security and have decided to exclude such imports from the EU up to a designated quota from the tariff proclaimed in Proclamation 9704 [the proclamation issued by President Donald Trump on 8 March 2018 that detailed adjustments to imports of aluminium into the USA] through December 31, 2025,” President Biden continued. “The United States will monitor the implementation January/February 2024

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predictability and stability to steel and aluminium workers and their families on both sides of the Atlantic.”

“Maintaining viable steel and aluminium production at home is vital to USA national security,” Ms. Tai continued, “and our efforts with trading partners, including the EU, will continue to be guided by this tenet.”

Image 2. Valdis Dombrovskis is the Executive Vice-President and Commissioner for Trade of the European Commission.

(The photograph was provided courtesy of the European Commission.)

and effectiveness of the tariff-rate quota and other measures agreed upon with the EU in addressing our national security needs, and I may revisit this determination, as appropriate.” Image 3 United States Trade Representative Katherine Tai issued a statement of support for the actions taken by President Biden.

“Under President Biden’s leadership, the USA is committed to defending workers, communities, and domestic industries from global non-market overcapacity and excessive carbon emissions,” said Ms. Tai. “By extending the European Union’s steel and aluminium TRQs for an additional two years, we can continue negotiations on a forward-looking, highstandard arrangement, whilst providing Image 3. Katherine Tai is the United States Trade Representative.

(The photograph was provided courtesy of the Office of the United States Trade Representative.)

Background on Trade Tariffs The trade situation today dates back to decisions made more than five years ago.

On 23 March 2018, the USA implemented a series of tariffs on the importation of aluminium and steel products into the USA; the tariffs were 10% on aluminium products and 25% on steel products. Imports of these products from certain countries, including nations in the EU, were initially excluded from these tariffs. On 1 June 2018, though, aluminium and steel products imported from EU nations into the USA became subject to these tariffs.

Collectively, these tariffs are known as “Section 232 tariffs.” That name came from the “Section 232” of the Trade Expansion Act of 1962 passed by the United States Congress and signed into law by President John Kennedy.

After the Section 232 tariffs began to be enforced on aluminium and steel products imported into the USA from the EU, the EU then implemented rebalancing tariffs on USA exports to the EU. The Section 232 tariffs were initially implemented by President Trump and were continued for a time under President Biden.

Whilst these tariffs were enforced on imports from the EU, there were ways for American businesses to request that certain imports be excluded from these tariffs if the products were not “produced in the United States in a sufficient and reasonably available amount or of a satisfactory quality,” according to the United States Department of Commerce.

On 17 May 2021, officials from both the EU and the USA issued a “Joint United States – European Union Statement on Addressing Global Steel and Aluminium Excess Capacity.”

With this statement, officials from the USA and the EU “…announced the start of discussions to address global steel and aluminium excess capacity…

They agreed to enter into discussions on the mutual resolution of concerns in this area that addresses steel and aluminium excess capacity and the deployment of effective solutions, including appropriate trade measures, to preserve our critical industries. To ensure the most constructive environment for these joint efforts, they agreed to avoid changes on these issues Aluminium International Today

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14 THE ALUMINA CHRONICLES

aluminium products so as to achieve climate neutrality by mid-century. Trade barriers between participating countries should be removed.

“European aluminium exports pose no threat to the USA national security,” according to European Aluminium.

“On the contrary, the trade relationship between our economies is based on longterm, mutually beneficial commercial partnerships between European and USA aluminium producers that work together to serve integrated supply chains on both sides of the Atlantic.”

Image 4. This image details the levels of aluminium production in Canada and the USA as well as the level of aluminium manufactured in Canada that was imported into the USA from 2007 through 2023.

(This image was produced from information from the Aluminium Association of Canada, The Aluminum Association, and United States International Trade Commission and provided courtesy of the Aluminium Association of Canada, 2023.)

that negatively affect bilateral trade.

They committed to engaging in these discussions expeditiously to find solutions before the end of the year that will demonstrate how the USA and EU can address excess capacity, ensure the longterm viability of our steel and aluminium industries, and strengthen our democratic alliance.”

In 2022, the EU suspended its rebalancing tariffs on imports of products from the USA until 31 December 2023 to provide time for the USA and the EU to agree on a longer-term solution. The USA replaced its Section 232 tariffs on steel and aluminium products imported from the EU with a tariff-based quota system based on historical trade volumes with the EU. The EU detailed in a statement that this quota system resulted “in above-quota EU steel and aluminium still being subject to tariffs.”

“With regard to aluminium, in 2022 the EU exported 289 Thousand Metric Tonnes (‘TMT’) of aluminium to the USA,” this statement from the EU continued.

“However, only 146 TMT of EU exports benefitted from the duty-free treatment under the USA 232 TRQs. In addition, according to the data shared by the USA administration with the European Commission, the USA Administration granted 70 TMT of exclusions to EU exporters.”

European Aluminium “European Aluminium and its members are convinced that a competitive global marketplace driven by an ambitious sustainability agenda requires free and fair trade whilst preventing subsidised aluminium from causing distortions,” noted a statement issued by European Aluminium in November of 2023.

“Compared to other industries, the global aluminium industry is disproportionally January/February 2024

Richard Mc donough.indd 3

exposed to market distortions.”

“The American and European aluminium industries have identified the issue of subsidised industrial overcapacity in China as the fundamental threat to our industries and national security,” the statement from European Aluminium continued. In 2019 and again in 2021, the OECD [Organisation for Economic Co-operation and Development] attested to China’s excessive state support of its aluminium companies, including belowmarket finance, and its damaging impact on global value chains.”

European Aluminium describes itself as “…the voice of the aluminium industry in Europe. We actively engage with decision makers and the wider stakeholder community to promote the outstanding properties of aluminium, secure growth and optimise the contribution our metal can make to meeting Europe’s sustainability challenges…Our 75 members include primary aluminium producers; downstream manufacturers of extruded, rolled and cast aluminium; producers of recycled aluminium and national aluminium associations, representing more than 600 plants in 30 European countries.”

The business organization indicated that it has “five guiding principles for an effective Global Arrangement on sustainable aluminium.”

A summary of those items: Global trade arrangements for aluminium should be established separate from benchmarks and methodologies focused on steel. The path to sustainable aluminium should be guided by fair market practices. Trade arrangements for aluminium globally should take into account the EU Carbon Border Adjustment Mechanism (CBAM) and the EU Emissions Trading System (ETS). Participating nations must commit to and have implemented the necessary legislative framework for low-carbon

The Aluminum Association In a joint statement by European Aluminium and The Aluminum Association issued to leaders of the USA and the EU on 19 December 2023, the two organisations noted that “The European and American aluminium industries have united in urging policymakers to continue negotiations aimed at achieving the crucial Global Arrangement on Sustainable Steel and Aluminium.”

“As historical allies, reaching a deal on the Global Arrangement represents a significant chance to implement and demonstrate solid cooperation amidst escalating global tensions and trade disputes,” the joint statement continued.

“Therefore, our associations are eager to collaborate with you to ensure we do not miss this opportunity.”

Though the decisions of the EU and the USA to continue the current trading arrangements were welcomed by many in the aluminium industry, both business organisations seek a long-term agreement between the USA and the EU. “Whilst we were pleased to see a deescalation of tensions and continued negotiation, The Aluminum Association hopes to see further progress made on the Global Arrangement and encourages policymakers from both sides of the Atlantic to persist in their collaborative efforts,” said Matt Meenan, Vice President of External Affairs at The Aluminum Association.

The Aluminum Association describes itself as representing “…aluminium production and jobs in the USA, ranging from primary production to value added products to recycling, as well as suppliers to the industry. The association is the industry’s leading voice, representing companies that make 70% of the aluminium and aluminium products shipped in North America.”

On 7 December 2023, Charles Johnson, President and Chief Executive Officer of The Aluminum Association, testified at a hearing of the United States International Trade Commission (USITC).

In his testimony, Mr. Johnson stated Aluminium International Today

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16 THE ALUMINA CHRONICLES

that the North American supply chain for aluminium involves multiple border crossings between Canada and the USA before the material reaches its final product stage highlighting the interconnected nature of the aluminium trade in the region.”

To provide a perspective of the economic significance of Canada in the trade of aluminium, Mr. Simard detailed that the value of unwrought aluminium exports surpassed (CAN) $12 billion in 2022.

Image 5

Image 5.The USA was the destination for most of the primary aluminium exported from Canada during 2021 through 2023.

(This image was produced from information included in the Canadian International Merchandise Trade Database of Statistic Canada and provided courtesy of the Aluminium Association of Canada, 2023.)

that “A World Bank analysis found that a robust effort to combat climate change could more than double global demand for aluminium by 2050. It is no exaggeration to say that there is no green energy transition without materials like aluminium. This growing shift has led to significant domestic investment – with nearly $10 billion committed or spent to build and expand USA aluminium plants and operations over the past decade.”

“However, our industry is not without challenges,” Mr. Johnson continued. “As aluminium recycling and semi-fabrication has grown, primary aluminium production in the United States has declined, driven by the twin challenges of electricity costs and unfair trade practices in China. Today, there are only five operational aluminium smelters in the United States, compared with more than three dozen in the 1980s.”

He explained that “The USA industry benefits from – and is frankly reliant upon – multiple low-carbon primary aluminium smelters in Canada which use renewable hydropower and feed a great deal of USA demand.”

“The aluminium industry supports efforts to further decarbonise aluminium production,” Mr. Johnson noted in his testimony. “There are essentially two ways to do this. First, by reducing emissions in upstream production through new research and technology development and by decarbonizing the electric grid overall.

Second, by recovering and recycling more scrap aluminium. The industry is actively pursuing both of these goals through policy advocacy, research and investment.”

He indicated that the carbon impact of North American aluminium production has been cut in half during the past 30 years. He also detailed that aluminium production in China and in the Middle East “can be two-to-three times as carbon intensive as making similar products here” because of reliance on electricity produced January/February 2024

Richard Mc donough.indd 4

using coal and natural gas in those areas.

Mr. Johnson concluded his testimony at the USITC hearing by stating that “We share your goal to move toward ever more sustainable aluminium production. We hope and believe industry and government can work constructively together toward this shared purpose.”

Aluminium Association of Canada Trade in aluminium between the USA and Canada is a critical element to consider when looking at trade in aluminium between the USA and the EU. Many aspects of the aluminium industry in the USA are directly intertwined with the aluminium industry in Canada. Image 4 “With an annual production capacity of 3.2 million tonnes, Canada constitutes 80% of North America’s primary aluminium production,” said Jean Simard, President and Chief Executive Officer of the Aluminium Association of Canada.

“Notably, the majority of Canada’s aluminium output is exported directly to the USA in the form of unwrought aluminium. Most of the rest is consumed locally, whilst a small portion may be exported to Europe or Mexico.”

Of the aluminium exported to Europe, much of it goes to The Netherlands.

This is primarily attributed, Mr. Simard explained, to the presence of official LME [London Metal Exchange] warehouses in the country.

“Founded in 1990, the Aluminium Association of Canada (AAC) brings together Canada’s three aluminium primary producers, Alcoa, Aluminerie Alouette, and Rio Tinto,” according to a statement from the Association. “A non-profit organisation, it represents the Canadian primary aluminium industry towards the population, public authorities, aluminium users, and key environmental and economic stakeholders.”

Mr. Simard noted that “it’s noteworthy

United Steelworkers Union Unionised labour is a critical aspect of the aluminium industry in both the USA and Canada. One of the major labour unions involved in manufacturing aluminium in North America is the United Steelworkers (USW) Union.

“Our membership is around 11,600 throughout the aluminium industry,” stated a spokesperson for the USW Union.

“Alcoa, Arconic, Century and Kaiser are some of the largest remaining employers.”

Approximately 3,500 of the union’s members working in the aluminium industry are employed in extruding aluminium in the USA. Beyond the aluminium industry, the USW Union is also a major source of labour in a number of industries operating in North America. The union describes itself as representing “…850,000 workers employed in metals, mining, pulp and paper, rubber, chemicals, glass, auto supply and the energy-producing industries, along with a growing number of workers in health care, public sector, higher education, tech and service occupations.”

The USW Union noted that it has been active in seeking to protect jobs within the aluminium industry in the USA and has encouraged strong trade relations between the USA and Canada. The labour union has strongly advocated for tariffs on aluminium imported into the USA from countries that it has deemed to engage in unfair trading practices.

At a hearing of the USITC on 23 October 2023, Roy Houseman, Legislative Director for the USW Union, presented testimony about trade in aluminium extrusions from China, Colombia, Dominican Republic, Ecuador, India, Indonesia, Italy, Malaysia, Mexico, South Korea, Taiwan, Thailand, Turkey, United Arab Emirates, and Vietnam. Of these countries, Italy is the only one that is part of the EU. “Our union is a co-petitioner because our USA members in the aluminium industry, no matter where they work, want a fair market which unfortunately requires relief from the subject imports in order to survive,” said Mr. Houseman Aluminium International Today

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THE ALUMINA CHRONICLES 17

in his testimony at this hearing. “The USW supports a large number of USA aluminium extruders, and nearly all of the primary aluminium facilities in the United States, as well as alumina producers and downstream manufactures that consume aluminium extrusions.”

“We are here today with the United States Aluminum Extruders Coalition in advocating for the survival of our industry, which includes protecting thousands of USA jobs,” Mr. Houseman continued.

“We also know that some of the coalition companies have facilities that are represented by other unions – we stand with them, as we stand with all workers in all facilities.”

“We are very concerned that unfairly traded imports in the aluminium extrusion industry will erode the value chain – both upstream and downstream,” he explained.

“This would have a devastating impact on USA jobs.”

In his testimony, Mr. Houseman urged the USITC to utilise the USA trade laws to level the playing field for USA producers facing unfair import competition.

“Our country needs a strong and vibrant domestic aluminium supply chain

free from non-market excess, and carbon intensive capacity,” stated Mr. Houseman.

“Unfortunately, these unfair imports now threaten the continued viability of the domestic supply chain. We have reached a critical moment for the future of the USA aluminium extrusion industry, which is facing a major crisis due to unfair imports.

These imports must be addressed to give aluminium extruders and the upstream and downstream aluminium industries a fair opportunity to serve our democratic, market-based economy for this and the next generation.”

Days before the testimony of Mr. Houseman and shortly after the conclusion of the United States – European Union Summit on 20 October 2023, David McCall, International President of the USW Union provided an overview of trade relations between the EU and the USA during the past few years as well as goals for the future trade relations.

“Steel and aluminium are vital to our national defence and critical infrastructure,” said Mr. McCall. “The USA acted under Section 232 of our trade laws in 2018 to maintain domestic capacity and keep us safe. These continue

to be urgent concerns, and we appreciate that the Biden Administration kept these priorities in the foreground in charting a course forward.”

“Over the past two years, our union coordinated with employers and labour unions in the United States and Europe that share our values,” Mr. McCall continued. “As more countries seek to join the arrangement, we welcome those who are serious about putting a stop to predatory trade practices and confronting the challenges of global climate change.

Now, they will need to earn the right to participate.”

Mr. McCall concluded his testimony by stating that “We look forward to continuing our work with the Administration and our European allies as together we seek to advance our opportunities to limit global overcapacity in steel and aluminium, reduce the carbon intensity of our industries, meet our critical mineral needs, and advance workers’ rights.”

Aluminium International Today will continue to keep our readers updated as trade negotiations continue between the EU, the USA, and other trading partners. �

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January/February 2024

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21-23 MAY 2024 | ISTANBUL | TURKEY

The Future Aluminium Forum is set to return and will take place in Istanbul on the 21-23 May 2024.

The Forum was originally developed to explore the transformational impact of digital technologies in the aluminium manufacturing processes and by hosting this next edition in Istanbul, we will be looking to uncover the potential to revolutionise the industry in Turkey and the surrounding regions.

FOR SPEAKING ENQUIRIES

By bringing together major aluminium manufacturers, suppliers

Unlock the spotlight! If you’re well-versed in Artificial Intelligence, Industry 4.0, Smart Manufacturing, Innovative uses of aluminium, Robotics & Automation, or Sustainable Technologies, seize the chance to captivate a room brimming with aluminum enthusiasts eager to soak in your expertise. Your moment to shine awaits!

of digital and sustainable technologies, and industry experts, the Forum aims to foster collaboration and knowledgesharing, paving the way for a more efficient, sustainable, and competitive aluminium sector.

Nadine Bloxsome, Content Director  +44 (0)7778 688 035  nadinebloxsome@quartzltd.com

EARLY BIRD TICKETS ARE NOW AVAILABLE UNTIL 29 FEBRUARY 2024

INTERESTED IN EXHIBITING OR SPONSORING?

Please contact Nathan Jupp, Commercial Sales Director  +44 (0)1737 855 027  nathanjupp@quartzltd.com

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09/01/2024 14:45

21-23 MAY 2024 | ISTANBUL | TURKEY

The Future Aluminium Forum is set to return and will take place in Istanbul on the 21-23 May 2024.

The Forum was originally developed to explore the transformational impact of digital technologies in the aluminium manufacturing processes and by hosting this next edition in Istanbul, we will be looking to uncover the potential to revolutionise the industry in Turkey and the surrounding regions.

FOR SPEAKING ENQUIRIES

By bringing together major aluminium manufacturers, suppliers

Unlock the spotlight! If you’re well-versed in Artificial Intelligence, Industry 4.0, Smart Manufacturing, Innovative uses of aluminium, Robotics & Automation, or Sustainable Technologies, seize the chance to captivate a room brimming with aluminum enthusiasts eager to soak in your expertise. Your moment to shine awaits!

of digital and sustainable technologies, and industry experts, the Forum aims to foster collaboration and knowledgesharing, paving the way for a more efficient, sustainable, and competitive aluminium sector.

Nadine Bloxsome, Content Director  +44 (0)7778 688 035  nadinebloxsome@quartzltd.com

EARLY BIRD TICKETS ARE NOW AVAILABLE UNTIL 29 FEBRUARY 2024

INTERESTED IN EXHIBITING OR SPONSORING?

Please contact Nathan Jupp, Commercial Sales Director  +44 (0)1737 855 027  nathanjupp@quartzltd.com

@Alu_Forum SPONSORED BY

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20

Aluminium in the USA

By Myra Pinkham* While North American light vehicle production remains below its preCovid-19 pandemic peak, when auto output reached over 17 million vehicles, it is currently in a much better place than it had been a year ago. Both the overall increase in auto production and a product mix that is increasingly conducive to the use of lighter weight materials good news for aluminium companies that sell into the auto market.

“This is probably the most exciting time that I have seen in at least the past 30 years,” declared Helen Weykamp, a principal research scientist for Norsk Hydro and a technical committee member for the Aluminum Association’s Aluminum Transportation Group (ATG).

She explained that with the combination of the transition from internal combustion engine (ICE) vehicles to more electric vehicles (EVs) and their very aggressive decarbonization targets, the automotive OEMs are relying on materials and materials suppliers to help them to achieve such goals as lightweighting and increased vehicle performance and safety.

There is no question that the North American automotive market has been very volatile ever since 2019-20, largely due to the adverse impact that the Covid pandemic and certain other factors have had upon both auto sales and production.

“But now we are heading into a period of at least a bit more stability,” Nick Dzierzak, director of Novelis’ North American director of automotive business

development, declared.

Abey Abraham, principal of Ducker Carlisle’s automotive and materials practice, noted that given the plethora of external factors that impact auto output there has also been some cyclicality over time. While they have generally just been small blips, that wasn’t the case when Covid hit in 2020 and North American auto production plummeted to just 12.9 million light vehicles.

It had been anticipated that there would be a rather large increase in auto production in 2021 and 2022, Phil Gibbs, a metals equity analyst for KeyBanc Capital Markets said that increase was much less than expected largely because certain supply chain issues, including limited availability of semiconductor chips.

“But now most of the supply chain issues are in the rear-view mirror,” JD Rutt, vice president of business development at Hydro Extruded Solutions North America. In fact, Bill Rinna, director of Americas vehicle forecasts for Global Data (formerly LMC Automotive) said that in 2023, other than the six weeklong United Autoworkers (UAW) strike against the US Big Three automakers, there were fewer production disruptions. He said because of that North American light vehicle production increased 9% year on year in 2023 to about 15.6 million vehicles from the already improved 14.2 million level in 2022. While still not reaching the previous peak, he said that NA auto output is expected to grow further to about 16.1

million units in 2024.

“A year ago, we thought that both North American production and sales in 2023 would be about 2% lower than they ended up,” Edwin Pope, a materials analyst for S&P Global Mobility, said. In fact, K.V. Prasad, senior vice president of research for the Center for Automotive Research (CAR), said that 2023 US light vehicle sales were up about 12.8% year on year including about a 13.6% increase for light truck sales and 9.8% increase for passenger cars.

According to Charlie Chesbrough, a senior economist for Cox Automotive, this is the largest increase in US auto sales since 2019, explaining that even with such headwinds as the high interest rates (therefore financing charges), inflation and potential for an economic recession, there are still a lot of individuals and businesses with enough needs and ability to sustain this sales recovery. He said that is especially the case given the average age of the vehicles that are currently on the road.

Rinna noted that the sales have been helped by the about 40% year-over-year improvement in auto dealer inventories, which has been partly the result of the higher production levels now that supply chain constraints are easing.

While steel is still generally viewed as the material of choice, accounting for about 54% of the weight of the average NA light vehicles, Matthew Abrams, a NA CRU aluminium analyst, said that

*US correspondent January/February 2024

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Aluminium International Today

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AUTOMOTIVE 21

given the push for lightweighting vehicles aluminium has been, and is expected to continue to, to make at least incremental gains, especially if demand for electric vehicles (EVs), particularly battery electric vehicles (BEVs) really starts to take off.

Another big driver for lightweighting, however, is continuing growth in the light truck share of the North American auto mix, which, according to Ducker Carlisle’s Abraham, due to the region’s preference for SUVs and pickup trucks, reached about 81% of all North American automobiles in 2023. He said that share is expected to increase to about 85% by 2030.

Novelis’ Dzierzak noted that this gradual shift away from sedans to light trucks, has occurring over the past 5-10 years, has been working in aluminium’s favour given that there is a stronger value proposition for lightweighting, therefore using lightweight materials like aluminium, for larger vehicles.

Weykamp said that aluminium is already benefitting from this with light trucks tending to use about 30% more aluminium than sedans.

The growth in light truck share is not only occurring for ICE vehicles, given that several automakers have recently been introducing EV light truck models – some of which are already in production, and others that will be available over the next few years.

While using lightweight materials like aluminium are seen as being particularly important for EVs to counter the weight of their batteries and to increase the vehicle’s range, Jack Pell, Hydro Extruded Aluminium International Today

Myra Hydro.indd 2

Helen Weykamp

Hilde Merete Aasheim,Managing Director, Norsk Hydro

Solutions North America’s vice president of automotive, said lightweighting is important regardless of the vehicle’s powertrain.

He said that one prime driver is to increase fuel efficiency – both due to more stringent governmental regulation and the growing desire for greater sustainability.”

Also, people just want to save money and the automakers are coming up with new mandates to encourage the use of lower carbon materials in their vehicles.

Weykamp said that the automakers know that they can choose aluminium to do this to achieve the size, safety and performance requirements that they are looking for.

The drivers of the lightweighting, however, varies by the type of vehicle.

Abraham said that for ICE vehicles using lighter materials like aluminium lowers the weight of the powertrain therefore allowing the vehicle to meet more stringent fuel efficiency and carbon emission standards. Meanwhile, a big benefit of using aluminium in EVs is to compensate for the weight of its batteries and, therefore, increase its range.

Abraham noted that according to Ducker Carlisle’s April 2023 study for the Aluminum Association indicated that the aluminium content of NA light vehicle averaged 501 lbs. per vehicle, up from 459 lbs. per vehicle in 2020 and that it is expected to continue to increase to an average of about 556 lbs. per vehicle by 2030.

But Abraham said that while the biggest growth had previously been for the aluminium sheet products used for the vehicles’ bodies and closures, from 2020-30 the greatest amount of growth is for extrusions, particularly for EV battery housings, battery frames and battery crossmembers. He noted that an average of 58 lbs. of aluminium extrusions were used per vehicle in 2022 from 35 lbs.

per vehicle in 2020 and that is expected to grow to at least 92 lbs. per vehicle by 2030 with most of that growth being for EVs. “The move toward the increased electrification of vehicles will be very important for future aluminium demand,” CRU’s Abrams said, estimating that EVs currently contain about 30% more aluminium than ICE vehicles including about 34 lbs. more extrusions, 15 lbs. more sheet, 3 lbs. more castings and 3 lbs. more forgings.

But one thing that could limit aluminium’s further inroads in EVs is its cost. While aluminium is lightweight it is also more expensive than the steel that it is looking to displace – even than advanced high strength steels, CAR’s Prasad said, and EVs are already seen as being pricey.

While there clearly has already been a push for electrification, to date the adoption curve in the US hasn’t been as strong as in some other regions of the world including Europe and even slower than some in the US had expected.

Global Data’s Rinna pointed out that even though it is believed that EV sales increased about 50% in 2023, their share of total North American vehicles is still quite low – about 8% for BEVs, 2% for plug-in hybrids and 7% for full hybrids.

While he said that it is possible that those shares could grow substantially – to about 30% for BEVs, 4% for plug-in hybrids and about 12% for full hybrids – there could be some headwinds to that.

One big one is their cost.

Other issues are consumer acceptance, range anxiety and the availability of both charging infrastructure and of certain materials, particularly battery materials.

But on the other hand, the tax credits and other incentives from the Inflation Reduction Act (IRA) and some other recently passed legislation could help going forward, as long as companies January/February 2024

08/01/2024 09:27:58

22 AUTOMOTIVE

meet the changing requirements.

Also, according to Jonathan Smoke, Cox Automotive’s chief economist, is coming to terms that consumers need to be sold on the merits of going electric and are offering more models, more incentives, more discounting, more advertising and more sales muscle to do so. He said that he believes more US EV sales will follow.

However, CRU pointed out that because of concerns about US consumers’ buying interest General Motors recently delayed the launch of some new BEVs and Ford announced that it will be producing fewer batteries than it originally planned at its new Michigan battery plant that is slated to come online in 2026.

Abraham pointed out that the transition from ICE to EVs is a bit of give and take for aluminium. But while there is the loss of the engine block, the engine head and the transmission case, that is being more than made up with aluminium content in EV battery housings, motor housings and applications in the vehicle chassis and body enclosures.

It isn’t just extrusions that will benefit when EV demand really starts picking up. Novelis’ Dzierzak observed that such applications in EV battery boxes, such as for battery cases and cooling plates, are also creating incremental opportunities for aluminium sheet. “Meanwhile for both EV and ICE vehicles we expect to continue to see strong growth in such closures as lift gates, doors and hoods, he said, noting that it is for those applications that the auto OEMs begin to look for lightweighting opportunities by converting them to a lighter weight material, such as aluminium sheet.

This comes as there has been a general push in the auto sector to use higher strength materials. That isn’t only true about steel, where advanced high strength steels are replacing mild steels for many applications, but Kaustubh Chandorkar, a flat-rolled aluminium analyst for CRU, noted that automakers have also been using more high strength aluminium sheet (and extrusions).

That includes the use of 6000- and 7000-series sheet for closures and 5000 series sheet, which has greater ductility and formability for internal body-in-white applications. Dzierzak explained that such higher strength aluminium products aid in the auto industry’s lightweighting efforts as it allows the auto OEMs to reduce weight through downgauging thicknesses of some components.

Even with its expected greater demand by the auto sector, it is generally believed that there will be enough aluminium available to meet the automakers’ current and future demand, Abraham said, noting, “Aluminium producers have always added January/February 2024

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capacity as needed and they continue to do so.”

“We knew this was coming,” Weykamp said. And because of the increase in demand for aluminium – not just by the automotive industry, but also in packaging and other end use applications – the industry invested more than $9 billion over the past decade to increase its production capacity and to achieve their sustainability goals. This has been a mixture of new greenfield mills, expansions at existing facilities and moves to increase their recycling and recycled content. Recently there have been some sizable investments by both flat-roll and extrusions producers.

With consumer demand starting to exceed available capacity, in May 2022 Novelis announced it was building a new rolling mill in Bay Minette, Ala., with an initial 600,000 tonne production capacity with the potential to expand that plant in the future. Dzierzak said that while a good percentage of that capacity will be for packaging applications, it will also serve the auto sector. He noted that this decision came shortly after Novelis broke ground on a $365 million recycling centre adjacent to its existing automotive finishing plant in Guthrie, Ky. Also, in July 2022 Steel Dynamics announced that it is building a 600,000 tonne a year low-carbon recycled aluminium flat-roll mill with two supporting recycled aluminium slab centres under the name of Aluminum Dynamics Inc. (ADI) in Columbus, Miss. CRU’s Abrams said that it is believed that the ADI mill will be evenly split between producing auto sheet, can sheet and common alloy while 60% of the aluminium produced by Novelis’ Bay Minette mill can sheet, 30% auto sheet and 10% common alloy. Dzierzak said he believes that other aluminium producers could also seek to increase their US flat roll

production capacity.

Meanwhile, Abrams said that about 25 new US extrusion presses are expected to come online over the next two years with about 60% of them believed to be transportation focused.

“Extruders have been already adding a bit of US capacity over the past several years,” Pell observed, noting that, for example, in November opened a new recycling plant in Cassopolis, Mich., which is expected to produce about 120,000 tonnes of extrusion ingot per year for a number of end markets, including the auto sector. Weykamp pointed out that the Cassopolis plant can produce Hydro CIRCAL, which contains 75% or more post-consumer scrap.

She pointed out that Hydro is upgrading its existing US plants, including a $15 million investment in its Henderson, Ky., facility to enable it to deliver certified recycled aluminium products to the automotive industry.

For the US auto market in general, Cox Automotive’s Smoke said that he is expects sales growth to be somewhat constrained and weak in 2024, but, barring any new black swan events, it should be bit more a bit more normal, which will be a welcome relief after the chaos in the market over the past three years.

“I think the outlook is bright for aluminium suppliers to the auto industry,” Weykamp said, maintaining, “Aluminium is important to enable the automakers to meet their lightweighting and sustainability goals.”

Nevertheless, Ducker Carlisle’s Abraham pointed out that there continue to be a lot of external factors that could continue to impact the industry’s risks and uncertainties. “Everyone from material suppliers, parts suppliers to the OEMs need to be very agile.” � Aluminium International Today

08/01/2024 09:28:04

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HEALTH & SAFETY 25

Quick to forget

By Alex Lowery*

Many in our industry assume large explosions occur rarely and, for the most part, have been prevented from occurring.

This mindset unintentionally downplays the seriousness of the hazard in their workplace(s). It exposes their workers and surrounding community to a deadly hazard. This false safety belief is farthest from the truth. Because for the past 23 years our industry has continued to suffer through one or more catastrophic molten metal explosions annually. An explosion killed six workers and destroyed a casthouse in April, 2022. 2023 seemed to be anomaly with no explosion until an explosion occurred in September killing four and injuring thirty workers. Another explosion occured killing two workers two weeks later.

The hazards associated with molten metal are universal and exist in every workplace that processes molten metal.

Still some workplaces downplay the severity of this hazard. No other hazard in our industry caused more financial losses than molten metal explosions. Insurance claims over the past 13 years have been filed for over $400,000,000 in the USA because of molten metal explosions. Why is our industry so quick to forget ?

Workplaces fail to acknowledge this

hazard because of a lack of education and awareness. Understanding how molten metal explosions occur can provide a workplace with the knowledge to inspect and identify machinery, tasks or procedures where an explosion could generate.

Industry knowledge of this hazard progressed through the decades of research by scientists around the globe.

These research studies formed the foundation for our industry’s best practice toward safety when handling molten aluminium.

Scientists proved explosions occur when molten aluminum reacts with water in either a physical or a chemical reaction.

Physical reactions are the most common.

They occur when molten aluminum covers

China 2020

China 2022

China 2020

*Author & General Manager, Wise Chem LLC Aluminium International Today

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26 HEALTH & SAFETY

Brasil, September 2023

water or moisture on a bare substrate (e.g., concrete, steel, stainless steel). The moisture expands rapidly propelling the molten metal covering it away. A common example is during transfer of a crucible and some of the contents spill onto a wet floor. When this occurs the temperature of the water rises instantaneously propelling or throwing off molten metal. The flying molten metal creates other hazards when it lands. If it lands on a combustible (e.g., wood, cardboard, etc.), the combustible will ignite. These explosions damage equipment and workers can be injured or killed.

Chemical reactions occur when aluminium bonds with oxygen (forming aluminium oxide) releasing hydrogen (in the form of energy) on a molecular level. Scientists have calculated that the force generated from one kilogram of molten aluminium is equivalent to three kilograms of Trinitrotoluene (aka TnT) exploding. Furnaces in aluminum plants contain 300,000 to 1,000,000 kilograms of metal. The explosions can be very large, destroying workplaces, injuring and killing workers and even create shockwaves detectable by seismic earthquakes stations. It should also be noted that in physical reactions the molten metal that reacts with water is unchanged with regards to its mass. If 1000 kg of molten aluminium physically reacts with water, the result is 1000 kg of solidified aluminium. Thi is not the case with chemical reactions. If the same 1000 kg chemically reacts with water, the 1000 kg instantly transforms to aluminum oxide. This is why after chemical reaction explosions a large mushroom cloud of aluminium oxide generating from the workplace occurs. The aftermath of the site will also look like it is covered in snow because of the aluminium oxide.

In 1980, the Aluminum Association started the Molten Metal Incident Reporting Program. It arose from a request within the industry to develop a January/February 2024

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Norway 2017

program where companies could learn from one another on an anonymous basis about molten metal explosions that were occuring. For the past 42 years, this program has been a valuable safety tool for companies around the globe.

There are currently 200 reporting plants worldwide that forward a detailed report when they experience an explosion in their workplace. The Aluminum Association states that the MMIR might catch less than 10% of all incidents. Regardless, this program is a great resource for educating plants on trends in our industry. All reporting companies receive a detailed annual report listing where in a workplace the explosions occurred (e.g., melting, transfer, and casting).

During the melting phase explosions have been recorded that included scrap, sows, alloy addition, ingot/t-bar, others.

Scrap is a growing source for raw material throughout our industry. Scrap can be divided into two categories, internal or

external. Internal scrap is material that was generated internally within the workplace and kept undercover. External scrap is either material received from outside the workplace or internally generated scrap that was stored outside and exposed to the elements. “Careful scrap inspection, storage and, where appropriate preparation, are vital to prevent molten metal explosions and other mishaps. A concern with scrap shipments is that hazards may be hidden or buried and difficult to discover.” states the Guidelines for Aluminum Scrap Receiving and Inspection Based on Safety and Health Considerations. This document is a useful resource on identifying the variety of hazards involved in scrap.

In addition to scrap causing explosions, sows, ingots, t-bars and RSI (remelt secondary ingot) can cause explosions too. For sows and RSI, the process of molten metal cooling in mold can result in a shrinkage cavity. Shrinkage cavities Aluminium International Today

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28 HEALTH & SAFETY

form during the cooling process when the outermost surfaces of the metal solidifies while the center remains molten. Overtime a shrinkage cavity can collect moisture. If a sow or a RSI is charged into a furnace without properly drying moisture in the shrinkage cavity an explosion can result.

One workplace reported a sow’s shrinkage cavity with a volume of 19 Liters.

The Molten Metal Incident Reports recorded over 1000 explosions during the casting phase of the direct chill (dc) process and during casting sows. These explosions have been reported at the beginning of cast, steady state and at the end of the cast. Hand tools and tools used by vehicles have been reported to be a source of an explosion. If a tool is “wet” an explosion will result. The MMIR has reported more than 116 reported explosions from “wet tools” over the past 45 years. Tools can become wet either through exposure to moisture (e.g., stored outside, or near an open door) or when the tool comes into contact with chemical salts. All tools, no matter their size, should be preheated prior to use to prevent explosions.

Over 850 molten metal explosions were reported during the transfer phase. These explosions occurred in drain pans, troughs, crucibles, and on floors. The causes varied from wet floor/spill, wet refractory or tools, and wet/rusty drain pans. Drain pans are an overlooked area that have generated a considerable number of explosions. The MMIR lists 357 reports of explosions from drain pans over its history.

There has been one or more force 3 explosions annually in our industry over the past 22 years. The root causes for these explosions vary but many share a common characteristic of molten metal escaping from its holding spot. Molten metal flowing uncontrollably from a furnace leak, trough overflow, bleed out on a casting table, etc. is a workplaces worst nightmare. An explosion may result when molten metal comes into contact with a surface not coated with an approved safety coating.

Workplaces need to properly maintain the safety coatings that are applied on steel substrate (e.g. casting table), concrete (e.g, casting pit, adjacent maintenance pit, under furnaces, etc.), and stainless steel (e.g., casting pit and tooling). The history of our industry changed when the Aluminum Association (USA) spearheaded an industry wide effort to research molten metal explosions in 1968. It was through that initial research study and subsequent studies of specific coatings to prevent molten metal explosions in our workplaces was developed. The Aluminum Association’s “Guidelines for Handling Molten Aluminum” lists four coatings that were tested and “found to be effective in preventive molten metal January/February 2024

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Korea, February 2023

India, September 2023

water explosions where molten metal comes into contact with water with steel, concrete (or stainless steel) following bleedouts and spills during bleedouts and spills during dc casting”. These approved coatings are Wise Chem E-212-F, Wise USA, 2026

Chem E-115, Carboline Multi Gard 955CP, and Courtaulds Intertuf 132HS products.

This hopefully clarifies that other coatings currently in the marketplace, such as Chemglaze and Lord’s E212, as far as I know, have never been tested by the industry and should not be recommended to for use anywhere near molten metal in our industry. If it has been tested and approved, I welcome correcting my statement. In addition, it was noted in the Rustoleum Red coating, that it “did not prevent explosions”. The elimination of untested coatings in our industry will make casthouses safer, as well as protect workers from injuries and fatalities.

The maintenance and reapplication of the approved safety coatings is required because the coatings wear away after repeated molten metal contact. The bare substrate beneath the coating eventually becomes exposed. Scientific studies proved that the minimum bare area to generate an explosion on a steel substrate is 5 cm x 5cm, on concrete it is twice as large. Periodic maintenance of the safety coatings should be completed and recoat of the casting pits every 16-20 months, and tooling every 12-16 months.

Each and every molten metal explosion that destroys an aluminium plant may result in the injury and death of workers and nearby residents. Through the Molten Metal Incident Reporting Program past incidents can be used to prevent future recurrences when workplaces use MMIR’s annual report and inspect their plant for similar hazards. It is hoped that the current record of 23 years of catastrophic explosions will finally be broken. �

Records are made to be broken.

Historical forgetting is rarely accidental.

Aluminium International Today

08/01/2024 09:29:26

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ASI launches 1.5 degree method Aluminium Stewardship Initiative Launches 1.5 Degree Aligned Target Setting Method While COP28 concluded last month with an unprecedented decision to transition energy systems away from fossil fuels, the Aluminium Stewardship Initiative (ASI) has, for almost five years now, been committed to driving the aluminium sector to a 1.5 degree aligned future – an achievement of which is only possible through a shift in smelter energy, among other pathways, to zero emitting technologies over the next three decades.

On the back of ASI’s decision for 1.5 degree alignment, and in a move that turns ambition into (proof of) action, Version 3 of the ASI Performance Standard, published in 2022, calls for certifying ASI Entities (no matter where they sit on the aluminium value chain) to “establish a GHG Emissions Reduction Plan and ensure a GHG Emissions Reduction Pathway consistent with a 1.5 degree warming scenario, using an ASIendorsed method, when available”.

ASI has been working on developing such a method for the past two years and will publish the outcomes of this work in January 2024.

The purpose of the method is to allow articulation of quantifiable aluminiumrelated emissions reduction pathways, specific to Entities/Companies/Assets under study, against which performance can be regularly measured and disclosed.

Ultimately, if each Entity-level pathway is followed, the outcome should be that the sector’s carbon emissions budget (currently around 15 Gt CO2e) is not exceeded. With the aluminium industry currently emitting over 1 Gt CO2e every year, according to the International Aluminium Institute (IAI), this is a huge undertaking that requires action at speed January/February 2024

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ASI-endorsed Method Timeline May 2022 – ASI Publishes Version 3 of the ASI Performance Standard with a requirement for 1.5 degree GHG Emission Reduction Pathways from all Certifying Entities  2021-2023 – ASI explores opportunities to leverage existing or developing methods (e.g. SBTi, Center for Climate Aligned Finance) but none is able to meet its specific requirements  January 2023 – ASI Climate Change Working Group and Standards Committee begin work in earnest to deliver an ASI-developed method  September 2023 – ASI Standards Committee agrees to recommend the method to ASI Board  November 2023 – ASI Board endorses the recommended method  January 2024 – ASI plans to publish the method and associated calculation tool � Q1 2024 – development of training materials, to allow Entities and Auditors to prepare for implementation/audits � May 2024 – Incorporation of method into Performance Standard Guidance (all ASI Performance Standard Audits from this point must seek evidence that the method has been used by the Certifying Entity) � 2024 - Further research and development by the ASI Secretariat regarding bauxite and alumina specific methods and the impact of land use change emissions. �

and scale, even as demand for aluminium is increasing.

The Method – from Sectoral Ambition to Corporate Action A 1.5 degree sector-wide pathway to 2050 was developed by the IAI in 2021 which broadly aligned with the International Energy Agency (IEA) Net Zero Emissions Scenario, but there has been a need to develop a science-based method that defines individual aluminium company action for some time.

In particular, ASI’s Performance Standard requires a method that is consistent with the sectoral scenario, but which is also applicable to the different types of Entities it certifies all along the value chain.

Some key expectations of the ASIendorsed method are that it should: � Be applicable to all ASI certifying Entities (not just those involved in primary production) � Be science-based � Be broadly aligned with the IAI/MPP/ IEA sectoral 1.5 degree scenarios � Address all direct and indirect GHG emissions � Be simple to implement and audit against.

While the bulk of aluminium industry emissions (and emissions reduction potential) lies in decarbonisation of the primary aluminium production process, work by the IAI demonstrates that a 1.5 degree aligned aluminium sector can only be achieved through the collaborative and combined action of all players along the supply chain, through direct emissions Aluminium International Today

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DECARBONISATION 31

reduction, resource efficiency (including but not limited to increased recycling) and low-carbon procurement practices.

With its full aluminium value chain membership and certification programme, based on third-party assurance and multi-stakeholder governance structure, ASI is in a unique position to hold producers, transformers, and purchasers of aluminium (as well as generators and recyclers of scrap) to account against this required action, no matter where they sit in the sector. The GHG Emissions Pathway method developed and endorsed by ASI is thus applicable to all, it covers direct and (upstream) indirect emissions. While for primary producers, it focuses on deep process and energysystem decarbonisation, for downstream Entities (in addition to improved process efficiency) the focus is on a transition to low carbon procurement - only achievable if the primary industry decarbonises rapidly and at scale, if post-consumer scrap quantity and quality recovery improves, and ultimately if pre-consumer scrap generation is reduced.

Early decisions by ASI’s Climate Change Working Group included a commitment to use and reference, where possible, existing (1.5 degree aligned) tools, approaches and data. These include, for the whole of global economy, the IEA Net Zero Emissions Scenario; for the global aluminium sector the International Aluminium Institute (IAI) 1.5 Degree Scenario and IAI/Mission Possible Partnership (MPP) scenarios for primary aluminium (cradle to gate) and recycling (gate to gate); and frameworks including the Center for Climate Aligned Finance, RMI Horizon Zero and Science Based Targets Initiative.

The method developed follows a “Sectoral Decarbonisation Approach (SDA)”, requiring convergence on a target emissions intensity (or intensities) in 2050 by similarly scoped Entities, with differing baseline emissions (taking care that no Entities describe Pathways that increase their emissions intensity).

ASI Performance Standard v3 Criterion 5.3 The Entity shall: a.

Establish a GHG Emissions Reduction Plan and ensure a GHG Emissions Reduction Pathway consistent with a 1.5oC warming scenario, using an ASI endorsed methodology when available. b.

Ensure that the GHG Emissions Reduction Pathway includes an Intermediate Target covering a period no greater than five years, which: i. Addresses all Direct and Indirect GHG emissions. ii. Is developed using a Science-Based Approach endorsed by ASI, if available. iii. Is publicly disclosed. c.

Review the GHG Emissions Reduction Plan annually. d.

Review the GHG Emissions Pathway on any changes to the Business that alter baselines or targets. e.

Publicly disclose: i. The latest version of the GHG Emissions Reduction Pathway. ii. The latest version of the GHG Emissions Reduction Plan. iii. Progress against the GHG Emissions Reduction Plan on an annual basis.

The SDA requires: 1.

A reference sectoral slope (or slopes) that is generated from sectoral 1.5 degree emissions budget data (numerator) over the target period: 2.

Sectoral activity data –production or output tonnages (denominator).

Using these pieces of information, ASI describes specific methods applicable for primary aluminium, casthouses, semifabrication, and fabrication processes.

Through the inputs of relatively few pieces of Entity specific data for a given baseline year - for primary aluminium, Aluminium International Today

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32 DECARBONISATION

cradle to gate emissions intensity; for all other processes, purchased aluminium emissions intensity and process emissions intensity – the method describes Entityspecific emissions reduction slope(s) to 2050, against which the Entity will need to demonstrate performance as part of its ASI Audit. A companion Excel-based tool has been published by ASI to ease calculation.

Even though now endorsed and published, we can expect the method to

evolve in the coming months and years as the science and underlying emissions data matures. In 2024, for instance, the ASI Climate Change Working Group will have a particular focus on land use change related emissions, which are relatively poorly quantified for the sector, on opportunities for methods focused on mining and refining and on updates to sectoral slopes.

For now, though, the focus is on implementation of criterion 5.3 by Entities

using the new method, with all ASI Audits requiring its use from May 2024.

Not all businesses will be able to achieve the requirements. We can expect to see non-conformances by ASI Entities, even those seeking recertification. What we hope to see is demonstrated action that meets the sector’s ambition. With the publication of a method for Entitylevel Pathways, finally all actors in the aluminium value chain have a way to know what that action looks like. �

More information: Climate Change Mitigation Efforts in the Aluminium Sector: ASI’s Approach https://aluminium-stewardship.org/climate-change-mitigation-efforts-in-the-aluminium-sector-asis-approach HP_Jupp Alum Int 13/12/2023 10:43 Page 1

E: Onlinesales@eddisons.com T: +44(0)1724 334411 W: www.eddisons.com

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Aluminium International Today

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DECARBONISATION 33

Decarbonisation – using oxygen now to reduce carbon emissions

By Ian Hibbitt* Emissions from UK manufacturing account for 17% of the UK’s total GHG emissions – the third highest emitting sector. As calls to use carbon pricing as an effective climate action tool increase, large emitters are finding that their compliance costs are dramatically increasing, with no end in sight. As these financial pressures increase in both scope and amount, and while carbon neutral technologies are still being researched and developed, there are options available to industry to reduce carbon emissions from natural gas now and save on carbon pricing.

This groundswell is converging with several market factors that seem to be strengthening the business case to start the journey of reducing emissions now.

It is forecast that the long-term solution for industry will be hydrogen. Industrial decarbonisation remains a crucial piece of the puzzle in delivering net zero, and hydrogen represents the most viable solution to decarbonising many of the hard-to-abate industrial processes that are facing numerous technical and commercial barriers. Currently BOC is the preferred supplier to six projects in Phase 2 of the Government’s Industrial Fuel Switching Competition, which include facilities recycling aluminium, using our experience and technology to demonstrate that hydrogen is a viable solution for a broad range of industries.

But while these demonstrations run, and hydrogen capacity increases to meet

demand and targets, what does industry do today when faced with mounting investor and customer pressure to decarbonise, and the financial implications of emissions?

Cost effective decarbonisation with oxyfuel There are proven technologies that industry can use to reduce energy consumption and carbon emissions that are deployable now. To mitigate carbon compliance costs, the use of oxygen can be a low-risk strategy, and the recommended first step towards reducing carbon emissions.

The use of oxygen in high temperature manufacturing process increases fuel efficiency, which in turn reduces carbon emissions.

While complying with environmental standards, the use of oxygen has numerous financial benefits as well – it reduces the amount of natural gas needed, reduces carbon emissions and the associated costs thereof, and lastly it has a positive effect on furnace refractory life and furnace aging characteristics. This is because flameless oxyfuel firing reduces peak temperature hot spots, providing temperature uniformity, and so reducing furnace maintenance and improving product quality.

Flameless oxyfuel combustion is obtained by burning a fuel using pure oxygen instead of air and entraining inert flue gas into the flame creating a temperature-uniform combustion cloud

instead of a distinct flame. This approach intensifies the combustion process which reduces fuel consumption and delivers better temperature uniformity. Depending on the nature of the process, it is possible to reduce the fuel consumption between 20% and 60% compared to air-fuel firing, with a consequent and similar reduction in carbon. An additional and important feature is the reduction of NOx emissions, i.e. it results in both less CO2 and NOx. We have seen these results in steel making applications.

Other applications that burn natural gas may be candidates for a ‘blending’ approach to fuel switching where hydrogen is mixed with the natural gas before combustion. The flameless oxyfuel combustion solutions are ready for use with hydrogen as fuel, and the first fullscale installations of such technology in the steel industry are being commissioned in 2023.

Companies have different motives to decarbonise. In practice, a combination of trigger points will encourage businesses to act. Supply chain expectations, increasing carbon costs, capital market and investor requirements, volatile energy prices and the emergence of low-regrets solutions, like the use of oxygen, will nudge businesses towards action. The journey to net-zero is a long one for industry, but the use of oxygen is a viable, cost-effective first step. �

*Business Development Manager for Industrial and Decarbonisation Applications, BOC UK & Ireland Aluminium International Today

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January/February 2024

05/01/2024 12:42:23

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DECARBONISATION 35

The aluminium industry’s milestone climate initiative at COP28

By Pernelle Nunez* As the world’s political and business leaders converge in the United Arab Emirates for COP28, the need to limit climate change and accelerate action to tackle the crisis has never been greater.

The aluminium industry has a central part to play. Accounting for 2% of global anthropogenic emissions, and a critical metal in many green technologies, our industry recognises its immense responsibilities and must commit to a collective effort to reduce its emissions in line with global climate goals.

There is no better place to do this than COP28.

we must take decisive action to do our bit when it comes to generational challenges such as the climate crisis.

Recognising its leading role in bringing the global industry together, the International Aluminium Institute (IAI) has launched a milestone initiative, unveiled at COP28, to transparently track and publicly report the progress of its member companies in reducing greenhouse gas emissions.

It means our member companies will clearly state their climate change ambition and annually publish data that will allow their progress to be judged.

Leading from the front The significance of the aluminium industry in shaping modern society cannot be overstated. In many regions it is a major economic driver, it provides jobs globally and contributes to the infrastructure that forms the backbone of communities in all corners of the world.

That standing and responsibility means

Why are we doing this now?

Because COP28 presents a unique opportunity for the aluminium industry to unite and commit to sustainable development. And there is no time to waste.

The IAI’s initiative signifies a commitment by major industry players at a critical point as climate ambitions and

plans become action. Companies will have to not only state long-term greenhouse gas emission reduction targets by 2024, but also outline their long-term emissions reduction plans for action.

This commitment, accompanied by interim milestones, and annual progress reporting, is proof of the industry’s dedication to fostering transparency and being held accountable to meeting ambitious targets.

We are already making great progress.

From decarbonising electricity to reducing direct process emissions and enhancing recycling and resource efficiency, the industry is actively pursuing solutions and as a result emissions intensity is declining.

China’s shift to hydropower, innovative technologies like inert anode electrolysis, and the adoption of renewable energy around the world showcase the industry’s tangible efforts.

Our commitment to decarbonisation must not waver and we know we must do more. We must continue investing in these

*Deputy Secretary General & Director of Sustainability, International Aluminium Institute Aluminium International Today

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36 DECARBONISATION

technologies, driving innovation, and actively participating in global discussions to accelerate the transition to a greener future.

The power of collaboration To achieve these goals, collaboration is not just beneficial; it is essential. The IAI’s partnership with World Climate Foundation at COP28 underscores the importance of engaging with the investment and business community to unlock essential capital and strategic partnerships that will be key to delivering on the sector’s ambitions.

The aluminium industry recognises

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our shared responsibility to deliver a sustainable material for consumers while at the same time driving down the costs of clean technologies and processes.

This collaboration is an investment in our industry and a demonstration of our commitment to a sustainable, low-carbon future.

Against a backdrop of rising inflation, geopolitical challenges, and an energy security crisis, our collective resolve must remain steadfast. Strengthening

partnerships with policymakers, governments, the finance sector, investors, and fellow industries is paramount to delivering meaningful solutions.

Failure to seize this opportunity at COP28 would send a message that we are not serious about addressing the climate emergency. The time for action is now, and our industry stands ready to ensure a greener and more resilient tomorrow, and a stronger, more sustainable aluminium industry for all stakeholders. �

E: Onlinesales@eddisons.com T: +44(0)1724 334411 W: www.eddisons.com

Instructed by Gränges Aluminium, Sweden

Fata Hunter 1700mm Doubling Aluminium Foil Mill For Immediate Sale - MAJOR PRICE REDUCTION - OFFERS INVITED AROUND €550,000 Dismantled by the owners and requiring new main motor & gearbox, and coiler motors and gearboxes.

- Roll sizes W/R and BU/R – 760/305mm - Max coil diameter – 1850mm - Rolling load 5000 kN - Max coil weight – 12,000kg - Mill speed (max) 1200 - Major mechanical upgrade in 2006 - Strip thickness: - Automation – ABB/VAI o Max entry Single – 700microns - Flatness control – shape meter o Max entry Double – 2 x 80microns - Work rolls included – 28 o Min exit Single – 14microns - Back-up rolls included – 9 o Min exit Double – 2 x 14 microns This mill was purchased, dismantled and transported to Finspång by Gränges from Skultuna and was earmarked for a specific project. The main motor and gearbox and coiler motors and gearboxes were scrapped as the intention was to replace them with new. Subsequently there was a change of policy at Gränges and the project was abandoned and the mill is now available for sale.

Location: Gränges Finspång AB, Finspång, Sweden Further information: Contact Charles Moses on +44 (0) 7831 854971 or email charles.moses@eddisons.com

Catalogues, bidding and FAQs are available through our website January/February 2024

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38 RECYCLING

Creating a sustainable future is more important than ever before and it is crucial that individuals are empowered and encouraged to take everyday steps to reduce their negative impact on the planet.

ECC Soapbox at F1 British GP, Silverstone

The infinity room

2023 in review: Every can counts reflects on its UK highlights Every Can Counts (ECC), a not-forprofit communications programme, has activated a collection of exhibits and partnerships with well-known brands in the UK throughout 2023 to bring the topic of aluminium can recycling to the forefront of people’s minds.

From an immersive ‘Infinity Room’ made of over 1,500 recycled cans, to a giant rainbow can installation and appearances at some of the country’s biggest festivals, ECC has used a variety of creative methods to engage the public and work towards its overall goal of achieving a 100% recycling rate for drink cans.

To infinity and beyond To kickstart 2023, ECC launched its ‘Infinity Room’, an immersive installation, at Dundee Science Centre.

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made of 1,500 smaller cans and 25 square meters of mirrors, giving those who step inside the illusion of being surrounded by a never-ending number of aluminium cans, helping people to visualise the capacity of cans to be recycled time and time again.

As visitors step into the exhibit, a narrator takes them on an educational journey through aluminium can recycling and its environmental benefits.

A Cans4City milestone Moving onto February, ECC celebrated a major milestone with Exeter City Football Club and Exeter City Council as their recycling programme, Cans4City, raised more than £10,000.

Cans4City is a scheme which encourages Exeter football fans to recycle used drink cans, with the funds raised from the cans then put towards projects and initiatives

run by the football club and its charity partner, Exeter City Community Trust (ECCT).

As part of this initiative, the Cans4City team successfully collected 12.5 tonnes of aluminium packaging, equating to 700,000 cans in volume, and were awarded the Green Can Award by ECC last year for their recycling efforts.

The rainbow over York Marking Global Recycling Day (Saturday 18th March), ECC arrived in York with a giant rainbow installation comprised of over 2,500 recycled cans. The sevenmetre-wide archway stood in front of York Art Gallery, accompanied by signage highlighting the importance of ensuring empty cans end up in the right bin.

After conducting a survey of York residents, ECC found that nine in 10 felt Aluminium International Today

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RECYCLING 39

by ECC in 2014, 28 schools, community groups, and other organisations have been commended.

World Environment Day and the International Recycling Tour To celebrate World Environment Day (Monday 5th June), ECC delivered the third edition of its annual International Recycling Tour, a coordinated event spanning across 16 different countries in 2023, including Austria, Belgium and Brazil.

In the UK, ECC unveiled a natureinspired PixelCan wall of art made of 2,000 recycled drink cans at Mighty Hoopla Festival in Brockwell Park. Meanwhile, in Dublin, ECC collaborated with Dún Laoghaire-Rathdown County Council to create a PixelCan design inspired by local marine life.

The International Recycling Tour is an annual ECC event, launched to commemorate World Environment Day and champion the cause of sustainable living whilst encouraging people to keep outdoor public spaces clean and recycle their empty drink cans no matter where they are.

ECC Ambassador at Mighty Hoopla

The rainbow over York

ECC Team with PixelCan at Mighty Hoopla

they had a good understanding of the benefits of recycling, but many had a desire for clearer signage on recycling bins (41%) and more recyclable packaging (40%).

Covent Garden CANvas For Earth Day (Saturday 22nd April), ECC worked with Covent Garden and renowned street artist, Jimmy C, to design a bespoke CANvas installation made of over 700 reused drink cans.

Jimmy C drew in the crowds as he painted the wall of cans live in Covent Garden’s North Piazza, creating an Earththemed artwork that inspired passers-by to do their bit for the planet.

The artist then returned the following week to paint a new wall of recycled cans with a crown design, ahead of the coronation of King Charles III. This piece Aluminium International Today

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remained in Covent Garden for five weeks, proving to be a popular photo opportunity for visitors to the area.

The Green Can Awards 2023 In the spring, ECC announced the 2023 winners of its national recycling award scheme, the Green Can Awards.

Bodega 51 Bar and Haileybury School were both recognised for their sustainability efforts and ongoing commitment to recycling.

Students at Haileybury School were also rewarded with a workshop led by social enterprise Casting Innovations, during which they learned about the infinite recyclability of aluminium, as well as the melting process, and were able to make their own keyring from recycled aluminium.

Since the awards scheme was launched

Festival season This summer saw ECC attend 12 major events across the UK, from Download Festival in Donington Park to the Formula 1 British Grand Prix.

These events combined immersive installations, games, and activities to engage and educate attendees. The renovated Every Can Counts Soapbox, which participated in last year’s Red Bull Soapbox Race in London, proved to be a particular highlight at Download Festival, turning heads as it roamed the site powered by its new electric motor.

ECC also teamed up with several of its drink brand partners, including Pernod Ricard UK, Red Bull, Most Wanted Wines, White Claw Hard Seltzer, and Canned Wine Co, to help get their customers engaged and recycling at their events by providing recycling backpacks, cages, and bins.

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40 RECYCLING

Chris Latham-Warde, programme manager at Every Can Counts, said: “This year has been particularly rewarding for us with a busy schedule of events, and we’ve been able to spread the positive impact recycling has further than ever in a variety of fun and innovative ways.

“Despite the unreliable British weather, festival season this summer was a personal highlight for me, as it was great to see so many festival goers engaging with our brilliant team on recycling and the environment.

“On top of this, more than 64,000 cans were collected by our team to be recycled, filled, and placed back on shop shelves.

The cycle is never-ending and together, we can create greener festival and event environments as we continue to strive towards our aim of achieving a 100% drink can recycling rate.”

The Infinity Room tour continues After starting the year at Dundee Science Centre, ECC’s ‘Infinity Room’ exhibit visited two more UK locations to help educate young people on the importance of recycling.

The installation was displayed at Catalyst Science Discovery Centre in Widnes for the

Jimmy C with #EarthDay PixelCan in Covent Garden

duration of the summer, before launching at W5 Interactive Discovery Centre in Belfast in October, during national Recycle Week.

The exhibit arrived at W5 after ECC research found that 44% of Belfast residents felt more could be done to educate young people about the importance of recycling, and only a third (31%) would take packaging home to recycle if they couldn’t find a recycling bin.

Looking ahead to 2024 With the New Year just around the corner, ECC has a number of events, installations,

and partnerships currently being explored.

Chris Latham-Warde said: “2023 will be a tough year to beat, but we’re determined to continue spreading awareness around the importance of recycling with a busy schedule of exciting activity and major partnerships in 2024.

“In the next few months, we look forward to celebrating another Global Recycling Day and working with councils and organisations across the UK to make a positive impact.” � *https://www.gov.uk/guidance/climate-changeexplained#

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January/February 2024

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@Furnaces_Int

16/01/2023 10:36

05/01/2024 15:26:58

FURNACE TECHNOLOGY 41

The Rock and Roll of continuous furnace aluminium log homogenisation monitoring

By Dr Steve Offley*

The homogenisation heat treatment process After casting, aluminium logs/billets undergo a homogenising heat treatment process to ensure uniform distribution of the alloying elements, such as Zn, Cu, or Mg2Si and Fe, within the structure of the log. This involves heating the log at a controlled rate, soaking at temperature (typically 480 °C to 540 °C / 896 °F to 1004 °F ) for a specific period of time, and cooling at a specific rate to allow the precipitating elements to become more evenly distributed throughout the material.

Each phase of the heat treatment process is temperature critical. An accurate means of monitoring the log internal temperature throughout the whole furnace cycle is, therefore, important to the success of the homogenisation process, material properties, and efficiency of the furnace heat treat operation.

Log Temperature Measurement Challenge When setting furnace conditions for

new production batches, monitoring the actual product temperature of the logs throughout the furnace is vital to maximise production throughput, while ensuring the correct metallurgical structure of the product.

Measurement of the product temperature is generally not considered a problem when the operation is conducted in a batch furnace. In such case, thermocouples can be run from the static logs, loaded in the furnace, to an external data logger without significant issues.

However, when homogenising is conducted in a continuous process, such as a walking beam furnace, monitoring the product temperature from a data logger external to the furnace is not possible because the logs generally travel in different directions as they enter, move through the hot zone, and exit the furnace.

Also, the logs can slowly rotate due to the action of the walking beam. These factors make external monitoring with long trailing thermocouples impractical, and even if possible, would not comply with

every increasing safety requirement for technical plant operatives.

The solution is to use a ‘thru-process’ temperature monitoring system where a thermal barrier can be attached to the log protecting a data logger as it gathers temperature data from thermocouples set within the test product. In this way the product temperature profile can be accurately monitored as the test product travels through the process. Short thermocouples are safely contained within the thermal barrier, before running along pre-cut routing channels within the log, eliminating the risk of tangling or being caught during the log movement through the furnace (Fig 3).

The innovative cylindrical thermal barrier design is critical to the success of the temperature monitoring system. The diameter and length of the thermal barrier matches a machined gap at the end of the aluminium log so that loading the log, with the monitoring system attached, can be achieved as if a standard log. No height restriction challenges are faced

*Product Marketing Manager Phoenix Temperature Measurement www.phoenixtm.com Aluminium International Today

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January/February 2024

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42 FURNACE TECHNOLOGY

1.1

1.2

Fig 1. PhoenixTM TS57 Rotating Evaporative Water Barrier solution.

1.1 Cylindrical thermal barrier fixed to aluminium log being monitored.

1.2 Schematic showing the PTM1210 datalogger located in cylindrical water tank that rotates with the aluminium log during transfer through walking beam furnace.

within the boundaries of the product (Fig 3).

When this is complete the thermocouples are positioned, the data logger reset and placed in the thermal barrier fixed to the test log, and the trial is ready to run.

Fig 2. PhoenixTM TS57 Rotating Evaporative Water Barrier Solution Set-Up

and most importantly being cylindrical the system can rotate safely with the log as it is transferred through the walking beam furnace.

The ‘thru-process’ Monitoring System Design Solution The PhoenixTM ‘thru-process’ monitoring system to accommodate the size restrictions of the homogenising processes and its long duration (up to 10 hrs) / high temperature (600 °C/1112 °F), employs a phased evaporation method of thermal protection. The data logger is encased in thermally insulated cylindrical water tank employing evaporating water as a phase change medium. As the water reaches its boiling point it changes from liquid to gas (steam) as it evaporates, but maintains the operating temperature of the logger at a safe 100 °C/212 °F, so prolongs the period it can remain in the furnace. The thermal protection provided by the thermal barrier can be controlled by selecting the volume of the water tank and so water capacity (Litres).

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The innovative barrier design must allow the steam to evaporate whilst not losing any water as the barrier rotates. For this type of system, it is also necessary for the data logger to be able to operate at 100°C as it is surrounded by boiling water (Fig 1). PhoenixTM TS57 Rotating Evaporative Water Barrier) Having established the diameter range of the logs and the process parameters, the size of the system (length and diameter) can be calculated and a piece of the log equal to the length of the thermal barrier can be cut off and discarded. The end of the log is then machined to allow the thermal barrier to be secured directly with steel bolts. Alternatively, a custom mounting plate can be bolted to the end of the cut log to which the barrier can be efficiently fixed and removed from test to test (Fig 2). A slot is machined longitudinally along the log to guide the thermocouples to holes drilled at right angles to the correct measuring depth.

This ensures that both the thermocouples and the ‘thru-process’ system are kept

Winning Solution providing Accurate Process Validation Requiring a solution to allow process monitoring of their walking beam aluminium log homogenisation furnace Service Center Metals (SCM) located in Prince George, VA, USA approached PhoenixTM. The resulting ‘thru-process’ temperature monitoring system provided to SCM is shown in Fig 2.

Fitted with a RF telemetry module the data logger allowed live ‘Real Time’ product temperature to be monitored through the whole furnace. With such information, SCM were able to validate mathematical models used to control the furnace and so optimise the efficiency of the entire homogenisation process.

Mr Calvin Wiggins, Quality Director at SCM, is quoted as saying “The ease of use of the PhoenixTM system allows us to do more surveys per year than compared to feeding thermocouple wires attached to a rigid log. However, its single best-selling point is improved safety by keeping tech’s away from the furnace entry door, where they would otherwise be feeding TC wires to the survey log as it advances through the furnace.”

System used to successfully monitor, in real time, the Homogenisation of cast aluminium logs in Service Center Metals (SCM) walking beam furnaces. Rotating cylindrical water barrier attached to a 356 mm/ 14” log with thermocouples positioned along its length at varying depths.

Installation of thermocouples on the aluminium log to allow of monitoring Aluminium International Today

05/01/2024 12:50:22

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44 FURNACE TECHNOLOGY

core temperatures in a machined channel along the length of the test piece. The thermocouple measuring tip (Hot junction) is inserted into aluminium bushes, located into drilled pilot holes, to required core depth in the log.

PhoenixTM Service with Style!

Recently a TS57 system was successfully commissioned at the Finnish aluminium

profile manufacturer Mäkelä Alu Oy who have been in business for over 80 years (https://makelaalu.fi/en/). The PhoenixTM system was ordered to help Mäkelä Alu Oy with the recycling of production scrap into low-emission aluminium billets.

PhoenixTM prides itself with not only providing monitoring technology but ensuring that it is fit for purpose and working to specification on site. Living

Fig 3.

Thermocouple Installation

up to the company tag line “where experience counts!” Managing Director Michael Taake took on the challenge of commissioning the system with the help of Scandinavian partner CalorMet .

Traveling from the PhoenixTM office in Bad Oeynhausen in Germany you would have thought the obvious transport choice would have been by plane.

Micheal decided otherwise as he says “Why should I sit on a cramped plane and sleep in overcrowded hotels when I can explore and enjoy the beautiful nature of Scandinavia by motorbike?”. It took him around 2,000 km along the coast of Sweden and the forests of Finland to Mäkelä Alu Oy. Michael Taake on site at Mäkelä Alu Oy Finland to commission the PhoenixTM TS57 system after his 2000 km / 1250 miles motor bike road trip from the PhoenixTM office in Germany.

On site, Michael, together with CalorMet conducted a comprehensive briefing on the PhoenixTM temperature measurement system, and witnessed the system being used for the first thruprocess temperature profile.

“It is fascinating that Mäkelä is always familiar with the latest technologies, implements improvements precisely and carries out their work in a sustainable and environmentally conscious way,” says Michael Taake.

Monitoring Power By employing the ‘thru-process’ temperature monitoring solution from PhoenixTM, major key casting plants have been able to measure the temperature profile of their aluminium log in all three stages of the homogenisation process.

With such critical information it has been possible to minimise time in the soak zone to increase productivity and optimize fuel efficiency without compromising product quality. �

Fig 4. Commissioning Style

Fig 5. PhoenixTM TS57 Rotating Evaporative Water Barrier Thru-process Monitoring System Set-up at Mäkelä Alu Oy 5.1 PhoenixTM PTM1206 six channel high temperature data logger installed in TS57 cylindrical barrier 5.2 TS57 cylindrical thermal barrier fixed to test log in situ within the homogenisation heat treat process

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Aluminium International Today

05/01/2024 12:51:49

Every step matters on the path to zero To continue developing modern society, we need more materials, and we need more from our materials, too. What we produce and consume must not only meet the ­surging demand, but also embody the principles of responsible sourcing, environmental ­consciousness, and recyclability.

Aluminium, with its infinite recyclability and corrosion-resistant longevity, is already a building block for a low-carbon, circular economy, but production comes with a ­footprint.

Our recycled and low-carbon aluminium products are one step closer to ­solving that ­problem, and one step closer on the path to zero.

Choose your materials with the future in mind. Visit hydro.com/path-to-zero to learn more.