A two-year internal testing program has successfully verified Hydro’s new primary aluminium production technology, HAL4e. The industrial-scale pilot plant is operating at around 15 percent lower energy consumption than the world average. The final performance test done at Hydro’s Technology Pilot in Karmoy in Norway has shown positive results. Aluminium is being produced with around 15 percent lower energy consumption than the world average.
In January 2018, aluminium production started at Hydro’s Technology Pilot at Karmoy in Norway. The ambition was an industrial full-scale verification of Hydro’s newest aluminium production technology that has around 15 percent lower energy consumption per kilo aluminium produced than the world average. The final performance test proved successful results.
The goal has been to produce aluminium with an energy consumption at 12.3 kWh/kg, around 15 percent below the world average, and furthermore, to bring the direct CO2 emissions from the electrolysis process well below Hydro’s low-carbon aluminium average of 1.67 kg CO2/kg Al.
The full-scale NOK 4.6 billion pilot plant consists of 60 electrolysis cells using Hydro-developed HAL4e technology; 12 of the cells in the pilot plant, called HAL4e Ultra, have demonstrated energy consumption potential down to 11.8 kWh/kg.
Twenty of the 60 HAL4e pots were selected for the final performance test, which was conducted for 75 days between October and December. During the test period, a range of additional measurements were performed on a number of parameters and exact production figures were traced and recorded. The energy results came in at 12.27 kWh/kg Al, below the set target of 12.3 kWh/kg Al.
Production at the Technology Pilot started in January 2018 and the annual capacity is around 75 000 tonnes primary aluminium per year
The performance test furthermore demonstrated a record low level of direct