Aluminium International Today March April 2024

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T H E J O U R N A L O F A L U M I N I U M P R O D U C T I O N A N D P R O C E S S I N G
THE DIGITAL MINE
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CONTENTS 1www.aluminiumtoday.com
 Aluminium International Today March/April 2024
 2 LEADER
 2 NEWS
 Volume 37 No. 2 – March/April 2024
COVER
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31 42
19
TECHNOLOGY
 19 Navigating the future of metalworking
 in 2024
THE ALUMINA CHRONICLES
 9 Aluminium industry in Indonesia
EUROPEAN UPDATE
16 European Aluminium calls for a real 
 “industry decarbonisation deal”
INTERVIEW
6 Women With Metal
DIGITAL TRANSFORMATION
23 Shaping the future: digital transformation in 
 the aluminium industry
TMS PREVIEW
25 Grain refi ner specialist to deliver results 
 from canlid stock trials
DECARBONISATION
27 Examining the latest technologies 
 decarbonising the aluminium sector
HYDROGEN
31 Hydrogen in the aluminium industry
PACKAGING
42 What the packaging recycling industry wants 
 to see in 2024
THE DIGITAL MINE
45 Ma’aden and Hexagon partner to launch 
 region’s fi rst digital mine
CASTHOUSE
47 Rail mounted charging machines for melting 
 furnace applications
Contents 2024.indd 1Contents 2024.indd 1 26/02/2024 15:33:2126/02/2024 15:33:21
COMMENT2
Welcome to the latest edition of 
Aluminium International Today 
magazine. As always, we strive 
to bring you detailed articles, in-
terviews, and updates that pro-
vide valuable insights into the 
ever-evolving landscape of the 
aluminium sector.
The year already feels like it is 
flying! I was asked by a colleague 
recently what I am planning to 
do on my ‘Bonus Day’ this year. 
It took me a second to figure out 
that they were referring to the ex-
tra day in February that we will be 
gifted and I realised it was exactly 
that, the gift of more time.
So, rather than saving this col-
umn to write then and use my 
day to do all the jobs I’ve been 
putting off, I’m going to plan to 
use it as productively as possible, 
while also taking some time to 
enjoy the extra hours and I en-
courage you to do the same!
One person who is a shining 
example of using every minute 
of the day to the max, is Kirsty 
Davies-Chinnock, founder of 
Women With Metal. I had the 
pleasure of speaking to her for 
this issue and found out what 
drives her passion for the project 
and ideas for growth and going 
global!
Additionally, we turn our focus 
to Indonesia, a key player in the 
global aluminium market. Our 
in-depth feature from regular 
columnist Richard McDonough, 
explores the latest developments 
and challenges in aluminium 
production in Indonesia, offering 
readers a comprehensive under-
standing of this dynamic sector.
And don’t miss Assistant Edi-
tor, Zahra Awan’s exclusive article 
on the use of hydrogen in alumin-
ium production. As the industry 
continues to explore sustainable 
alternatives, is hydrogen a prom-
ising solution...?
nadinebloxsome@quartzltd.com
March/April 2024
TOP STORIES
The new recycling plant will pro-
duce 120,000 metric tonnes of 
low-carbon recycled aluminium 
per year and create approximately 
70 new jobs in Torija. The products 
will be aluminium extrusion ingots 
for key European industries such 
as transport & automotive, build-
ing & construction, renewable en-
ergy installations, and consumer 
durable markets.
“Worldwide demandand
most complex alloys: 4.5 tph to 8 tph
CCR Aluminium Rod Lines with large
and extra-large production output for
E.C. grade and most common alloys:
8 tph to 15 tph, reaching a yearly
output of up to 100,000 tons
CAN THE
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YES, TO
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TECHNOLOGY 19
Aluminium International Today March/April 2024
Navigating the future 
of metalworking in 2024
*General Manager of CNC automation system manufacturer, Tezmaksan Robot Technologies
Manufacturers turn to digitalised CNC machining 
and interconnected smart factories
The rise of smart factories, digitalised CNC machining and the industrial metaverse are set to 
reshape the manufacturing landscape in 2024. Here, Hakan Aydogdu* looks at the key trends in 
manufacturing and explores why manufactures should embrace transformative technologies with user-
friendly interface and adaptability to keep up with the evolving needs of the metalworking industry –
while staying competitive.
 “As of July 2023,” according to Deloitte’s 
latest report on the US manufacturing 
industry, “annual construction spending 
in manufacturing stands at $201 billion, 
representing a 70 per cent year-over-
year increase and setting the stage for 
further industry growth in 2024.” The 
continued growth of the metalworking 
industry is driven by several factors. One 
is rising demand for lightweight, strong 
and durable materials like aluminum or 
titanium, particularly in the aerospace 
and automotive industries where these 
materials support energy efficiency. 
Manufacturers will also seek to invest more 
in electrification and decarbonisation, in 
general.
Another driving factor is new 
technological advancements as, according 
to Aptean’s Discrete and Process 
Manufacturing: 2024 Trends and Outlook 
for North America report, manufacturers 
“focus on innovation/R&D, product 
development” to diversify into new 
markets and “acquire new customers.” 
But what are the core technologies that 
will underpin the continued growth of the 
metal fabrication industry in the new year? 
Let’s look at some examples of systems 
and processes that manufacturers should 
embrace to stay competitive.
Artificial intelligence (AI) and 
Machine Learning (ML) 
In 2024, the metalworking and machine 
shop landscape will witness a profound 
shift, with Artificial Intelligence (AI) and 
Machine Learning (ML) emerging as critical 
trends. AI-driven product design tools 
are becoming integral to the industry, 
as they facilitate the creation of intricate 
and precise components. Meanwhile, ML 
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making in the real world.
In 2024, manufacturers are set to take 
the digital twins concept to another level. 
This will combine the 3D modelling, 3D 
scanning and immersive environments 
with the data analytics, cloud computing 
and IoT technologies of smart factories 
to create larger metaverses, that replicate 
real machines and factories, buildings and 
cities, grids, transportation systems and 
more in a virtual world. By establishing 
model-based enterprises, manufacturers 
can foster global connectivity and 
collaboration with internal and external 
stakeholders.
Forbes predicts that industrial 
metaverses will foster more immersive and 
collaborative working processes. While, 
in the 2023 Deloitte and MLC industrial 
metaverse study, an overwhelming 92 
per cent of manufacturers are actively 
experimenting with metaverse initiatives, 
projecting a substantial increase in sales, 
quality, throughput, labour productivity 
and more.
Interconnected technologies
Digitalised CNC machining is another 
anticipated trend for 2024, as 
machines become more automated 
and interconnected in order to 
increase efficiency and productivity in 
metalworking processes. To facilitate this, 
IoT sensors and devices and data analysis 
will become more integrated into control 
systems. 
Elsewhere, the July 2023 AI Pulse Survey 
by Forrester found that manufacturers are 
growing more intrigued by the potential 
of AI tools, such as ChatGPT, to generate 
code for CNC machines. 67 per cent 
of enterprises researched by Forrester 
indicated they are bringing generative 
AI into their overall AI strategy. 
Although 29 per cent described their 
company’s use of generative AI as 
“experimentation” – which suggests 
many enterprises are proceeding 
with caution for now.
Nevertheless, the survey suggests 
manufacturers’ minds are turning 
more towards the possibilities of more 
integrated machinery on the shop floor. 
A further example of this is the CubeBOX 
system, a compact robot cell designed 
to operate up to three CNC machines 
continuously, addressing the industry’s 
demand for increased efficiency and 
productivity. The system operates without 
downtime during loading and unloading, 
providing a seamless and uninterrupted 
24-hour production cycle.
One of CubeBOX’s key advantages is 
its user-friendly software, ROBOCAM, 
which eliminates the need for robot 
programming and CAM knowledge. This 
aligns with the industry’s call for simplified 
processes and enhanced automation. 
The software converts 2D CAD drawings 
of workpieces to CAM, streamlining 
the integration process and allowing 
operators to focus solely on loading and 
unloading the workstation.
Moreover, CubeBOX’s lean and flexible 
design, coupled with the ability to handle 
various models and adapt to different CNC 
machines, addresses the industry’s need 
for versatility. The system’s compatibility 
with all CNC machines and control units, 
as well as its adaptability to different 
robot brands, positions it as a versatile 
and adaptable solution for manufacturers 
with diverse Industry 4.0 needs.
In the context of the challenges 
outlined for 2024, CubeBOX excels in 
reducing operator intervention and 
improving night shift efficiency. The 
system’s capacity to run continuously for 
24 hours enhances overall production 
output, aligning with the industry’s goals 
of reducing lead times and optimising 
efficiency. By automating the loading and 
unloading processes, CubeBOX minimises 
downtime, contributes to predictive 
maintenance and digitalised CNC 
machining, integrating seamlessly with 
the vision of interconnected technologies 
in smart factories.
In conclusion, manufacturers must stay 
on top of current technological trends 
to address the challenges faced by the 
metalworking industry in 2024. Ideas 
once confined to the pages of science-
fiction, like AI and the metaverse, must 
be embraced with an open mind, and 
combined with practical Industry 4.0 
approaches to interconnecting machines 
on the shop floor. Such strategies will 
be essential if manufacturers are to stay 
competitive in 2024’s rapidly evolving 
industrial landscape.
If you are interested in improving your 
manufacturing efficiency and would like 
to learn more about CubeBOX automation 
systems, visit the Tezmaksan website. �
For further information please visit 
www.tezmaksan.com 
Aluminium International Today 
TECHNOLOGY20
algorithms are adept at analysing vast 
datasets, enabling data-driven decision-
making that enhances overall productivity. 
Both technologies enhance efficiency and 
competitiveness within the industry. 
Analysis by Deloitte reveals that 86 per 
cent of manufacturing executives believe 
smart factories will be primary drivers of 
competitiveness in the next five years. 
As soon as 2024, smart factories are 
poised to be pivotal in the metalworking 
and machine shop sector, integrating 
advanced interconnected technologies 
such as AI, 5G, Internet of Things (IoT), 
data analytics and cloud computing. 
As these machines become more 
interconnected and automated, so too 
will digitalised CNC machines, leading to 
increased efficiency and productivity.
For instance, predictive maintenance 
within smart factories utilises AI 
algorithms to forecast equipment 
malfunctions, minimising downtime 
and optimising machineperformance. 
The implementation of 5G ensures 
seamless communication between 
devices, facilitating quicker decision-
making and response times. IoT sensors 
collect and transmit real-time data, 
allowing manufacturers to monitor and 
optimise production processes remotely. 
Furthermore, cloud computing enables 
the storage and analysis of vast datasets, 
fostering data-driven decision-making for 
improved productivity. 
Digital twins 
The idea of the metaverse once belonged 
only in science fiction, a concept of 
the Internet as a single, universal and 
immersive virtual world accessed through 
virtual reality (VR) and augmented reality 
(AR) headsets. This has been changing 
in recent years, as digital twins — 
where real-world objects or systems are 
replicated digitally and virtually — allow 
manufacturers to create immersive 3D 
environments and simulate equipment, 
processes and other assets to support 
better safer and more profitable decision 
CNC.indd 2CNC.indd 2 26/02/2024 11:35:2426/02/2024 11:35:24
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DIGITAL TRANSFORMATION AND CYBER RESILIENCE 23
Aluminium International Today March/April 2024
Shaping the future: Digital 
transformation in the aluminium industry
*Aston Business School, Aston University, Birmingham, UK. 
By Professor Alexeis Garcia Perez*
Introduction
The aluminium industry, a vital 
cornerstone of the global economy, is 
on the brink of a transformative era. 
Traditionally characterised by physical 
labour and mechanical processes, it is 
now rapidly embracing the digital age. 
This shift, driven by the need for greater 
efficiency, innovation and sustainability, 
is reshaping the industry’s landscape. 
For decision-makers, particularly in the 
European Union, where environmental 
and technological leadership is a priority, 
understanding and harnessing this digital 
transformation is crucial. This article 
examines the historical evolution of the 
industry, explores the core aspects of its 
digital transformation, and discusses the 
opportunities and challenges it presents, 
along with a glimpse into the future.
Historical context
The journey of the aluminium industry 
has been marked by constant evolution 
and adaptation. From its early days, 
when aluminium was a precious metal, 
more valuable than gold, the industry has 
grown exponentially, especially after the 
introduction of the Hall-Héroult process 
in the late 1880s. This process made 
mass production of aluminium feasible, 
drastically reducing its cost and laying the 
foundation for its widespread application. 
Throughout the 20th century, the industry 
continued to expand, but it was primarily 
reliant on manual labour and simple 
mechanisation of processes. 
The advent of the digital age towards 
the end of the century marked the 
beginning of a significant shift. Early 
adoption of computerised systems 
brought improvements in process control 
and operational efficiency, albeit modestly. 
These were the initial steps towards a more 
connected and data-driven manufacturing 
environment for the aluminium sector.
Core aspects of the digital 
transformation of the aluminium 
sector
As in most sectors, the digital 
transformation in the aluminium 
industry is a comprehensive and 
multifaceted process. The incorporation 
of automation and robotics has been a 
game changer. These technologies have 
not only streamlined operations but also 
significantly improved employee safety by 
taking over high-risk tasks. Automated 
systems handle repetitive, high-precision 
tasks with remarkable consistency, 
reducing human error and increasing 
overall productivity.
Simultaneously, the industry is 
witnessing a surge in the use of data 
analytics and artificial intelligence (AI). 
These technologies are leveraged to 
predict equipment failures, optimise 
production processes and enhance quality 
control. AI algorithms assist in identifying 
patterns and insights that were previously 
inaccessible, enabling smarter decision-
making and more responsive production 
strategies.
Another critical aspect of this 
transformation is the digitalisation of 
the supply chain. By integrating digital 
solutions, companies can better track and 
manage resources, forecast demand and 
streamline logistics. This not only ensures 
a more efficient supply chain but also 
reduces waste and enhances sustainability.
Digital twin technology, which involves 
creating virtual replicas of physical 
systems or processes, is becoming 
increasingly popular. It is used to model 
and simulate manufacturing processes, 
allowing for optimisation and testing 
without interrupting actual production. 
This technology enables manufacturers 
to experiment with different scenarios, 
foresee potential issues and make 
proactive adjustments.
Furthermore, the Internet of Things 
(IoT) has transformed manufacturing 
facilities into smart factories. In these 
interconnected environments, machinery 
and equipment continuously exchange 
data, enabling real-time monitoring and 
adjustment of manufacturing processes. 
This connectivity ensures a more agile and 
responsive manufacturing system, capable 
of adapting to changing conditions and 
demands.
Digital transformation: opportunities 
and challenges for the sector
The digital transformation journey offers 
numerous opportunities for the aluminium 
industry, especially within the European 
Union. It enhances operational efficiency 
and competitiveness, aligning with the 
EU’s commitment to environmental 
sustainability. Technologies that optimise 
energy use and reduce waste contribute to 
the efforts of the industry to meet stringent 
and continuously evolving environmental 
regulations and carbon emission targets. 
Digital transformation also fosters 
innovation and market expansion, as 
advanced data analytics and digital twin 
technologies allow for the development 
of higher-quality products, tailored to 
specific market needs. Furthermore, it 
enhances supply chain resilience, crucial 
in a region where supply chain disruptions 
can have significant impacts.
Alexei cyber security.indd 1Alexei cyber security.indd 1 26/02/2024 11:36:2426/02/2024 11:36:24
Aluminium International Today March/April 2024
DIGITAL TRANSFORMATION AND CYBER RESILIENCE24
However, this transformation is not 
without its challenges. The high initial 
costs of digital transformation, including 
investments in new technologies, training 
and potential restructuring, can be a 
significant barrier, especially for small and 
medium-sized enterprises. 
Cybersecurity is another critical 
concern. As operations become more 
digitalised, protecting sensitive data 
and production processes from cyber 
threats is paramount. The shift towards 
a more digitalised industry also requires 
a workforce that is skilled in these new 
technologies. Managing the transition 
for existing employees and bridging 
the skill gap is a challenge that requires 
thoughtful strategies and investment 
in training. Additionally, navigating the 
complex regulatory environment of the 
EU, especially concerning data protection 
and digital operations, can be challenging 
for companies.
Future Trends 
Looking ahead, the aluminium industry 
is likely to witness increased adoption of 
AI and machine learning, driving further 
improvements in efficiency and innovation. 
Blockchain technology is anticipated to 
enhance traceability and transparency in 
the supply chain. The expansion of 3D 
printing technology will revolutionise the 
design and manufacturing of complex 
aluminium components. The industry 
is also expected to integrate circular 
economy principles more fully, embracing 
sustainable business models. The concept 
of smart factories will evolve further 
with IoT technology becoming more 
advanced.Regulatory changes related 
to environmental protection, digital 
operations and data security will continue 
to influence industry practices, and 
collaboration between industry players, 
technology providers and academic 
institutions is expected to increase, 
fostering innovation and sustainable 
practices.
Conclusion
The future of the aluminium industry 
is closely tied to digital innovation and 
sustainability. For EU decision-makers, 
embracing these changes is imperative for 
maintaining relevance and leadership in 
the industrial world. The journey of digital 
transformation is ongoing. The ability 
of the aluminium industry to integrate 
digital advancements will be crucial in 
maintaining its relevance and leadership 
in the industrial world. The decisions 
made today by industry leaders will set 
the course for a more efficient, innovative 
and sustainable aluminium industry in the 
future. �
About the author:
Professor Alexeis Garcia Perez is an expert in Digital Business and Society at Aston Business School, UK. Alexeis has collaborated 
with ALFED over the last decade to raise awareness of the challenges related to the cyber readiness of the sector. With a rich 
career spanning academia and industry, Alexeis’s expertise in digital transformation, cyber security management and digital 
resilience enables him to guide both established enterprises and startups towards digital readiness. Connect with Alexeis to 
navigate the complexities of digital innovation and secure your company’s future in the digital age.
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TMS PREVIEW 25
Aluminium International Today March/April 2024
Grain refiner specialist to deliver
results from canlid stock trials 
The founder of MQP is set to deliver a key 
technical paper on how high efficiency 
grain refiner is helping canlid stock 
producers improve their operations at 
TMS 2024.
Chairman John Courtenay said the 
company, which continues to build on its 
portfolio of high efficiency Optifine grain 
refiners and casthouse solutions, had 
been working producers worldwide to 
optimise the quality of the end products 
and reduce costs.
At his presentation at the Hyatt Regency 
Orlando on Monday 4th March, John 
will be focusing on results from trials at 
Henan Zhongfu Industrial Co Ltd - a major 
aluminium producer making more than 
600,000 tonnes of canbody, canlid and 
foil stock annually.
John, who worked on the paper with 
Lei Shi, technical director at Henan, 
and Weitao Zhao, technical director at 
MQP’s parent company STNM, said: “We 
conducted successful trials with Henan 
in 2021 and our Optifine 5:1 100 high 
efficiency grain refiner was then fully 
adopted in production usage. 
“The study of grain refiners for 
aluminium alloys is a crucial research topic 
in the industry. At TMS, I will be sharing 
details of the quantitative studies made on 
the company’s canlid stock reduction since 
changing to Optifine, which has resulted 
in reduced grain refiner consumption, 
improvements in finished product quality 
and reduced costs.”
Grain refinement is a method that 
can improve both strength and ductility, 
playing a significant role in synergistically 
enhancing the material’s strength and 
plasticity. 
In products with grain sizes typically in 
the range 100-1000µm, the grains can 
increase dislocation density and material 
strength. Compared to larger grains, the 
coordination of small-scale deformation 
within a unit volume can enhance overall 
material elongation and increase material 
ductility. 
In practical casting processes, grain 
refinement can also reduce the formation 
of twins caused by dendritic growth, 
decrease process segregation, cold shut, 
and hot cracking tendencies, improve 
solidification shrinkage during the 
process, eliminate or better disperse 
porosity, enhance casting density and 
surface quality, improving the success 
rate of casting and facilitating subsequent 
ingot processing. 
Aluminium sheet for canlid stock is 
typically supplied to a thickness of 250µm, 
then drawn and wall ironed down to 
100µm or 0.1mm. The process is highly 
demanding of the aluminium cleanliness 
and mechanical properties. 
Grain refiner is primarily added to 
prevent cracking, but over addition 
can lead to increases in particle count, 
resulting in pinholes, tears and significant 
production outages due to time lost while 
equipment down.
By using Optifine 5:1 125 grain refiner, 
an even higher efficiency grain refiner 
than the Optifine 5:1 100 as used by 
producers such as Henan, the addition 
rate is reduced by a game-changing 85%. 
“A particle count of 4,000 would be 
reduced to just 600, preventing pinholes 
and tears and improving elongation and 
shape,” said John.
Optifine is today used in the production 
of over five million tonnes of alloys a year 
at 45 major casthouses worldwide. �
Find out more about how MQP can 
help your operations at www.mqpltd.
com. To register to hear John’s technical 
presentation at TMS, visit https://
register.rcsreg.com/r2/tms2024/ga/
top.html 
MQP.indd 1MQP.indd 1 26/02/2024 11:41:2726/02/2024 11:41:27
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DECARBONISATION 27
Aluminium International Today March/April 2024
Examining the latest technologies 
decarbonising the aluminium sector
As more people explore how to cut carbon emissions, they must focus on improvements in the 
aluminium sector. What technologies will help people and the industry at large achieve this goal? 
Renewable Energy
As a 2023 report from the Environmental 
Integrity Project pointed out, aluminium 
presents a paradox. It’s a critical material 
for many products necessary for a more 
sustainable future, such as electric vehicles 
and wind turbines. However, aluminium 
production is a high-emissions activity 
that must change to fit into the world’s 
eco-friendly future. 
The report noted how five of six 
smelters [1] in the U.S. still use fossil fuel 
energy sources. The exception is New 
York’s Alcoa Massen plant, which runs on 
hydroelectricity. However, transitioning to 
renewable energy will be a collaborative 
effort, relying on the expansion of 
infrastructure, the adoption of relevant 
location-based policies and commitments 
from aluminium manufacturing leaders 
that they’ll gradually switch to cleaner 
sources. 
Emerging technologies will undoubtedly 
play a role in the shift as well. In one 
example, energy reactor company GH 
Power developed a renewable energy 
technology that meets multiple needs. 
It uses exothermic reactions to produce 
alumina, exothermic heat and hydrogen. 
The zero-waste and zero-carbon process 
creates no emissions and requires only 
recycled aluminium and water.
Company representatives say GH 
Power’s co-product production costs for 
making alumina are more than 80% less 
expensive [2] than alumina processes using 
hydrochloric acid leaching and hydrolysis.
Another approach to the renewable 
energy possibilities in the aluminium 
industry comes from India, where an 
aluminium company has signed a 25-
year power purchase agreement [3] with a 
renewable energy company. This approach 
will provide the aluminium producer with 
100 megawatts of continually available 
renewable energy from wind and solar. 
Improved Recycling
Aluminium is a frequently recycled 
material, with nearly three-quarters of 
thematerial [4] produced in the United 
States still used today. In one case, a 
Norwegian aluminium and renewable 
energy company opened a recycling plant 
in Michigan. That location will become 
its largest producer of a proprietary 
material made from 75% [5] recycled, post-
consumer aluminium scrap.
Other countries are on board with 
recycling, too, and some find particularly 
creative uses for it. One English hospice 
used recycled aluminium to make a 
decorative display of 1,000 [6] roses for a 
memorial.
In another instance, the Watt Electric 
Vehicle Company is a United Kingdom-
based startup that builds its flagship 
commercial van from recycled aluminium. 
The company expects this vehicle will last 
at least 20 years [7], compared to the five to 
seven years most comparable automobiles 
do. 
The company offers a holistic program 
for customers that includes maintenance 
and upgrades for the vehicle’s life. It also 
By Ellie Gabel*
*Contributor
Ellie decarbonising.indd 1Ellie decarbonising.indd 1 26/02/2024 15:22:1426/02/2024 15:22:14
Aluminium International Today March/April 2024
DECARBONISATION28
has in-depth recycling plans, including 
some extending to the battery, powertrain 
and chassis. The long-term goal is to 
have a closed-loop supply chain. That 
aim would have multiple environmental 
benefits if met. 
However, many of the most successful 
aluminium recycling efforts will go further 
through collaboration. That happened 
with The Recycling Partnership, a non-
governmental organisation working 
to achieve better recycling methods to 
advance the circular economy. Internal 
statistics indicated one of its initiatives –
which received five grants – obtained an 
extra 4.1 million pounds [8] of aluminium 
per year beyond initial estimates. Those 
efforts took the equivalent of 18,750 
metric tons of greenhouse gas emissions 
from the atmosphere. 
Shell Energy leaders also have their 
sights set on aluminium decarbonisation. 
They’ll work with a provider in the United 
Kingdom to provide clean energy for 
aluminium recycling. Estimates suggest 
this approach will allow the recycling plant 
to maintain metrics of 2.3 kilograms [9] of 
CO2 per kilogram of aluminium handled. 
Low-Carbon Aluminium
As building managers, construction site 
leaders and others explore feasible carbon 
reduction methods, some choose low-
carbon aluminium for their projects. That 
was the decision made for Irish office 
buildings that collectively incorporated 
2,000 low-carbon [10] aluminium fins to 
minimise heating and cooling demands.
One collaboration between two 
companies also showed how even 
relatively small low-carbon aluminium 
applications can make big differences. 
The businesses will design low-carbon 
aluminium caps [11] for wines and spirits, 
effectively halving the market’s associated 
emissions footprint. 
Another notable factor is that the 
companies sought to design the closures 
in the European Union for organisations 
operating there. Most of the aluminium 
formerly used came from China, resulting 
in significant transport emissions. 
Automaker BMW also got into the 
low-carbon aluminium industry by 
becoming the first customer of a United 
Arab Emirates-headquartered company 
specialising in it. That producer uses an 
innovative approach blending recycled 
aluminium with that produced by 
solar energy. This method results in the 
production process resulting in less than 
four metric tons [12] of CO2 equivalent 
per metric ton of aluminium. BMW will 
use the material for large structural 
parts, drivetrain housings and engine 
components. 
Porsche is another automaker interested 
in low-carbon aluminium. It partnered 
with a supplier and set a 2025 goal of 3.5 
kilograms of CO2 
[13] per kilogram of the 
material used. That would allow Porsche 
to use approximately 60% less primary 
aluminium than the European average. 
Potential Challenges in Aluminium 
Decarbonisation 
The possibilities outlined here show that 
technology will significantly decarbonise 
the aluminium industry and work toward 
a greener future. However, doing things 
differently may result in occasional 
unintended consequences and obstacles 
yet to be overcome. 
For example, if a company begins using 
low-carbon aluminium, will that decision 
result in higher consumer costs? If so, will 
sufficiently large market segments agree 
to pay them? Although many people are 
becoming more sustainability conscious, 
most will draw the line if products are too 
far out of their budget or substantially 
more expensive than what competitors 
offer. 
Company leaders also must consider 
whether the technologies they choose 
will be scalable enough once operations 
grow or move to different locations. Some 
options that look great in small-scale 
trials fall short when production volumes 
increase. 
Even so, aluminium decarbonisation 
is essential to address now and for the 
foreseeable future. Finding greener ways 
to use and produce this widely available 
material will benefit society and the planet. 
The things people learn now will build the 
foundation for practical and efficient ways 
to shrink aluminium’s carbon footprint, 
showing the goal is always within reach 
when individuals stay open to new 
avenues. �
[1] https://environmentalintegrity.org/wp-content/uploads/2023/09/Aluminum-Paradox-report-EMBARGOED-for-09.27.23.pdf 
[2] https://hydrogen-central.com/gh-power-developed-unique-renewable-energy-technology-uses-exothermic-reactions-to-create-hydrogen-alumina-alumi-
num-oxide-and-exothermic-heat-killing-three-birds-with-one-high-tech-ston/ 
[3] https://www.mercomindia.com/ayana-supply-100-mw-rtc-renewable-hindalco-odisha 
[4] https://www.harboraluminum.com/en/green-aluminum 
[5] https://www.crainsgrandrapids.com/news/manufacturing/norwegian-aluminum-recycler-opens-150m-plant-in-southwest-michigan/ 
[6] https://www.bbc.com/news/uk-england-wiltshire-66798478 
[7] https://electrek.co/2023/11/14/watt-electric-vehicle-companys-van-recycled-aluminum/ 
[8] https://recyclingpartnership.org/aluminum-recycling-impacts/ 
[9] https://aluminiumtoday.com/news/hydro-partners-with-shell-energy-to-decarbonize-uk-operations 
[10] https://www.irishtimes.com/property/commercial-property/2023/06/07/coopers-cross-to-use-low-carbon-aluminium-fins-to-cut-energy-use/ 
[11] https://sustainabilitymag.com/articles/amcor-launches-low-carbon-product-to-halve-carbon-footprint 
[12] https://aluminiuminsider.com/bmw-becomes-first-customer-for-egas-celestial-r-low-carbon-aluminium/ 
[13] https://newsroom.porsche.com/en/2023/sustainability/porsche-cooperation-norsk-hydro-decarbonize-supply-chain-sportscars-32129.html 
Ellie decarbonising.indd 2Ellie decarbonising.indd 2 26/02/2024 15:22:2726/02/2024 15:22:27
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 Aluminium International Today March/April 2024
Hydrogen in the 
aluminium industry 
The element with the atomic 
mumber 1
The lightest, colourless, odourless, 
tasteless, non-toxic, and yet most 
abundant, most combustible, and one 
of the most needed elements; hydrogen 
is one of today’s number one most 
problematic topics. 
The simplest element to exist in our 
universe has a trail of fans, and as a result, 
a shadow of confl ict. Which turns out to 
be not as simple. Naturally occurring, 
the element is found as, in the form 
of a compound with other elements, 
liquid, solid, or gas. 75% of all mass in 
the universe is hydrogen and 90% of all 
atoms in the universe are hydrogen atoms 
[1]. This element, as effortless as it appears, 
is perhaps one of the most complex we 
have in our periodic table. 
The Element with the Atomic 
Number 13
Aluminium is the 12th most common 
element in the universe. Its low density, 
high strength, corrosion- resistant, highly 
recyclable, parallel nature makes it a 
material that fi ts to THE job. The main 
inconvenience that this metal is bonded 
and latched upon oxygen. About 8.2% 
of the earth’s crust is aluminium [2]; of 
this, aluminium most commonly occurs in 
the form of alumina (aluminium oxide – 
Al2O3). 
This unfortunate occurrence leaves 
the aluminium industry in confl ict with 
supplying demand, and sustainable 
consciousness. 
1 and 13: The Annoying prime 
numbers 
Hydrogen can, and has been, used in 
two main ways in the production of 
aluminium: As a combustion fuel for a 
direct fl ame source, usually in smelting or 
secondary aluminium production; or as 
a source to create electricity, which can 
then be used throughout the production 
of aluminium. 
Unfortunately, as abundant as hydrogen 
is, all industries have common challenges 
to contend with if they are to successfully 
implement the use of hydrogen. Namely: 
Supply, Storage, and Cost. 
In 2022, the worldwide primary 
aluminium smelting energy consumption 
(reported as AC and DC power used for 
electrolysis by the Hall-Héroult processes 
per tonne of aluminium production) by 
the International Aluminium institute (IAI) 
was: Total AC energy 14,103 kilowatt 
hours (kWh) per tonne of aluminium (see 
table 1, data from IAI)[3].
In 2022, the world average primary 
aluminium smelting power consumption 
was 903,980 GWh. The total primary 
aluminium production for 2022 was 
69,038 thousand metric tonnes of 
aluminium. That’s 13 GWh per tonne of 
aluminium. See table 2.
In 2022, global hydrogen use reached 
95 million tonnes (Mt) [5: Page 20] (global 
hydrogen production reached almost 95 
Mt in 2022 [5: Page 64]). Of which, 53 Mt of 
hydrogen was used in industry [5: Page 25]. The 
usage of one tonne of hydrogen outputs 
approximately 33 MWh of energy” [6]. 
Theoretically, this means that we would 
need 27.39 Mt of hydrogen to produce 
the current amount of energy for primary 
aluminium smelting alone! That’s 28.8% 
of total global hydrogen production of 
2022. 
What is more troubling is that only 0.7% 
of the global production of hydrogen in 
2022 qualifi ed as low-emission. [5: Page 64]
The colours of Hydrogen
The type of hydrogen is another topic of 
discussion where further issues tend to 
surface. Different colours refer to the way 
in which hydrogen has been produced[7]. 
Grey hydrogen is the most common 
occurring hydrogen fuel, which supports 
the rather shocking statistic that only 0.7% 
of hydrogen is qualifi ed as low-emission. 
The global Hydrogen Review 2023, noted 
that “virtually all hydrogen used in industry 
is produced from unabated fossil fuels” [5: 
page 25]. This statistic blatantly shouts out 
that there are major challenges that we 
need to be overcome, should hydrogen 
be a realistic solution. 
Cranfi eld University is one of the 
leading universities collaborating in the 
international partnership, HyPT, which 
aims to make “low-cost, large-scale, Net 
Zero hydrogen production a reality.” [8] The 
Global Hydrogen Production Technologies 
Centre (HyPT) is a £14.1 million, fi ve-year 
project led by Arizona State University 
(US), University of Adelaide (Australia), 
University of Toronto (Canada), and 
Cranfi eld University (UK). The aim is to 
achieve approximately one dollar per kg of 
hydrogen [8]. Commenting on the types of 
hydrogen, and its future in the aluminium 
industry, Professor Vasilije Manovic, 
Professor of Carbon Systems Engineering, 
School of Water, Energy and Environment, 
Cranfi eld University, said: 
“Hydrogen, if sourced from renewables 
(green hydrogen), provides a highly 
promising avenue for decarbonising 
aluminium production. However, 
additional considerations should be 
given to the viability of utilising hydrogen 
produced from fossil fuels and employing 
carbon capture and storage (CCS), 
for example, blue hydrogen. I would 
anticipate that the direct integration of 
By Zahra Awan*
*Assistant Editor, Aluminium International Today 
Hydrogen.indd 1Hydrogen.indd 1 26/02/2024 11:47:2926/02/2024 11:47:29
Aluminium International Today March/April 2024
HYDROGEN32
CCS with aluminium production is likely to 
be less technically challenging and more 
cost-effective than the integration of CCS 
with hydrogen production, followed using 
decarbonised hydrogen for aluminium 
production.
In general, when decarbonising carbon-
intensive industrial processes using 
hydrogen, key considerations include 
the availability of green hydrogen and 
prioritisation between utilising renewable 
sources to meet the high energy demands 
of those processes, as well as the 
production and use of green hydrogen for 
mitigation of inherent process emissions. 
Green hydrogen represents a long-term 
solution, while blue hydrogen serves as a 
short- to mid-term alternative. The latter 
still needs to prove its competitiveness 
compared to the direct decarbonisation of 
industrial processes with inherent process 
emissions employing CCS.”
Reviewing the figures from the 
previous section, it is evident that as the 
demand continues to run parallel and 
match consumption year on year, the 
Three current main types of hydrogen [7]:
� Green hydrogen: Green hydrogen is made by using clean electricity from 
surplus renewable energy sources, such as solar or wind power, to electrolyse water. 
Electrolysers use an electrochemical reaction to split water into its components of 
hydrogen and oxygen, emitting zero-carbon dioxide in the process.
� Blue hydrogen: Blue hydrogen is produced mainly from natural gas, using a 
process called steam reforming, which brings together natural gas and heated water 
in the form of steam. The output is hydrogen, but carbon dioxide is also produced as 
a by-product. So, the definition of blue hydrogen includes the use of carbon capture 
and storage (CCS) to trap and store this carbon.
� Grey hydrogen: Currently, this is the most common form of hydrogen 
production. Grey hydrogen is created from natural gas, or methane, using steam 
methane reformation but without capturing the greenhouse gases made in the 
process. Grey hydrogen is essentially the same as blue hydrogen, but without the 
use of carbon capture and storage.
(Visit source for more definitions)
* The AC value refers to the power consumed by facilities for the smelting process including rectification from AC to DC and normal 
smelter auxiliaries (including pollution control equipment) up to the point where the liquid aluminium is tapped from the pots. It ex-
cludes power used in casting and carbon plants. The DC value is a process efficiency metric, measuring the energy intensity of the electro-
lytic process as the consumption of DC power after rectification per tonne of liquid aluminium is tapped from the pots.[3]
Kilowatt hours (kWh) per tonne of aluminium: Total Energy (AC), Process Energy (DC) 
Type Africa North South Asia Europe Oceania Gulf China World
 America America (ex China) Cooperation Council 
 
TotalEnergy (AC) 14,463 14,944 15,572 14,739 15,481 15,027 14,833 13,448 14,103
Process Energy (DC) 13,704 14,001 14,651 13,597 14,316 13,783 13,623 12,783 13,253
Table 1. A Table to Show Primary Aluminium Smelting Energy Intensity 2022
** Data from International Aluminium Institute[4] . Note: Electrical power used in primary aluminium production includes power used for electrolysis by the Hall-Héroult processes (including rectification from 
AC to DC) and normal smelter auxiliaries (including pollution control equipment) up to the point where the liquid aluminium is tapped from the pots. It excludes power used in casting and carbon plants.
Global Data for 2022 in Gigawatt hours (GWh)
 Region
 Africa North America South America Asia Europe Oceania Gulf Cooperation China World 
 (ex China) Council Reported 
 8,147 46,819 22,841 1,159 111,198 16,274 0 103,832 310,270
 10,344 1,828 95 21,277 777 18,126 0 402,890 455,337
 0 2 2 2 199 0 2 0 207
 0 3 3,734 0 1,060 133 89,980 0 94,910
 0 30 28 0 1772 0 0 3,245 5,075
 0 257 625 167 3,932 1,424 810 30,825 38,039
 0 0 0 0 142 0 0 0 142
 18,491 48,939 27,324 22,606 119,081 35,956 90,791 540,792 903,980
Table 2. Primary Aluminium Smelting Power Consumption 2022
Po
w
er
 M
ix
Hydro
Coal
Oil
Natural Gas
Nuclear
Other Renewable
 Other non-renewable
Total
need for more hydrogen is obvious. The 
production of more hydrogen is pivotal 
for hydrogen to be a realistic assistant 
in the global sustainability agenda. 
However, it is also clear that hydrogen 
faces many challenges, globally, let alone 
the aluminium industry. 
Professor Manovic raises an important 
point: “The latter [blue hydrogen] still 
needs to prove its competitiveness 
compared to the direct decarbonisation 
of industrial processes with inherent 
process emissions employing CCS.” 
Assessing whether hydrogen is in the 
decarbonisation picture at all is essential 
for the progression of industry. We do 
not want to take a giant, complex, and 
expensive detour.
As a solution, perhaps Professor 
Manovic’s recommendation that green 
hydrogen becomes a long-term solution, 
and blue hydrogen a short- to mid-
term alternative, is what hope looks 
like. Allowing for time to tell whether 
hydrogen is indeed a long term, realistic 
solution. 
Looking to hydrogen for a positive 
future, key players in the aluminium 
industry are investing in projects, 
experimentations, and tests to assess 
the applications that hydrogen could 
assist with in the aluminium production 
process. In this article, we will be 
looking into some of the investments 
that have experimented with hydrogen 
application in the secondary production 
of aluminium, as well as prompting you 
to question whether hydrogen is on our 
side. 
Or is hydrogen just salt disguised as 
sugar. 
Hydrogen as a fuel to secondary 
aluminium: Examples already in the 
industry 
Hydro: Hydro Havrand 
“Hydro Havrand’s ambition is to be the 
Hydrogen.indd 2Hydrogen.indd 2 26/02/2024 11:47:2926/02/2024 11:47:29
precimeter.com
Aluminium International Today March/April 2024
HYDROGEN34
leading provider of industrial fuel switch 
solutions.” – Jan Helge Mårdalen, Head of 
Hydro Havrand.
Aluminium and renewable energy 
company Norsk Hydro, set up Hydro 
Havrand, in 2021, to with the aim of 
achieving and investing in a sustainable 
future[9]. Hydro Havrand is pioneering 
the fuel switch from fossile alternatives to 
green hydrogen in aluminium. 
Hydo Havrand states that they aim 
to “develop, operate and own green 
hydrogen facilities, and provide expertise 
to enable transition to renewable 
energy.”[9] They are working on a pipeline 
of projects[9]. 
In a previous interview with Aluminium 
International Today (see Vol.36 No. 5 
2023[10]), Per Christian Eriksen, former 
Head of Hydro Havrand, spoke about 
the inspiration behind Hydro’s recent 
test to create the first batch of recycled 
aluminium with 100% hydrogen fuel, a 
project that took place in Jun 2023 [11] 
first batch.
Hydrogen was chosen to decarbonise 
a “processes where it’s difficult to use 
electrification directly. This typically refers 
to the high heat processes and calcination 
process,” [10] therefore, this test focused on 
replacing the fuel used in a furnace to melt 
scrap metal. The project, in collaboration 
with the Fives Group, worked using an 
adapted a furnace to suit hydrogen.
Eriksen stated that “One of the biggest 
challenges we faced was getting a hold 
of the volume of green hydrogen that we 
needed to execute these tests. We had 
two trucks of hydrogen per day during 
the nine days of testing. We ended up 
burning around three tonnes of hydrogen 
during these weeks, and we produced, 
in total around 200 tonnes of [recycled] 
aluminium. 150 tonnes of the aluminium 
were produced using only hydrogen.” [10] 
Despite this rather hard to ignore 
challenge, Hydro have announced that 
they will be completing a Pilot Test on 
“local production of hydrogen, with an 
electrolyser (5 Megawatt), to produce 
hydrogen leading directly into the 
furnace.” [10] They have stated that they 
aim for an industrial scale pilot to work on 
this set up, in Norway, where they intend 
on running the furnaces on hydrogen 
over a longer period. This is scheduled for 
“a year or two from now.” [10]
However, referring to the figures of 
global production and observing the 
figures from this test, one questions 
once again whether the implementation 
of hydrogen is truly achievable, or 
sustainable. Charles Schroer, Vice 
President, Sales & Marketing - Fives North 
American Combustion, Inc., when asked 
whether he believes hydrogen to be a 
realistic fuel of the future, answered: 
“There are many variables with 
respect to the manufacture, distribution, 
availability, and cost of hydrogen to 
be worked out before it will become a 
realistic fuel. From the perspective of a 
thermal process solution provider though 
we, at Fives North American Combustion, 
plan to be ready if it does become a 
reality. All we can control is making sure 
we develop “Hydrogen Proven” products 
for processes that safely and efficiently 
combust hydrogen for customers that 
want to use it on their high temperature 
thermal processes. We have partnered 
with early adopter companies such 
as Hydro Havrand to study the use of 
hydrogen on their high temperature 
thermal processes. Their interest was in the 
metallurgy and process performance; our 
interest was in the design and reliability of 
the combustion system. Both in our test 
furnaces and at customer sites we have 
worked with aluminium, forging, steel 
and whiteware companies to investigate 
the metallurgical and material effects 
on their end product when exposed to 
high temperature hydrogen products 
of combustion instead of those from 
natural gas. We have invested over a 
half million dollars to install a permanent 
bulk compressed hydrogen gas pad and 
stainless-steel pipe distribution system 
to all our lab furnaces so that we can 
run extended time tests on our burner 
equipment to confirm their durability and 
performance with 100% hydrogen under 
conditions approximating our customers’ 
thermal processes.”
When asked whether the current Head 
of Hydro Havrand, Jan Helge Mårdalen, 
thinks Hydrogen is a realistic fuel of the 
future, he replied: 
“Green hydrogen is key to tackle the 
hard-to-abate emissions, where direct 
electrification isn’t an option. The world 
will not get to zero without green 
hydrogen. But we need to find the right 
applications for it. One example could be 
the high heat processes in industry, where 
green hydrogen is an alternative to fossil 
fuels. So yes, green hydrogen is a realistic 
fuel.”
If we narrow down the use of hydrogen 
to the production of secondary aluminium, 
we can establish the conditions where 
hydrogen has a positive future. 
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HYDROGEN 37
 Aluminium International Today March/April 2024
Novelis and HyNet: Implementing in 
recycling 
In June of 2023, Novelis announced 
that they were awarded £4.6 million to 
“establish hydrogen burning trials as part 
of the UK Government’s £55m Industrial 
Fuel Switching Competition, as part of the 
£1bn Net Zero Innovation Portfolio (NZIP), 
and the wider regional HyNet project.”[13] 
Novelis have noted that the fi rst of the 
trials will used a recycling furnace located 
at the Novelis Latchford, and the test is 
expected to take place during 2024. 
Results of this trial will be announced later 
this year. 
In a press release, Emilio Braghi, 
Executive Vice President, Novelis, and 
President, Novelis Europe, stated: 
“Switching to renewable energy sources 
is a key initiative to advance on our journey 
toward carbon-neutral production.” [13]
Adding to this, Allan Sweeney, Plant 
Manager, Novelis Latchford stated: 
“We are proud to be one of the pioneers 
using hydrogen within the aluminium 
industry and that these trials at Latchford 
will additionally advance research on the 
viability of integrating hydrogen power 
in our recycling operations around the 
world.” [13]
It will be interesting to see what the 
outcome of this project will be. We will 
have to sit tight in the meantime. 
Rio Tinto: Can hydrogen help reduce 
emissions in the aluminium industry
In July 2023, Rio Tinto announced it will 
be building a ‘fi rst of its kind’ hydrogen 
plant, in partnership with Sumitomo 
Corporation and the Australian Renewable 
Energy Agency, at their Yarwun alumina 
refi nery in Gladstone, Queensland, 
Australia.[14]
The project aims to demonstrate 
the viability of using hydrogen in he 
calcination process, where hydrated 
alumina is heated to temperatures of up 
to 1,00 degrees Celsius. [15] 
Providing details of the project, Rio 
Tinto have stated that: 
“The project will consist of construction 
of a 2.5MW on-site electrolyser to supply 
green hydrogen to the Yarwun refi nery 
and a retrofi t of one of Yarwun’s four 
calciners so it can operate at times with 
a hydrogen burner. If successful, the 
program could pave the way for adoption 
of the technology at scale globally.
“The trial is expected to produce the 
equivalent of about 6,000 tonnes of 
alumina per year while reducing Yarwun’s 
carbon dioxide emissions by about 3,000 
tonnes per year.
“Converting the entire plant to green 
hydrogen could reduce emissions by 
500,000 tonnes per year, which is the 
equivalent of taking about 109,000 
What is HyNet? 
HyNet is the leading UK industrial 
decarbonisation project focused 
in the North West. 
HyNet is made up of several 
different elements. Together, 
these elements aim to provide 
the infrastructure to produce, 
transport and store low carbon 
hydrogen across the North West 
and North Wales. There will also 
be the infrastructure to capture, 
transport and lock away carbon 
dioxide emissions from industry. 
[12]
internal combustion engine cars off the 
road.
“Construction will start in 2024. The 
hydrogen plant and calciner are expected 
to be in operation by 2025. [14]
This investment, again, shows the 
dedication to hydrogen within the 
aluminium industry, and with millions 
of dollars being invested in projects that 
intend to go ‘global’, one begins to 
believe that hydrogen does in fact have a 
place in the aluminium industry. The top 
fi ve global hydrogen generation market 
leaders are: ITM Power plc, Linde plc, 
Engie SA, Air Liquide S.A, and Messer 
Group GmbH,.[16] Four of the fi ve are 
European companies. 
So, what about Governments, policies, 
and wider assistance? Are we looking at 
local hydrogen or global hydrogen? 
Making Hydrogen stable: The UK 
Government 
It is well known that Hydrogen is highly 
fl ammable. With this, and many other 
challenges in mind, the success of 
hydrogen implementation within any 
industry is the surrounding support 
that strengthens this fuel. Without 
Government and policies, hydrogen will 
not be successful. 
We have already seen global research 
and development projects, such as HyPT, 
and large local projects, which work with 
global players, such as HyNet. So now 
let’s look closer into government support: 
The UK has announced funds for the 
investment of hydrogen, the Hydrogen 
Production Business Model (HPBM) and 
Net Zero Hydrogen Fund (NZHF).
What are the intentions of The 
Hydrogen Production Business Model 
(HPBM) and Net Zero Hydrogen Fund 
(NZHF): [17]
� Kickstart the low carbon hydrogen 
economy across the UK, helping meet 
the ambition of up to 1GW of electrolytic 
hydrogen production capacity in 
operation or construction by 2025,
� Deploy at scale at the earliest 
opportunity, advancing government’s 
aim to deploy up to 10GW of low carbon 
hydrogen production capacity by 2030, 
subject to affordability and VfM, with 
at least half from electrolytic hydrogen 
production capacity, and to do so at 
affordable costs by harnessing economies 
of scale. This could potentially unlock up 
to £11 billion of private investment and 
support more than 12,000 jobs by 2030,
� Help deliver carbon savings to allow 
us to stay on track to meet Carbon Budget 
5, Carbon Budget 6 and other net zero 
commitments, by providing hydrogen to 
a range of end user sectors.
The fi rst Hydrogen Allocation Round 
(HAR 1: July 2022) announced 11 
successful projects, totalling 125 MW 
capacity.[21] Over £90 million from the 
Net Zero Hydrogen Fund has been 
allocated in support of these projects 
[21]. But how many of these projects were 
rejected? And, how many will continue 
to be successful. The UK Government 
anticipate that the fi rst projects will 
become operational in 2025. How many 
will make it to 2030? 
HAR 3 has already been announced, 
despite projects from HAR 1 predicted to 
start in 2025. This could be seen as long-
Hydrogen.indd 4Hydrogen.indd 4 26/02/2024 11:48:5226/02/2024 11:48:52
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Aluminium Today.indd 1Aluminium Today.indd 1 07/09/2023 11:18:4107/09/2023 11:18:41
HYDROGEN 39
Aluminium International Today March/April 2024
term thinking, or it could be considered 
as a rash decision to satisfy the industry in 
the short term. 
With obvious millions, and perhaps 
billions being spent on the investment of 
the hydrogen industry, it is clear that we 
will be taking this path with or without 
my scepticism, and multiple questions. 
However, what is clear is that without 
government collaboration hydrogen 
would not have a future. 
Industry Point of View
Fives, when asked what the biggest 
challenge is when looking into hydrogen 
for industry, their opinion of a solution, 
and what their advice is to the industry, 
Charles Schroer, Vice President, Sales 
& Marketing - Fives North American 
Combustion, Inc. replied: 
“Each industrial customer will face 
different challenges when looking into 
the use of hydrogen to replace their 
carbon-based fuels. The challenges are 
many and well documented: manufacture 
of hydrogen, availability in sufficient 
quantities, the distribution network, 
and its cost to name a few. Many of 
these challenges are outside the control 
of the industrial customers. Our advice 
to industry is to be ready for the day 
when hydrogen is your only available 
fuel: start preparing now. Work with 
suppliers to run tests now to confirm 
the effect that hydrogen will have on the 
quality of your product. From these tests 
determine if your thermal processes need 
to be changed to maintain the quality 
of product you currently manufacture. 
Investigate your internal gas distribution 
system to confirm its compatibility with a 
hydrogen fuel. Start to train your people 
to safely work around hydrogen pipelines. 
Make the lists of equipment and action 
items that would need to change or be 
upgraded to work with hydrogen. You 
have the time now to study what you 
need to do to make the conversion to a 
“Hydrogen Proven” process; spend your 
time wisely and be ready. Fives stands 
ready to support its customers and all 
industry players looking to make the 
transition to hydrogen.”
Alternative methods of producing 
primary aluminium are well known for 
keeping the industry in suspense: Elysis 
being the biggest culprit. Hydro have 
come forward with HalZero technology 
aimed at revolutionising this primary 
process. When asked whether he thinks 
hydrogen will be compatible with HalZero 
Technology/ high energy demanding 
processes, Jan Helge Mårdalen replied: 
Well, hydrogen and HalZero really 
address different parts of the primary 
aluminium production process. HalZero 
is a revolutionary technology that 
can replace the current CO
2-emitting 
What is the UK standard of low carbon hydrogen? 
The UK Department for Energy Security and Net Zero have published a UK Low 
Carbon Hydrogen Standard. This standard was published after a report on the 
‘options for a UK low carbon hydrogen standard [18] and Consultation from the 
government on ‘designing a UK low carbon hydrogen standard [19]. 
There is now a version three of this standard, and a low carbon calculator for 
industry to use to calculate their standard of hydrogen. 
The 169-page standard with numerous criteria’s, requests for endless data, and 
space for the unknown, sums up how simple defining low carbon hydrogen is. I 
wonder, does this UK standard differ from the EU, USA, China, Far East, African, 
South American, Russian, Australian, Middle East etc definition. Does that mean 
we have to reed 100 plus pages for each standard? 
View the UK Low Carbon Hydrogen Standard through reference [20]
electrolysis process in the production of 
primary aluminium. This step is where 
the white powder alumina is made into 
liquid aluminium metal. But after the 
alumina has been made into aluminium, 
it still needs to go into a casthouse and 
be formed to aluminium moulds. The 
casting require high heat temperature, 
and is often today fueled by natural 
gas. By replacing natural gas with 
green hydrogen, we can remove these 
emissions.
Conclusion
Per Christian Erikson, when asked whether 
he considers hydrogen as a feasible global 
solution, he replied: 
“Definitely. That is one of the motivations 
for doing these tests. The roadmap, at this 
stage, aims to bring up the maturity level 
of both the technology and the hydrogen 
to later implement these permanently in 
the process of producing aluminium. So, 
this is definitely the plan. The pilot project 
aims to assist this vision, and to bring this 
fuel switch technology to full maturity.”[10]
Predictions that demand for hydrogen 
will reach 500MtH2 by 2050, relying on 
carbon capture and storage to qualify 
as low carbon, which means that for 
now there is a clear need for more 
hydrogen. Hydrogen has a long way to 
go and requires a lot of global monetary 
investment for it to be the saviour, and it 
also needs a global standard. 
It seems like secondary aluminium is the 
place for hydrogen. However, and without 
going on a tangent, it has long been 
known that the demands for aluminium 
cannot be satisfied by the quantity 
produced by secondary aluminium alone, 
Hydrogen.indd 5Hydrogen.indd 5 26/02/2024 11:49:0526/02/2024 11:49:05
Aluminium International Today March/April 2024
HYDROGEN40
as each year demand continues to rise. 
Plus, the quantity and accessibility to 
scrap metal is yet another issue that we 
must contend with and consider. Of all 
the issues we face, knowing that people 
want more of our material is a juxtaposing 
blessing and curse. 
I look forward to seeing how our 
adaptable aluminium adapts to this fuel. 
I suppose with great power comes 
great responsibility. �
References and Citations:
[1] Norwegian hydrogen, Norwegian 
Hydrogen. Available at: https://
n o r w e g i a n h y d r o g e n . c o m / g r e e n -
h y d r o g e n / f a c t s - a b o u t - h y d r o g e n 
(Accessed: 24 January 2024). 
[2] Cardarelli, François (2008). Materials 
handbook: A concise desktop reference 
(2nd ed.). London: Springer. pp. 
158–163. ISBN 978-1-84628-669-8. 
Available at: https://books.google.co.uk/
books?id=PvU-qbQJq7IC&printsec=fr
ontcover&source=gbs_ViewAPI&redir_
esc=y#v=onepage&q&f=false 
[3] Primary aluminium smelting energy 
intensity - International Aluminium 
Institute (2022) International Aluminium 
Institute. Available at: https://
international-aluminium.org/statistics/
primary-aluminium-smelting-energy-
intensity/ (Accessed: 24 January 2024).
[4] Primary aluminium smelting power 
consumption - International Aluminium 
Institute (2022) International Aluminium 
Institute. Available at: https://international-
a lumin ium.org / s ta t i s t i c s /p r imary-
aluminium-smelting-power-consumption/ 
(Accessed: 24 January 2024). 
[5] Global Hydrogen Review 2023 - 
International Energy Agency (IEA) (2023) 
Global Hydrogen Review 2023 . Available at: 
https://iea.blob.core.windows.net/assets/
ecdfc3bb-d212-4a4c-9ff7-6ce5b1e19cef/
G l o b a l H y d r o g e n R e v i e w 2 0 2 3 . p d f 
(Accessed: 14 February 2024).
[6] Goodall, C. (2021) Some rules of 
thumb of the hydrogen economy, Carbon 
Commentary. Available at: https://www.
carboncommentary.com/blog/2021/6/11/
some-rules-of-thumb-of-the-hydrogen-
economy (Accessed: 14 February 2024).
[7] The hydrogen colour spectrum 
(2023) National Grid Group. Available 
at: https://www.nationalgrid.com/stories/
energy-explained/hydrogen-colour-
spectrum#:~:text=Why%20is%20a%20
colourless%20gas,between%20the%20
types%20of%20hydrogen (Accessed: 24 
January 2024).
[8] Cranfield University at the forefront 
of new £14.1m Global Initiative to 
Transform Net Zero Hydrogen production 
(2023) Cranfield University. Available 
at: https://www.cranfield.ac.uk/press/
news-2023/cranfield-at-the-forefront-of-
new-global-initiative-to-transform-net-
zero-hydrogen-production (Accessed: 14February 2024).
[9] Hydro Havrand (2023) Hydro.com. 
Available at: https://www.hydro.com/
en-GB/energy/hydrogen/ (Accessed: 14 
February 2024).
[10] Awan, Z. (2023) ‘Worlds first batch 
of recycled aluminium using Hydrogen ’, 
Aluminium International Today , pp. 20–
22.
[11] World’s first batch of recycled 
aluminium using hydrogen fuelled 
production (2023) Hydro.com. Available 
at: https://www.hydro.com/en-GB/media/
news/2023/worlds-first-batch-of-recycled-
aluminium-using-hydrogen-fueled-
production/#:~:text=Hydro%20has%20
produced%20the%20world’s,of%20
aluminium%20during%20the%20test 
(Accessed: 14 February 2024).
[12] Hynet North West (no date) HyNet. 
Available at: https://hynet.co.uk/ 
(Accessed: 14 February 2024).
[13] Toward carbon neutral production: 
Novelis to trial use of hydrogen in recycling 
furnaces (2023) Novelis. Available at: 
https://www.novelis.com/toward-carbon-
neutral-production-novel is-to-tr ial-
use-of-hydrogen-in-recycling-furnaces/ 
(Accessed: 14 February 2024).
 [14] Could hydrogen help reduce 
emissions in the aluminium industry? 
(2023) Rio Tinto. Available at: https://
www.riot into.com/en/news/stor ies/
could-hydrogen-help-reduce-emissions 
(Accessed: 14 February 2024). 
[15] Rio Tinto and Sumitomo to build 
Gladstone Hydrogen Pilot Plant to... 
(2023) Aluminium International Today. 
Available at: https://aluminiumtoday.com/
news/rio-tinto-and-sumitomo-to-build-
gladstone-hydrogen-pilot-plant-to-trial-
lower-carbon-alumina-refining (Accessed: 
14 February 2024).
[16] Hydrogen generation market - Report, 
Size & Share Analysis - Growth Trends & 
Forecasts (2024 - 2029). Available at: 
https://www.mordorintelligence.com/
industry-reports/hydrogen-generation-
market (Accessed: 14 February 2024).
[17] Department for Energy Security and 
Net Zero (2023) Hydrogen production 
business model / net zero hydrogen fund: 
Successful projects, GOV.UK. Available 
at: https://www.gov.uk/government/
publ icat ions/hydrogen-production-
business-model-net-zero-hydrogen-
fund-shortlisted-projects (Accessed: 14 
February 2024).
[18] Department for Energy Security and 
Net Zero (2021) Options for a UK low 
carbon hydrogen standard: Report, GOV.
UK. Available at: https://www.gov.uk/
government/publications/options-for-a-
uk-low-carbon-hydrogen-standard-report 
(Accessed: 14 February 2024).
[19] Department for Business, (2022) 
Designing a UK low carbon hydrogen 
standard, GOV.UK. Available at: https://
www.gov.uk/government/consultations/
designing-a-uk-low-carbon-hydrogen-
standard (Accessed: 14 February 2024).
[20] Department for Business, (2022) 
Designing a UK low carbon hydrogen 
standard, GOV.UK. Available at: https://
www.gov.uk/government/consultations/
designing-a-uk-low-carbon-hydrogen-
standard (Accessed: 14 February 2024).
[21] Hydrogen production business model 
/ net zero hydrogen fund: HAR1 successful 
projects (published December 2023) (2023) 
GOV.UK. Available at: https://www.gov.
uk/government/publications/hydrogen-
production-business-model-net-zero-
hydrogen-fund-shortl isted-projects/
hydrogen-production-business-model-
net-zero-hydrogen-fund-har1-successful-
projects (Accessed: 14 February 2024).
[22] Hydro at Herøya contributes to zero 
emissions in the aluminium industry (no 
date) Herøya Industrial Park. Available at: 
https://www.heroya-industripark.no/en/
news/hydro-at-heroeya-contributes-to-
zero-emissions-in-the-aluminium-industry 
(Accessed: 20 February 2024).
[23] Halzero process (no date) Hydro.
com. Available at: https://www.hydro.
com/en-GB/media/on-the-agenda/hydros-
roadmap-to-zero-emission-aluminium-
product ion/halzero-zero-emiss ion-
electrolysis-from-hydro/ (Accessed: 20 
February 2024).
Hydrogen.indd 6Hydrogen.indd 6 26/02/2024 11:49:0526/02/2024 11:49:05
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Aluminium International Today March/April 2024
PACKAGING42
What the packaging recycling 
industry wants to see in 2024
*Executive Director of Alupro.
Tom Giddings* looks to the year ahead and explains what the aluminium packaging recycling industry 
wants to see in 2024. 
When we look back over the past 
12 months, it’s likely to go down in 
history as a year of frustration for the 
packaging value chain. Delays to expected 
consultations, disappointing decisions 
from the government and fluctuating PRN 
prices all played their part.
However, there were, of course, 
numerous upsides too. Finally receiving a 
consultation response regarding DRS was 
a massive step in the right direction, while 
setting an official date for the mandatory 
recycling of kerbside and commercial food 
waste put real fire power behind tackling 
a growing environmental challenge. 
In addition, while consistency in 
collections legislation may have been 
shelved as part of Prime Minister Rishi 
Sunak’s net-zero shake-up, Simpler 
Recycling will take us a welcome step 
forward towards a more uniform material 
scope for kerbside recycling collections 
and a higher recycling rate for England. It 
must be said that the opportunity for the 
future looks incredibly bright.
For those of us working towards 
achieving a more circular economy, it’s 
therefore important to see 2024 as a year 
of progress, decision-making and action 
– an opportunity to build momentum 
and drive real, positive, proactive change. 
From an aluminium perspective, this can 
be condensed down into three key asks: 
1. A record year for aluminium 
packaging recycling rates
Aluminium packaging recycling in the UK 
continues to go from strength to strength. 
Continued investment into awareness 
and education initiatives is helping to 
drive widespread behavioural change, 
with households appreciating both the 
environmental and economic value of best 
practice recycling. 
The latest PRN data perfectly reflects this 
impressive growth. In September 2023, 
for example, the industry had already 
achieved 92% of its annual obligation (an 
uplift from 116,439 tonnes to 137,275 
tonnes compared to the same period in 
2022), with aluminium collected through 
kerbside, bring, on-the-go and via 
incinerator bottom ash (IBA) all rising.
While some industry critics had 
suggested that the high recycling rates 
reported during the COVID-19 pandemic 
were just a short-term trend, it’s positive 
to see that impressive volumes and 
positive consumer recycling behaviours 
have continued.
In 2024, we’d like to see even higher 
collection and recycling volumes of 
aluminium packaging. After all, we’re 
hugely ambitious about aluminium’s role 
within a circular packaging economy and 
we’re committed to leading from the 
front. If PRN prices remain realistic, we 
see no reason as to why this shouldn’t 
happen.
Alupro.indd 1Alupro.indd 1 26/02/2024 11:53:4826/02/2024 11:53:48
PACKAGING 43
 Aluminium International Today March/April 2024
2. Real progress when it comes to 
future legislation
With policy now progressing fast, the next 
12 months should be seen as a period of 
real opportunity. Specifi cally, we’d like to 
see progress made in appointing a DRS 
scheme administrator, as well as the detail 
of the scheme fi nally bottomed out. We’d 
also like to see further momentum made 
towards agreeing a series of decisions that 
will ensure the scheme’s best possible 
long-term output. You can read our 
thoughts in further detail here.
Elsewhere, we welcome the formation 
of an EPR steering group and think 
that Margaret Bates is an excellent 
appointment as interim Head of the UK 
Extended Producer Responsibility for 
Packaging Scheme Administrator. Let’s 
now accelerate momentum and ensure 
that it delivers fair proposals, while 
securing widespread input from the wider 
supply chain. 
3. Clear, consistent, creative 
communication
As we move ever closer towards a 
bright new future for the recycling 
industry, relevant, timely and consistent 
communication is more important than 
ever. We’re proud to be continuing 
with our hugely successful aluminium 
packaging recycling programmes 
(MetalMatters and Every Can Counts) and 
remain committed to fl ying the fl ag – both 
in terms of awareness and education.
Our initiatives delivered widespread 
benefi t in 2023 and proved instrumental 
in increasing consumer engagement 
across the UK. Results from our 
programmes highlighted the real value 
of communication, as well as changing 
consumer behaviours when it comes to 
best practice recycling. 
In 2024, we’ll continue to lead by 
example. However, banging the drum 
when it comes to consumer education is a 
gauntlet that we all must pick up and I’d 
like to see this happening across the wider 
packaging value chain. After all, with 
new legislation looming and widespread 
change likely, communicating with clarity, 
consistency and creativity must remain our 
utmost priority.
While 2023 might go down on record 
as somewhat of a frustrating year, the 
next 12 months are perfectly positioned 
to deliver progress, decision-making and 
action. Personally, I believe that our most 
important priorities are striving to reach 
ever higher recycling rates, inspiring real 
momentum when it comes to future 
legislation, and communicating with 
clarity.
As a sector we have the opportunity 
to build real momentum. It’s certainly an 
exciting time ahead, but collaboration is 
key to achieving the best possible results. 
�
For more information about the Aluminium 
Packaging Recycling Organisation, visit 
www.alupro.org.uk. 
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DIGITAL MINE 45
 Aluminium International Today March/April 2024
Ma’aden and Hexagon partner to 
launch region’s fi rst digital mine
Saudi Arabian mining company Ma’aden, 
and Hexagon have announced that they 
have partnered to launch the Middle East’s 
very fi rst digital mine.
Hexagon’s life-of-mine technology 
solutions are being successfully deployed 
at Mansoura Massarahfor mate-
rials like aluminium is growing as 
we build the infrastructure need-
ed for the green transition. To 
reach our climate goals, we must 
also change how these materials 
are produced. Key European in-
dustries, including the automo-
tive and building & construction 
sectors, need access to respon-
sibly produced materials with a 
low-carbon footprint. Hydro’s 
new state-of-the-art aluminium 
recycling plant in Torija will be 
ideally positioned to help custom-
ers reach their sustainability goals 
by offering low-carbon alumini-
um with a high share of recycled 
post-consumer scrap,” says Eivind 
Kallevik, Executive Vice President 
for Hydro Aluminium Metal.
The investment is pending final 
build decision, which is expected 
in the second half of 2024. Pro-
duction is expected to commence 
in 2026.
BONUS DAY
Alcoa have announced that it 
will supply global cable producer 
Nexans with aluminium produced 
from a revolutionary process that 
eliminates all direct greenhouse 
gas emissions from the traditional 
smelting process.
Nexans will be the world’s first 
cable manufacturer to use metal 
from the breakthrough ELYSIS™ 
process, which replaces all green-
house gas emissions with oxygen. 
The technology uses proprietary 
materials, including inert anodes, 
first developed at the Alcoa Tech-
nical Center near Pittsburgh. That 
research and development work 
became the technological basis for 
ELYSIS™, a technology partnership 
that is working to ramp up the 
process to commercial scale.
Several Nexans facilities in West-
ern Europe and Scandinavia will 
use aluminium produced from the 
ELYSIS™ process to start qualifica-
tions for the metal’s use in various 
types of cables, from low, medium 
to high voltage. Aluminium rod 
produced with this breakthrough 
ELYSIS™ technology could elimi-
nate a significant portion of carbon 
dioxide emissions in the future.
Since the launch of ELYSIS™ 
in 2018, the technology compa-
ny has produced R&D quantities 
of the metal. Alcoa is marketing 
and selling its share of the ELYSIS 
metal, which has also been used 
for the wheels on the Audi eTron 
GT, the automaker’s first electric 
sports car. Apple is also an in-
vestor in the technology and has 
used ELYSIS metal for some of its 
products.
EGA to supply alumina
Emirates Global Aluminium has 
announced it has signed an agree-
ment to supply alumina to The 
Alumina Industrial Company, en-
abling the development of a new 
industry making speciality prod-
ucts from alumina and contrib-
uting to the achievement of the 
UAE’s industrial growth strategy 
Operation 300bn.
The Alumina Industrial Com-
pany, established by the Maithan 
Group and Bathwal Corporation, 
intends to develop the UAE’s 
first complex to make speciality 
products from alumina in Khalifa 
Economic Zone Abu Dhabi. These 
products have widespread appli-
cations in refractories and abra-
sives for industrial applications.
The project requires a local 
source of alumina, and EGA is the 
only UAE producer. The supply 
agreement is the first time EGA 
has sold alumina from its refinery 
to a third-party, extending EGA’s 
support to industrial expansion in 
the country. Alumina is the main 
feedstock for aluminium smelters. 
All the production from EGA’s Al 
Taweelah alumina refinery is cur-
rently used in EGA’s smelters.
Hydro invests EUR 180 million in 
new Spanish aluminium recycler
Alcoa to supply Nexans with low-
carbon aluminium from ELYSIS™
EGA’s supply of alumina to the 
project is a further expansion of 
EGA’s local commercial sales that 
enable downstream industrial ac-
tivity. 
Nadine News.indd 1Nadine News.indd 1 26/02/2024 15:36:2526/02/2024 15:36:25
 
3
NEWS IN BRIEF
NEWS
Aluminium International Today
Henan Yirui starts production on 
the new aluminium hot rolling mill 
Alba Inks 10-year gas supply deal 
with Bapco Energies
“Securing a 10-year Natural Gas 
Supply Agreement marks a signifi-
cant chapter for Alba”, as stated by 
Aluminium Bahrain B.S.C. (Alba)’s 
Chairman of the Board, Mr. Khalid 
Al Rumaihi, during the Signing 
Ceremony with Bapco Upstream, a 
100% owned subsidiary of Bapco 
Energies, on 23 January 2024 at Al 
Dana Hall, Alba.
The signing ceremony was at-
tended by Alba’s Chairman, Mr. 
Khalid Al Rumaihi, Bapco Up-
stream’s Chairman, Eng. Faisal Al 
Mahroos, Alba’s CEO, Ali Al Baqa-
li, Bapco Upstream’s CEO, Johann 
Pleininger, and other Alba’s offi-
cials.
This Agreement takes effect on 
23 January 2024, and supersedes 
all previous agreements. It serves 
as a continuation of the Company’s 
current natural gas requirements 
under one contract. Another key 
highlight of this Agreement is the 
fixed price structure for the first 
5-year period at US$4 per million 
British thermal units (MMBTU) post 
which the price will be determined 
by the Competent Authority.
Adding further to mark this mile-
stone, Mr. Al Rumaihi stated: “Five 
years of stable gas price are just the 
foundation. This partnership with 
Bapco Energies lays the ground-
work for a future where collabora-
tion and transparency will fuel our 
sustainable growth.”
MYTILINEOS Energy & Metals 
expanding production activities
MYTILINEOS Energy & Metals 
(MYTILINEOS) has obtained a Pros-
pecting License from the Ghana 
Integrated Aluminium Develop-
ment Corporation (GIADEC) to 
explore and subsequently extract 
bauxite deposits in the Ninayhin – 
Mpasaaso region.
Highlighting the successful En-
ergy & Metals model and the syn-
ergies resulting from it, MYTILINE-
OS have said it seeks to implement 
a similar mode of operation in 
Ghana, already having an in-depth 
understanding of the country’s en-
ergy sector, through the execution 
of a multitude of energy projects.
In the initial 18-month imple-
mentation stage of the project, 
the company state they will con-
duct necessary studies to confirm 
reserves and develop mines. Si-
multaneously, a comprehensive 
feasibility study will be conducted. 
The area containing the deposits 
under concession, designated as 
Ninayhin Block C, is estimated to 
possess geological reserves of ap-
proximately 300 million tons of 
bauxite and is anticipated to yield 
around 10 million tons of bauxite 
annually, equivalent to an esti-
mated annual turnover of $500 
million at current market prices. 
MYTILINEOS, in collaboration with 
GIADEC, have announced they will 
assess the potential construction 
of an alumina production unit, 
projecting an annual production 
capacity of up to 1.5 million tons. 
The current annual aluminum pro-
duction in Agios Nikolaos, Viotia, 
amounts to 865,000 tons.
Two months ahead of the contrac-
tually agreed date, the first alu-
minium coil was successfully rolled 
on the new hot mill at Henan Yirui 
New Material Technology Co., Ltd.
The new hot mill is an essential el-
ement of the strategic expansion 
project of Henan Yirui, a subsidi-
ary of the Henan Mingtai group, 
which is located in the city of 
Gongyi, Henan Province, China. 
This underlines Henan Yirui’s trust 
in the expertise and experience of 
SMS group and its many success-
ful references in the aluminium 
industry.
SMS group developed a solu-
tion to refurbish and integrate 
components from a secondhand 
1+1 hot rolling mill, comprising 
a roughing mill and a single-stand 
finishing mill, into the 1+4 hot 
strip mill at the Gongyi site.
Rolling of the first coil was orig-
inally scheduled for the first quar-
ter of 2024. However, installation 
and commissioning times were 
significantly shortened
OTTO JUNKER 100 years
OTTO JUNKER GmbH looks back 
at 2023. With many successful 
trade fair participations, new 
partnerships and major orders, 
the company has strengthened its 
position and is looking forward 
to the future. This year, the 
company will celebrate its 100 
year anniversary.
2024 Outlook for the UK - 
ALFED report
Last year, the UK aluminium 
industry was characterised by 
low inventories, prolonged and 
extensive slumps in demand, 
and sanctions still hanging over 
Russianmine, combining 
sensor, software, and autonomous 
technologies to enhance effi ciency, 
productivity, quality and safety across the 
mine’s operations.
Located in the central Arabian region, the 
Mansourah Massarah represents Ma’aden’s 
largest and most technologically advanced 
gold mine. It consists of the Mansourah 
and Massarah resources, which are being 
developed as conventional open-pit mines.
The Mansourah deposit is estimated to 
hold 27.7 million tonnes of proven and 
probable ore reserves grading 5.06 g/t 
gold, while the reserves estimates for the 
Massarah open-pit stand at 17.3 million 
tonnes grading 1.99 g/t gold.
Anchoring the open-pit mines is a 
4-million-tonne-per-year plant that employs 
carbon-in-leach and pressure oxidation 
processes and autoclave technologies 
for ore production. The project reached 
fi rst gold pour in September 2022, and is 
expected to produce 250,000 oz. of gold 
annually over an estimated mine life of 12 
years.
Duncan Bradford, Executive Vice 
President Base Metals and New Metals, 
Ma’aden, said: “This partnership strongly 
aligns with our digitisation strategy, as 
we work to use the vast amounts of data 
that we mine to make our mine safer and 
more effi cient. We look forward to working 
closely with Hexagon to implement and 
utilise the region’s fi rst digital mine to 
elevate Mansourah Massara’s operations.”
Nick Hare, President of Hexagon’s Mining 
division, said: “We are excited to help 
bring to life this important shift toward 
digitisation of the mine, one that holistically 
leverages intelligent data and automation 
across workfl ows to minimise the impacts 
of mining while simultaneously improving 
safety, productivity and operational 
effi ciency. This is about co-authoring the 
next chapter of mining in this region with 
a partner who shares in our drive toward a 
sustainable future.” �
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CASTHOUSE 47
 Aluminium International Today March/April 2024
Rail mounted charging machines 
for melting furnace applications
Introduction:
RIA Cast House Engineering provides 
precision rail-mounted Cast House proven 
Charging and Skimming equipment 
for Aluminium Cast Houses worldwide. 
The design and development of all RiA 
Machines take reliability, durability, 
maintenance and occupational safety 
into account. RiA has supplied over 
eighty Furnace Charging and Skimming 
Machines, all rail-mounted and capable 
of Charging up to 30 Metric Tonnes 
in less than 90 seconds or Skimming a 
Furnace faster than a traditional Forklift 
Truck or wheeled Furnace Tending 
Vehicle, but with more repeatable results 
and without damaging the refractory 
lining. Key customers include Hydro, 
Constellium, Matalco, and many others. 
Several clients have multiple Machines in 
the same Cast House or across multiple 
sites and territories. One client alone 
has implemented more than thirty RiA 
Machines in ten different countries. 
RiA installed their fi rst rail mounted 
Charging and Skimming Machine pair in 
2001, both of which are still in operation 
today after 23 years of continuous 
operation. Since this installation, the 
furnaces supplied to the aluminium 
remelting market have transformed 
to satisfy the growing demand for 
aluminium scrap recycling and the 
increased recycling of contaminated scrap. 
RiA’s product offering has grown with 
the changing landscape of aluminium 
remelting furnaces and today RiA offer 
robust and reliable rail mounted Charging 
and Skimming Machines to serve a varied 
range of furnace types that includes 
Multi-Chamber and Tilt Rotary Furnace 
applications that are now common 
features of Cast Houses around the world.
RiA Charging Machine for Multi-
Chamber Furnace Applications
RiA rail mounted, precision Furnace 
Charging Machines for Multi Chamber 
Furnaces typically operate differently to 
a standard Charging Machine serving a 
single chamber reverberatory furnace. 
Smaller volumes of scrap are charged 
within each charging cycle, however the 
pushes are more frequent and continuous.
Multi-Chamber Furnaces typically 
operate with a clean chamber and a dirty 
chamber which includes a hearth that 
scrap is charged onto. RiA’s rail mounted 
Furnace Charging Machine regularly 
deposits material on to the scrap hearth, 
pushing the material at the end of the 
hearth into the bath, therefore creating 
room on the hearth for the next charge.
With such regular charges required 
when running this type of operation, an 
effi cient and reliable Charging Machine 
is essential to a productive and effi cient 
operation to ensure cycle times are as fast 
as possible and down time is kept to a 
minimum to allow for a constant feed of 
input material into the furnace.
Each RiA rail mounted Furnace Charging 
machine is bespoke and engineered to 
serve the furnace(s) they tend, and RiA’s 
Multi Chamber Furnace Charging Machine 
is no exception. Our Charging Machine 
container fi lls the width and height of 
the charging door, and the stroke of the 
container is confi gured based on the 
furnace operation and the length of the 
hearth. Scrap material is then distributed 
evenly distributed across the length 
and breadth of the hearth to allow the 
combustion system access to the material 
for preheat and removal of contaminants.
The RiA Multi-Chamber Furnace Charing 
Machine pictured in Figure 1, recently 
commissioned, swivels 90 degrees, in front 
of the Furnace. A fume hood connects 
with the Furnace giving more opportunity 
to the furnace fume hood to capture any 
off gases that may leave the furnace when 
the door opens, can be seen in fi gure 2. 
Typically the Charging cycle, the process 
of adding more material onto the hearth 
of the furnace is less than 90 seconds, 
minimising the door opening time and 
conserving energy. Fig 1
Although this RiA Charging Machine is 
serving a Multi-Chamber furnace, the core 
RiA philosophy remains as the machine 
is fully automated, without an Operator 
Cabin, nor Operator onboard. The Charge 
cycle is initiated from a single push button 
on a remote Operator Desk in a safe 
location. Therefore, maximising the safety 
Fig 1. RiA Multi-Chamber Furnace Charging Machine with 
the ability to rotate 90 degrees for easier loading
Fig 2. RiA Multi-Chamber Furnace Charging Machine with retractable fume hood
Ria cast house converted.indd 1Ria cast house converted.indd 1 23/02/2024 11:30:3123/02/2024 11:30:31
Aluminium International Today March/April 2024
CASTHOUSE48
for operators and ensuring a safe and 
efficient charge, every time. Fig 2
 
RiA Charging Machine for Tilt Rotary 
Furnace Applications
Building on the knowledge and expertise 
acquired from RiA’s extensive Charging 
Machine reference list, in 2023, RiA 
commissioned their first rail mounted 
pusher type Charging Machine to serve 
a Tilt Rotary Furnace. The design and 
development of all RiA Machines take 
reliability, durability, maintenance and 
occupational safety into account. RiA’s 
pusher type TRF Charging Machine is no 
different, as you can see in Fig 1.
The machine pictured in fig 3 is 
designed and engineered to charge up 
to 10 metric tonnes of material in under 
90 seconds. Conventional methods often 
consist of charging Tilt Rotary Furnaces 
with a wheel loader or a vibratory feeder. 
Wheel loaders are limited by the size of 
the bucket, typically charging 1 or 2 
metric tonnes of material, meaning the 
charging process takes longer which limitsthe productivity of the tilt rotary furnace. 
Using wheel loaders to charge a Tilt Rotary 
Furnace also requires the operator to be 
near and in front of the furnace during 
the charging process, you will notice the 
RiA machine pictured in figure 1 has no 
operator cabin on board the machine. 
Once loaded with the charge material, 
from the push of a single button the 
machine will move to the furnace, send 
a signal to the furnace PLC to open the 
door, charge the furnace and then move 
back to the loading position. To avoid any 
risk loading the machine at height, this 
machine is equipped with a scissor lift to 
allow for the machine to be loaded at a 
safe height.
Above each wheel block the Charging 
Machine is equipped with load cells, 
the charge weight is then displayed on 
a screen nearby the loading position 
enabling Cast House operators to monitor 
the scrap weight per charge. This ensures 
the furnace is being charged with the 
correct charge weight and ensures it is 
simple to monitor material flows through 
the Cast House.
RiA have engineered the adjustable 
pusher plate of the Charging Machine to 
fit closely to the inner walls of the charge 
container and Charging Machine nose to 
ensure it is possible to charge fine material 
and even salt using the Charging Machine.
Although vibratory feeders also eliminate 
the requirement for an operator to be on 
board the machine, when charging dross 
and loose material the vibrating action can 
create excess dust and fume, as well as 
noise, which causes its own health, safety 
and environmental concerns for those 
working in close proximity. Maintenance 
breakdowns can also commonly become 
an issue with a vibratory machine over 
time. 
RiA provide a remote desk where an 
operator can view the machines operation 
from a safe location through a camera 
mounted on a mast at the rear of the 
machine. Joysticks are also integrated 
within the desk to allow for manual 
movement of the machine if required in 
maintenance mode for example, however 
in typical operation the machine operates 
from the push of a button with no other 
operator interaction required.
Each RiA rail mounted Furnace Charging 
machine is bespoke and engineered to 
serve the furnace they tend, and the 
new Pusher Type Tilt Rotary Charging 
Machines are no exception. The diameter 
of the furnace door is used to calculate 
the diameter of the nose of the Charging 
Machine. With laser positioning, the 
refractory around the door of the furnace 
is protected from accidental collisions 
which can occur when charging dross and 
scrap with a wheel loader. An operator 
charging a furnace with a wheeled vehicle 
does not have the same limits, control 
and repeatability that a laser positioned 
rail mounted Charging Machine does. 
When Charging large pieces of scrap and 
dross skulls for example, it is inevitable 
that charging them inside the furnace 
door on a very frequent basis is going to 
cause rapid wear of the refractory around 
the door, potentially impacting the door 
sealing and therefore furnace performance 
whilst also leading to regular downtime 
and expensive repairs.
With Tilt Rotary Furnaces in the market 
now exceeding 60 metric tonnes in 
capacity, it Is more important than ever to 
charge the material in the quickest, safest 
and most energy efficient way possible. 
RiA Charging Machine for 
Reverberatory Furnace Applications
Parallel to engineering new, efficient 
and robust Charging Machine solutions 
for varied furnace applications, RiA have 
continued to improve and enhance their 
Charging Machine solutions for single 
chamber reverberatory furnaces. It is now 
over 20 years since RiA’s first Charging 
Machine installations, and those machines 
are still in operation today. 
Through continuous development, the 
machines looks vastly different today 
and they have the ability to operate 
autonomously, not only not having an 
operator on board but utilising In-Furnace 
smart cameras to monitor the height of 
the scrap pile within the furnace and 
signalling to the Charging Machine to 
charge the furnace at the earliest and 
safest time, every time. Ensuring maximum 
throughput of material into the furnace 
whilst safeguarding operators.
RiA have now successfully designed 
and installed Charging Machines with 
a capacity of 30 metric tonnes of scap 
material that can be charged into a 
furnace in less than 90 seconds. The 
machine pictured in Fig 4 charges 20 
metric tonnes in less than 90 seconds, 
considerably faster than if that volume 
of material was to be loaded with a fork 
lift truck or wheel loader, all without an 
operator needing to be on the machine 
or exposed to the potential hazards that 
charging a furnace can pose. 
Whilst furnace configurations have 
changed in recent years, so have the size 
of furnaces, and RiA now supply Charging 
Machines that are serving furnaces in 
excess of 120 metric tonnes. Furnaces 
of this size have wide doors and deep 
hearths so it is vital that the Charging 
Machine serving the furnace has sufficient 
stroke to penetrate deep into the furnace 
to deliver the charge evenly from the 
very back, right to the front, to ensure a 
shallower scrap pile with a larger surface 
area to achieve the fastest melt rates. 
The growth of RiA Charging Machines 
has been simultaneous with the growth 
of melting furnaces as end users and 
furnace suppliers understand the need to 
have efficient and safe furnace charging 
practices when charging increased 
amounts of scrap into larger furnaces. �
Fig 4. RiA Charging Machine serving a single chamber 
reverb furnace
Fig 3. RiA’s Pusher Type Tilt Rotary Furnace Charging 
Machine
Ria cast house converted.indd 2Ria cast house converted.indd 2 23/02/2024 11:30:3223/02/2024 11:30:32
MODERN ALUMINUM
EXTRUSION
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.
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 e� cient, 
sustainable, and competitive aluminium sector.
INTERESTED IN EXHIBITING 
OR SPONSORING?
Please contact Nathan Jupp, Commercial Sales Director 
+44 (0)1737 855 027 nathanjupp@quartzltd.com
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FAF-24-A4-Ad-v2-PRINT.indd 1 05/03/2024 13:06
EVENT PREVIEW: ALUMINA 2024 51
 Aluminium International Today March/April 2024
Industry Events
Alumina 2024, the 12th AQW International 
Conference, Exhibition and Workshop, 
will be held the Grand Hyatt Conference 
Centre in Dubai, UAE, from 21st to 26th 
April 2024. As a readily accessible hub for 
global participation at the centre of major 
regional developments in alumina and 
aluminium production, this is the ideal 
location for this fi rst AQW Conference 
outside Australia. Alumina 2024 will be 
a stand-out event in the Alumina Quality 
Workshop (AQW) tradition of “for the 
industry, by the industry” with a world-
class program and opportunities for 
networking and sharing knowledge with 
over 300 delegates from the alumina 
industry, academia, suppliers, and other 
stakeholders from all over the world.
The Conference Theme “Beyond the 
Cycle” challenges us to look beyond 
the familiar cycles of economic and 
technological development for the 
innovations essential to transform 
alumina production to the low carbon,low environmental impact industry that 
the future world demands. 
The “Net Zero Alumina Refi ning” 
Workshop on Friday 25 April, sponsored 
by the International Aluminium Institute 
(IAI), will address the Challenges and 
Knowledge Gaps in adapting our refi neries 
for GHG Emission Reductions and the 
Circular Economy. It will examine the 
implementation gaps in the adoption of 
decarbonisation technologies to answer 
questions such as - Are we ready for 
tomorrow’s low-carbon technologies? 
What happens to existing heat and energy 
minimisation systems? What are our blind 
spots, and what don’t we know that we 
don’t know…?
The Registration and Welcome event 
on Sunday 21 April will be followed by 
upwards of 70 papers to be presented 
in the three-day Technical Program (22-
24 April). Alumina 2024 will follow the 
usual AQW format of common plenaries 
followed by parallel technical sessions on 
topics including Decarbonisation; Process 
- Design & Optimisation, - Management 
& Maintenance, - Chemistry; Analysis & 
Product Quality; Education & Training; 
Environment, Health & Safety; Bauxite 
Characterisation & Digestion; Residue 
Management & Utilisation. 
Poster sessions will be held at designated 
times in an adjacent area and breaks 
Aerial of Al Taweelah alumina refi nery ATA 2019
Alumina 2024.indd 1Alumina 2024.indd 1 26/02/2024 15:53:5626/02/2024 15:53:56
Aluminium International Today March/April 2024
EVENT PREVIEW: ALUMINA 202452
between sessions will be held in the 
Exhibition and Poster spaces to promote 
discussion and networking. 
Technical Tours of EGA’s world-leading 
Al Taweela alumina refinery and smelter 
will be available on Thursday, 24 April. 
Morning and afternoon tours of each 
will ensure that delegates will have the 
opportunity to visit both facilities in small 
groups.
EGA’s Al Taweelah smelter was built in 
two phases. The first began production 
in 2009, and the second in 2013. On 
completion it was the largest single-site 
smelter in the world, extending over 
six square kilometres. In 2019, the site 
became the first in the Middle East to 
receive certification to the Aluminium 
Stewardship Initiative Performance 
Standards, the aluminium industry’s 
internationally recognised standard for 
environmental and social performance 
and governance. 
EGA built Al Taweelah alumina 
refinery next to the smelter, and it began 
production in 2019. The refinery is the 
first in the UAE and only the second in the 
Middle East. It supplies over 45 per cent 
of EGA’s alumina needs. 
AQW is committed to fostering 
Full details of the Conference can be found at Alumina 2018 
website: https://www.alumina2024.com
education and promoting the alumina 
industry as a great career choice for 
technology professionals. We strongly 
encourage student participation in the 
Conference, and will provide discount 
registration, financial and mentoring 
support to students arriving from overseas 
and wishing to present their work at 
Alumina 2024. 
The conference provides an excellent 
social program to enable delegates to 
network and share experiences in the 
exciting milieu of ultra-modern Dubai and 
the Grand Hyatt. In addition to networking 
opportunities throughout the Conference 
week, an informal Dinner Event will be held 
on the Viewing Deck of Palace Downtown 
on the evening of Tuesday 23rd April. The 
AQW Gala Conference Dinner and Awards 
Ceremony will be held at the Grand Hyatt 
on Wednesday 24th April. 
The Alumina 2024 Exhibition will 
continue the tradition of excellence of 
AQW Conferences, showcasing the latest 
in technology from suppliers. It will be 
held in an Exhibition Hall adjacent to 
the Conference presentation areas with 
co-located breakout and refreshment 
facilities to foster networking. �
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Alumina 2024.indd 2Alumina 2024.indd 2 26/02/2024 15:54:0826/02/2024 15:54:08
At Hydro, we put our people at the center of everything we do. By supporting our 
employees’ growth professionally and personally, we are fostering a community 
of colleagues who are united in the shared purpose of solving our industries’ most 
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A job where
you matter.metal. There is, however, 
an expected economic upshift 
by the end of 2024, and with 
new EU regulations adding taxes 
to high carbon imports from 
2026, the aluminium industry 
can expect a year of transitional 
change, with renewed focus on 
supply chains and sustainability.
Runaya & TAHA International 
have announced the extension 
of their cooperation from India 
to the rest of the world. Through 
a strategic partnership, Runaya 
and TAHA aim to set up end-to-
end dross processing and refining 
facilities for major primary global 
aluminum smelters. 
Refractories manufacturer 
RATH: Strategic growth in 
future market Asia
RATH Group announces it 
acquires 33% stake in Avanee 
Refsol India as part of its Evolution 
2030+ strategic growth plan. 
Production is scheduled to start 
at the beginning of 2025. 
Runaya and TAHA extend 
their global footprint
Nadine News.indd 2Nadine News.indd 2 26/02/2024 15:36:5326/02/2024 15:36:53
Aluminium International Today
www.aluminiumtoday.com
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 high-
profile 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
JULY
3rd - 5th
ALUMINIUM CHINA
ALUMINIUM CHINA brings 
together high-quality 
resources from the aluminium 
industry and end-use 
applications at home and 
abroad to comprehensively 
display innovative technologies 
and products. 
Held in Shanghai 
www.aluminiumchina.com
2024 DIARY
For a full listing visit
www.aluminiumtoday.com/
events
4
The European Commission un-
veiled its Communication ‘Secur-
ing our future: Europe’s 2040 
climate target and path to climate 
neutrality by 2050 building a sus-
tainable, just and prosperous soci-
ety’ outlining the needed climate 
and energy policy framework 
post-2030.
The framework recommends an 
ambitious greenhouse gas (GHG) 
emissions reduction target of 90% 
by 2040, compared with 1990 
levels. This presents a significant 
opportunity and challenge for the 
aluminium industry, as demand 
is set to surge in support of the 
green transition. European Alu-
minium emphasises the pressing 
need for coherent energy, trade 
and industrial policies that facil-
itate the industry’s decarbonisa-
tion and incentivising recycling 
while remaining competitive on 
global markets. This will enable 
the industry to meet the growing 
demand with sustainable alumini-
um ‘made in Europe’.
“The link between climate, 
trade and industrial policy must be 
strengthened and at the forefront 
of the agenda of the next EU Com-
mission. We are ready to work 
with the EU Commission and the 
Member States on bridging solu-
tions to bring down the cost of en-
ergy and boost the transformation 
of our industry while remaining 
competitive on global markets,” 
notes Paul Voss, Director General 
of European Aluminium.
European Aluminium calls for a real 
“industry decarbonisation deal”
March/April 2024
GREEN NEWS
The Aluminium Association of 
Canada (AAC) welcomes the ad-
dition of aluminium to Quebec’s 
list of critical and strategic min-
erals.
The government’s decision 
comes at a strategic moment in 
our industrial development, when 
Quebec, which produces 75% 
of North America’s primary alu-
minium, will play a major role in 
the decarbonisation of the North 
American economy through its 
contribution to electrification.
“From the production of re-
newable energy with solar panels 
through transmission lines and all 
the way to batteries and electric 
vehicles, Quebec’s low-carbon 
aluminium is essential from start 
to finish,” said Jean Simard, Presi-
dent and CEO of AAC.
Aluminium is listed as a criti-
cal mineral in the USA, Canada 
and, more recently, Europe. Can-
ada produces more than 80% of 
North America’s primary metal, 
and nearly 45% of all primary 
metal in Europe and the United 
States combined. It is also the 
largest source of low-carbon met-
al production from a democracy.
Rio Tinto has announced that they 
will drive development of Austral-
ia’s largest solar power project 
near Gladstone, after agreeing to 
buy all electricity from the 1.1GW1 
Upper Calliope Solar Farm to pro-
vide renewable power to Rio Tin-
to’s Gladstone operations.
The agreement will bring more 
renewable power into one of Aus-
tralia’s most important industri-
al hubs and marks another step 
towards Rio Tinto’s climate goal 
of halving its global Scope 1 & 2 
carbon emissions this decade2. 
If combined with more renewa-
ble power and suitable firming, 
transmission and industrial policy, 
it could also provide the core of 
a solution to repower Rio Tinto’s 
three Gladstone production assets 
- the Boyne aluminium smelter, 
the Yarwun alumina refinery and 
the Queensland Alumina refinery.
Under a new power purchase 
agreement (PPA) signed with Eu-
ropean Energy Australia, Rio Tinto 
will buy all power generated from 
the Upper Calliope solar farm for 
25 years. The plant will be built 
and operated by European Ener-
gy, at a site about 50 kilometres 
south-west of Gladstone, pending 
development and grid connection 
approvals.
Once approved and developed, 
Upper Calliope would have the 
potential to lower Rio Tinto’s op-
erating carbon emissions by 1.8 
million tonnes per year.
Rio Tinto Chief Executive Jakob 
Stausholm said “This agreement 
is a first important step in our 
work to repower our Gladstone 
operations and illustrates our 
commitment to keeping sustain-
ably powered industry in Central 
Queensland.”
Rio Tinto to drive development of
Australia’s largest solar farm
Aluminium added to Quebec’s list 
of critical and strategic minerals
Nadine News.indd 3Nadine News.indd 3 26/02/2024 15:37:0126/02/2024 15:37:01
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Aluminium International Today March/April 2024
INTERVIEW6
Women With Metal 
*Editor, Aluminium International Today
Dedicated to creating a connection 
between all women and allies working 
in the metal sectors, Women With Metal 
is the latest and greatest project headed 
up by Kirsty Davies-Chinnock, Managing 
Director of Professional Polishing Services 
Ltd. Nadine Bloxsome* was in attendance 
at the first Women With Metal conference 
last year and met with Kirsty to find out 
more about future plans to align with 
broader industry trends and initiatives 
related to gender equality and diversity. 
I’m always in awe of those people who 
get up at 5am to start their day with a 
workout and give themselves some time 
to prepare for what’s ahead. I’m much 
better at doing this in the summer months, 
but the dark, winter mornings currently 
mean I lack this extra motivation. If Kirsty 
Davies-Chinnock however couldbottle 
up her energy and offer that as a treat in 
the goody bags at the next Women With 
Metal conference, I’d be very grateful! 
After the success of the first conference 
in October 2023, the Women With Metal 
brand has gone from strength to strength. 
Now a registered company, Kirsty and 
her growing team have announced that 
this year’s conference will be even bigger 
and there will be a stream of regional 
workshops organised across the year, 
focusing on topics such as goal setting 
and how to unlock success. 
With Aluminium International Today 
recognised as a proud media partner for 
the event and supporting in the success, it 
was great to speak with Kirsty to find out 
about the passion behind the project and 
her hopes for how it will evolve. 
Q1. Can you provide an overview of the Women With Metal conference 
and its objectives? How it started, to where it is now? 
A. The conference was the start of Women With Metal and it was almost accidental. 
I’d had a conversation with someone who was being asked a lot about gender 
equity in the metal industry. There were lots of networking events in the industry 
already, but these were things like golf days and clay pigeon shooting, but there 
didn’t seem to be anything that’s particularly aimed at women within the metal 
industry, and there have always been women in the metal industry, and they’re 
becoming more and more visible. 
I took it in the way he intended it, which was very positive. But he said to me, 
Kirsty, can you arrange an afternoon tea? And that was, I think, on a Wednesday 
and by the Friday I’d got five speakers booked and, on the Tuesday, secured the 
Birmingham Park Regis Hotel for a one-day conference! 
We had the conference on the 10th of October and by the end of the month 
Women With Metal was a limited company, and we were already looking for the 
2024 conference venue and also starting to plan regional events as well. 
Something that started as a way to develop an event that was more inclusive 
for women, has now moved on and is contributing to this advancement and 
representation of women in the metals industry. So, it is not just showing as an 
event form, but actually showing more roles that women are now playing in the 
sector as well. 
Q2. How does the Women With 
Metal conference contribute to the 
advancement and representation 
of women in the metal industry, 
particularly in the UK? 
A. I want to encourage more women 
to go into more visible leadership roles, 
without detracting from the men in those 
roles, who doing a great job, I want to 
show that there are great women out 
there, running businesses at C-Suite level 
or as senior managers with incredible 
technical skills and showing that there are 
great careers in the metal sector for both 
men and women. 
When we look at the skill shortages and 
how difficult it is to change the perception 
of the metals industry, it’s just going to 
benefit companies to have this positivity 
out there for further recruitment, both for 
skilled men and women coming into the 
industry. 
women with metal.indd 1women with metal.indd 1 26/02/2024 11:32:1526/02/2024 11:32:15
INTERVIEW 7
Aluminium International Today March/April 2024
Q3. In what ways does the 
conference aim to foster diversity 
and inclusion within the metal 
sector? 
A. One thing I am very conscious of is 
not creating a ‘them and us’ agenda, 
but it’s great to network with people 
that are like you. 
Whilst I focused heavily on delivering 
a ‘return on investment’ conference 
for companies who were sending 
delegates, I was also very keen that 
they would come away with new skills. 
It’s nice to have just have a coffee and 
a chat with somebody who is similar 
to you; we all find our own tribe. 
We all get on with some individuals 
better than others, it doesn’t matter 
what their gender is. When you find 
someone, you have a common ground 
with and someone who has had a 
similar experience to you, whether 
that’s being a working mother, being 
the only woman in your team or 
having trouble accessing decent PPE, 
we’re human beings at the end of 
the day and we want to connect with 
somebody who has similar experiences. 
We’ve already had a number of men 
booking onto the 2024 conference 
and whilst there will be aspects that 
are aimed particularly at women, 
this doesn’t mean that allies aren’t 
welcome. When you talk about equity 
in the workplace, these issues benefit 
men and women. There are men who 
want to go and see their children in 
the school play, or want to do the 
university run, or have to take their 
turn in running a parent to a hospital 
appointment and just feeling confident 
that they can have those conversations 
will benefit the whole company. 
The more this equity and change 
becomes visible, the easier it’s going 
to be to attract new people into the 
industry, and that’s what we need. 
Q4. Can you share some success 
stories or notable achievements 
resulting from the latest Women with 
Metal conference and workshops?
 
A. We had the first regional workshop 
recently and we had a mixture of 
architects and designers, fabrication 
companies, stockholders, large and small 
and associated industries, people who 
have clients within the metal sectors. 
There was a lot of networking which was 
great, and I know that one company has 
started supplying another company that 
was there, which is fantastic. 
One of the things we’re doing with the 
regional events is they are more workshop 
based, with a meal and some drinks 
and just seeing the level of networking 
afterwards. The feedback so far and 
during the night has been good, so we’re 
looking forward to hosting more over 
the coming months and taking them to 
different areas of the country. 
Q5. How does the Women with 
Metal conference align with broader 
industry trends and initiatives related 
to gender equality and diversity? 
A. We are currently preparing the agenda 
for October, and we will be looking to bring 
in more elements of building networking 
skills. I’m also hoping to focus more on 
mindset and how to not take stresses at 
work home, because if people have the 
skills to not do that, it means when they 
come back to work the next day, they’re 
not going to have been lying in bed at 
2am worrying about something! They’re 
going to be more refreshed; they’re going 
to be positive and in a lighter physical 
and mental frame of mind to deal with 
that challenge, which means they’ll deal 
with it better, both for them and for the 
outcome of that challenge. 
Another area we are looking at is the 
development of AI and how potentially 
that will look in the metal sector moving 
forward, how we can use it for our benefit, 
whether it’s using sensors on machinery 
and then using AI to analyse the data or 
whether it’s going to be in other areas. 
I’m talking to a variety of people about 
that now and trying to find something 
that will appeal to the majority of the 
people attending, because obviously 
we’ve got people in every department you 
can think of. 
Q6. Looking ahead, what are the 
future development plans for the 
Women with Metal conference, and 
how do you envision its growth and 
impact in the coming years? 
A. Ideally, I would love the main UK 
conference to turn into a two-day 
event with a dinner in the evening and 
the opportunity of splitting off into 
workshops, looking at how we can add 
value for individuals going forward. 
We’re also producing quite a lot of 
content in the background, as well as 
workbooks and eBooks that go out each 
month and there’s a code every single 
month so people can download them for 
free. 
We’re also planning to create 
Continuous development courses which 
will be a big project, but I really want to 
get going on that in 2025 and partner 
with organisations who can help. 
There’s still a lot of work to do, but we’re 
all about collaboration overall! The more 
we can work together and the more we 
can shout about how these industriesare 
fantastic, we’re all having fulfilling careers 
that are interesting, dynamic and there 
are plenty of opportunities there. 
women with metal.indd 2women with metal.indd 2 26/02/2024 11:32:4726/02/2024 11:32:47
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THE ALUMINA CHRONICLES 9
Aluminium International Today March/April 2024
Aluminium industry 
in Indonesia
*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
Indonesia is one of the largest nations in 
the world in terms of population and in 
size of its territory. This Asian nation is also 
one of the largest producers of bauxite 
and one of the largest refiners of alumina 
in the world. 
The United Nations Population Fund 
estimated that 277,500,000 people were 
living in Indonesia in 2023. This ranks the 
country as the fourth largest in the world 
in terms of population. Only India, China, 
and the United States (USA) have larger 
populations.
Indonesia includes more than 
approximately 1,904,569 square 
kilometers of territory, according to the 
Central Intelligence Agency of the USA. 
This size ranks the island nation as the 
14th largest in terms of territory in the 
world.
The International Monetary Fund (IMF) 
projected the Real Gross Domestic Product 
(GDP) of Indonesia will grow 5% to (US) 
$1,540,000,000,000 in 2024. This GDP 
level would rank Indonesia as the 16th 
largest economy in the world. To put this 
level in perspective, the IMF indicated the 
economy of Indonesia is larger than the 
economies of such nations as Türkiye, the 
Netherlands, and Saudi Arabia.
Consumer Prices in Indonesia are 
projected by the IMF to increase 2.5% in 
2024.
According to a report from the United 
States Geological Survey (USGS) issued 
in 2023, 1,100,000 metric dry tonnes 
of alumina was estimated to have been 
refined in Indonesia in 2022. That was an 
increase from the 1,000,000 metric dry 
tonnes of alumina estimated to have been 
refined in the country in 2021.
The estimated level of alumina 
production in 2022 placed Indonesia as 
the 15th largest producer of alumina in 
the world. The estimate for 2021 by the 
USGS indicated that Indonesia was the 
16th largest producer of alumina globally 
in that year.
The USGS estimated Indonesian bauxite 
production was 21,000,000 metric dry 
tonnes in both 2021 and 2022.
With those estimated levels, the USGS 
indicated that Indonesia was the 5th 
largest producer of bauxite among all 
nations in both 2021 and in 2022.
Reserves of bauxite were estimated by 
the USGS to be 1,000,000,000 metric 
dry tonnes in Indonesia as of 2022. This 
would place the country with the sixth 
largest reserves of bauxite in the world. 
Only Guinea, Vietnam, Australia, Brazil, 
and Jamaica are estimated by the USGS to 
have larger reserves of bauxite.
Trade
Indonesia was ranked as the 28th largest 
importing nation of aluminium and articles 
thereof in 2022. In 2021, the country 
also ranked number 28 among countries 
importing aluminium and articles thereof. 
In 2020, Indonesia ranked number 29; in 
2019, number 26; and in 2018, the nation 
was ranked as number 25 worldwide.
In 2022, Indonesia was ranked as the 
48th largest country globally in exports of 
aluminium and articles thereof. It was also 
ranked at number 48 in 2021, number 46 
in 2020, number 51 in 2019, and number 
47 in 2018.
This information is according to the 
International Trade Centre (ITC). Unless 
otherwise stated, statistics detailing 
imports and exports of aluminium and 
articles thereof (hereafter noted as 
“aluminium and related products”) to and 
from Indonesia are approximate and are 
from the most recent reports issued by 
the ITC. This also includes the statistics 
detailing individual segments of the 
aluminium industry. Pic 1
Imports
Pic 2. Imports of aluminium and related 
products into Indonesia increased about 
11.2% overall from 2018 to 2022. There 
were, though, decreases in the intervening 
years. In 2019 to 2020, these types of 
imports decreased, but then increased in 
2021 and 2022.
In 2018, imports of these products 
amounted to (US) $2,172,792,000; in 
2019, (US) $1,891,555,000; in 2020, 
(US) $1,415,704,000; in 2021, (US) 
$2,086,137,000; and in 2022, imports 
of aluminium and related products were 
valued at (US) $2,416,068,000.
Major sources of aluminium and related 
products imported into Indonesia included 
countries in Asia, North America, and 
other nations in the Pacific Ocean region.
As has been the case with most 
countries, Indonesia’s largest source of 
aluminium and related products imported 
into the country was China for the time 
By Richard McDonough*
(The photograph 
was provided 
courtesy of Harry 
Purwanto.)
Aluminium industry 
in Indonesia
Richard alumina chronicles.indd 1Richard alumina chronicles.indd 1 26/02/2024 15:45:0426/02/2024 15:45:04
Aluminium International Today March/April 2024
THE ALUMINA CHRONICLES10
period from 2018 to 2022. Indonesia 
imported (US) $881,213,000 of these 
products from China in 2018; imports 
from that country increased to (US) 
$981,141,000 in 2022.
In addition to imports of these products 
into Indonesia from China, other nations 
that saw increases in actual amounts 
of imports into this country during that 
five-year time period were the United 
Arab Emirates (UAE), Australia, Malaysia, 
South Korea, Thailand, India, Singapore, 
and Taiwan. India saw its imports of these 
products into Indonesia more than double 
during this time period.
There were also decreases in the actual 
amounts of aluminium and related 
products imported from some countries. 
The USA, Japan, and Russia each saw its 
level of imports of these products into 
Indonesia decrease from 2018 to 2022.
The level of imports of these products 
from China amounted to 40.6% of all 
aluminium and related products imported 
into Indonesia in these two years.
All of the other sources of imports of 
aluminium and related products each 
represented less than 7% of all of these 
products imported into Indonesia in 2018 
and 2022.
The UAE, Australia, Malaysia, the 
USA, and South Korea were the next 
five sources of aluminium and related 
products imported into Indonesia in 2022. 
Respectively, these countries accounted 
for imports of these products valued 
at (US) $155,364,000 and represented 
6.4% of aluminium and related products 
imported in that year; (US) $151,147,000, 
6.3%; (US) $141,791,000, 5.9%; (US) 
$138,638,000, 5.7%; and imports of these 
products valued at (US) $135,652,000, 
representing 5.6% of aluminium and 
related products imported in 2022.
Other major sources of these products 
imported into Indonesia in 2022, the 
amounts of imports, and the percentage 
that those imports amounted to as a 
portion of all such imports into Indonesia 
were Thailand, (US) $82,985,000, 
3.4%; India, (US) $81,027,000, 3.4%; 
Singapore, (US) $78,320,000, 3.2%; 
Japan, (US) $67,035,000, 2.8%; Taiwan, 
(US) $60,182,000, 2.5%; and Russia, (US) 
$50,966,000, 2.1%.
Aluminium and related products 
imported from these 12 countries into 
Indonesia represented 87.9% of all of the 
imports of these products into the nation 
in 2022.
Five years earlier, in 2018, the USA was 
the second largest source of aluminium 
and relatedproducts imported into 
Indonesia with (US) $142,058,000 in 
these products; this represented 6.5% of 
all such imports in that year.
Other top sources were Australia, with 
imports into Indonesia of aluminium 
and related products valued at (US) 
$138,747,000 representing 6.4% of 
the import market for these products; 
Malaysia, with (US) $135,014,000 
representing 6.2%; the UAE, with (US) 
$121,254,000 representing 5.6%; and 
South Korea, with these products valued 
at (US) $101,150,000 representing 4.7% 
of the overall market for aluminium and 
related products imported into Indonesia 
in 2018.
Thailand, Japan, Russia, Singapore, 
India, and Taiwan were also major sources 
of these products imported into Indonesia 
in that year. The amounts and percentages 
those amounts represented of the import 
market into this country for 2018 were, 
respectively, (US) $79,363,000 and 
3.7%, (US) $78,332,000 and 3.6%, (US) 
$71,002,000 and 3.3%, (US) $69,623,000 
and 3.2%, (US) $32,425,000 and 1.5%, 
and (US) $26,226,000 and 1.2%.
The amount of products imported from 
the 12 countries noted represented 86.4% 
of all aluminium and related products 
imported into Indonesia in 2018.
Exports
Pic 3. The amount of exports of aluminium 
and related products from Indonesia 
increased 14.7% from 2018 to 2022. 
Other than a large decrease from 2018 to 
2019, there were increases in each of the 
other year-to-year pairings.
Aluminium and related products 
exported from Indonesia were valued 
at (US) $775,838,000 in 2018, and 
(US) $890,156,000 in 2022. In the 
intervening years, the amounts were (US) 
$527,027,000 in 2019, (US) $610,105,000 
in 2020, and (US) $784,542,000 in 2021.
Key export markets for Indonesia 
included nations in North America, Asia, 
Europe, and other nations in the Pacific 
Ocean region.
During the five-year time period 
from 2018 to 2022, exports of these 
products increased to China, Vietnam, the 
Netherlands, Australia, India, Papua New 
Guinea, Poland, and the United Kingdom 
(UK). Substantial increases in these exports 
occurred with each of these countries, 
with the exceptions of India that saw a 
more modest increase.
Exports of aluminium and related 
products from the USA, Malaysia, Japan, 
Thailand, and Singapore decreased from 
2018 to 2022; exports of these products 
decreased by more than half to Japan and 
Thailand during that time period.
In 2022, the top five export destinations 
Pic 1. Bauxite is mined and alumina is refined in West Kalimantan, Indonesia.
(The aerial photograph is provided courtesy of the United States Geological Survey, 2023.)
Pic 2. Sources of aluminium and related products imported 
into Indonesia in 2022.
(Image created with data provided courtesy of the 
International Trade Centre.)
Richard alumina chronicles.indd 2Richard alumina chronicles.indd 2 26/02/2024 15:45:0726/02/2024 15:45:07
Aluminium International Today March/April 2024
THE ALUMINA CHRONICLES12
for aluminium and related products 
produced in Indonesia were the USA, 
China, Vietnam, the Netherlands, and 
Australia. A total of (US) $185,563,000 
in these products were exported from 
Indonesia to the USA in 2022, (US) 
$104,178,000 to China, (US) $82,762,000 
to Vietnam, (US) $75,964,000 to the 
Netherlands, and (US) $71,885,000 to 
Australia.
These amounts represented 20.8%, 
11.7%, 9.3%, 8.5%, and 8.1%, 
respectively, of the exports of aluminium 
and related products from Indonesia in 
2022.
Other top destinations for these 
products exported from Indonesia in 
2022 were India – aluminium and related 
products valued at (US) $50,635,000, 
representing 5.7% of the overall amount 
of these exports; 
Malaysia: (US) $37,736,000, 4.2%; 
Papua New Guinea: 
 (US) $27,632,000, 3.1%; 
Japan: (US) $25,060,000, 2.8%; 
Thailand: (US) $24,056,000, 2.7%;
Singapore: (US) $19,292,000, 2.2%; 
Poland: (US) $19,091,000, 2.1%; and 
the UK: (US) $19,077,000, 2.1%.
The level of exports to the 13 countries 
noted represented 83.5% of all aluminium 
and related products exported from 
Indonesia in 2022.
In 2018, the top destinations for exports 
of aluminium and related products from 
Indonesia were the USA, Malaysia, Japan, 
Thailand, India, and Vietnam. Other major 
markets were Singapore, Australia, and 
Papua New Guinea. The Netherlands, the 
UK, China, and Poland were all, relatively 
speaking, small markets for aluminium 
and related products exported from 
Indonesia in 2018.
Indonesia exported (US) $344,265,000 
in these products to the USA in 2018, 
(US) $65,341,000 to Malaysia, (US) 
$57,623,000 to Japan, (US) $52,073,000 
to Thailand, (US) $42,213,000 to 
India, (US) $39,414,000 to Vietnam, 
(US) $30,712,000 to Singapore, (US) 
$15,108,000 to Australia, (US) $9,846,000 
to Papua New Guinea, (US) $4,334,000 
to the Netherlands, (US) $3,365,000 to 
the UK, (US) $2,661,000 to China, and 
(US) $217,000 in aluminium and related 
products to Poland in 2018.
Exports of these products from 
Indonesia to the USA represented 44.4% 
of the overall market of aluminium and 
related products exported from this 
country in 2018; to Malaysia, 8.4%; to 
Japan, 7.4%; to Thailand, 6.7%; to India, 
5.4%; to Vietnam, 5.1%; to Singapore, 
4%; to Australia, 1.9%; and to Papua New 
Guinea, 1.3% in 2018.
The Netherlands, the UK, China, and 
Poland each represented less than 1% of 
aluminium and related products exported 
from Indonesia in 2018.
Exports to these 13 countries represented 
about 84.6% of all aluminium and related 
products exported from Indonesia in 
2018.
The ITC also provided additional details 
about production and trade for different 
portions of the aluminium industry. In 
one of the market segments, for example, 
Indonesia is a substantial part of this 
industry: the country is the third largest 
exporter of aluminium ore worldwide. 
Unlike with other market segments, 
though, all of the aluminium ore exported 
from Indonesia, according to the ITC, has 
been exported to one nation from 2018 
through 2022.
Raw Aluminium
Pic 4. The ITC reported that Indonesia 
was the 28th largest importer of raw 
aluminium in 2022. The country imported 
(US) $726,629,000 in raw aluminium in 
that year; this amount represented less 
than 1% of total imports of this product 
into all nations.
In 2018, Indonesia was the 25th largest 
importer of raw aluminium among all 
countries. A total of (US) $641,386,000 
in raw aluminium was imported into the 
nation at that time, representing about 
1% of worldwide imports of this product.
Imports of raw aluminium into 
Indonesia increased from 2018 to 2022 
from the UAE, Malaysia, India, Qatar, 
South Korea, South Africa, Spain, Bahrain, 
Taiwan, Nigeria, and Singapore. India, 
South Korea, South Africa, and Bahrain 
each saw their imports of this product 
into Indonesia more than double during 
this time period, whilst Spain and Nigeria 
saw increases that were more than four-
fold in 2022 from relatively small amounts 
of these imports in 2018.
There were decreases in the actual 
amounts of raw aluminium imported from 
Australia and Russia into Indonesia from 
2018 to 2022.
Raw aluminium imported into 
Indonesia in 2022 included products 
valued at (US) $153,447,000 from the 
UAE, (US) $108,354,000 from Australia, 
(US) $98,727,000 from Malaysia, (US) 
$69,512,000 from India, and (US) 
$50,703,000 from Russia.
Imports from these top five sources 
represented more than two-thirds (66.2%) 
of all raw aluminium imported into 
Indonesia in 2022. Specifically, imports 
of this product from the UAE represented 
21.1% of the total; from Australia, 14.9%; 
Pic 3. Destinations of aluminium and related products 
exported from Indonesia in 2022.
(Image created with data provided courtesy of the 
International Trade Centre.)
PIC 4. Sources of raw aluminium imported into Indonesia 
in 2022.
(Image created with data provided courtesy of the 
International Trade Centre.)
Pic 5. Export destinations of raw aluminium produced in 
Indonesia in 2022.
(Image createdwith data provided courtesy of the 
International Trade Centre.)
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THE ALUMINA CHRONICLES 13
Aluminium International Today March/April 2024
from Malaysia, 13.6%; from India, 9.6%; 
and from Russia, 7% of the total in 2022.
Other sources of raw aluminium 
imported into Indonesia in 2022 were 
from Qatar, (US) $43,276,000; 
from South Korea, (US) $41,466,000; 
from South Africa, (US) $18,959,000; 
from Spain, (US) $16,476,000; 
from Bahrain, (US) $15,620,000; 
from Taiwan, (US) $15,351,000; 
from Nigeria, (US) $14,356,000; and 
from Singapore, (US) $14,036,000.
Combined, the top 13 sources of raw 
aluminium represented 90.9% of all of the 
product imported into Indonesia in 2022.
In 2018, the UAE, Australia, and 
Malaysia were also the top sources of 
raw aluminium imported into Indonesia. 
The amounts and percentages of the 
total imports of this product were, 
respectively, (US) $120,637,000, 18.8%; 
(US) $116,407,000, 18.1%; and (US) 
$85,971,000, 13.4%.
Russia was the fourth largest source 
of raw aluminium imported into this 
nation in 2018. Indonesia imported (US) 
$70,870,000 in raw aluminium from 
Russia in that year, representing 11% of all 
imports of this product.
Amounts of raw aluminium imported 
into Indonesia from other major sources 
of this product in 2018 included (US) 
$39,803,000 
from Qatar, (US) $28,239,000 
from India, (US) $18,053,000 
from South Korea, (US) $13,005,000 
from Taiwan, (US) $11,651,000 from 
Singapore, and (US) $7,363,000 from 
South Africa. 
These amounts represented, respectively, 
6.2%, 4.4%, 2.8%, 2%, 1.8%, and 1.1% of 
all of this product imported into Indonesia 
in 2018.
Collectively, these top ten sources of 
raw aluminium imported into Indonesia 
in 2018 represented 79.8% of all of the 
imports of this product in that year.
Pic 5.
Indonesia was ranked as the 38th 
largest exporter globally of raw aluminium 
in 2022. The country exported (US) 
$361,190,000 in raw aluminium at that 
time. In 2018, Indonesia was the 43rd 
largest exporter of raw aluminium among 
all countries. A total of (US) $194,105,000 
in raw aluminium was exported from the 
nation in that year.
In both 2022 and 2018, these amounts 
represented less than 1% of total exports 
of this product from all nations in those 
two years.
Exports of raw aluminium from 
Indonesia more than doubled to Vietnam 
from 2018 to 2022. According to the ITC, 
there were zero exports of raw aluminium 
to China, the Netherlands, and India in 
2018; all three nations were destinations 
of large amounts of raw aluminium from 
Indonesia in 2022.
There were decreases in the actual 
amounts of raw aluminium exported 
from Indonesia to Malaysia, Japan, and 
Thailand from 2018 to 2022.
In 2022, the main destinations for raw 
aluminium produced in Indonesia were:
China, (US) $102,042,000; 
the Netherlands, (US) $75,422,000; 
Vietnam, (US) $70,600,000; 
India, (US) $28,723,000; 
Malaysia, (US) $24,226,000; 
Japan, US) $11,087,000; and 
Thailand, (US) $8,749,000.
These amounts represented 88.8% 
of all of the exports of raw aluminium 
from Indonesia in 2022. The individual 
percentages for the top seven markets 
listed for this product were 28.3%, 
20.9%, 19.5%, 8%, 6.7%, 3.1%, and 
2.4%, respectively.
In 2018, the top four destinations for 
raw aluminium produced in Indonesia 
were Malaysia, with (US) $47,432,000 
in this product representing 24.4% 
of all of this product exported in that 
year; Japan, with (US) $41,719,000 and 
21.5%; Thailand, with (US) $39,796,000 
and 20.5%; and Vietnam, with (US) 
$24,667,000 and 12.7%.
These four nations represented 79.1% 
of all of the exports of this product in that 
year.
Aluminium Ore (Bauxite)
Pic 6. Indonesia is not a major importer 
of aluminium ore. The nation was the 
59th largest importer of aluminium ore in 
2022. In that year, the country imported 
(US) $780,000 in aluminium ore; this 
amount represented less than 1% of all 
worldwide imports of aluminium ore.
In 2018, the country was the 64th 
largest importer of this product. At that 
time, Indonesia imported (US) $608,000 in 
aluminium ore. Globally, this represented 
less than 1% of all imports of aluminium 
ore.
Imports of aluminium ore into Indonesia 
increased from Guyana, China, Brazil, 
South Korea, and the UK from 2018 to 
2022. Other than China, according to the 
ITC, the level of imports from each of the 
other four countries was zero in 2018.
The amount of imports of this product 
into Indonesia decreased dramatically 
from the Netherlands and India during 
this five-year time period.
Guyana was the source of (US) 
$397,000 of the aluminium ore imported 
Pic 6. Sources of aluminium ore imported into Indonesia 
in 2022.
(Image created with data provided courtesy of the Inter-
national Trade Centre.)
Pic 7. Sources of scrap aluminium imported into Indonesia 
in 2022.
(Image created with data provided courtesy of the 
International Trade Centre.)
Pic 8.Export destinations for scrap aluminium produced in 
Indonesia in 2022.
(Image created with data provided courtesy of the 
International Trade Centre.)
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Aluminium International Today March/April 2024
THE ALUMINA CHRONICLES14
into Indonesia in 2022. Other large 
suppliers of aluminium ore were China, 
(US) $117,000; Brazil, (US) $78,000; 
South Korea, (US) $72,000; and the UK, 
(US) $36,000.
Together, these five countries 
represented 89.7% of all of the aluminium 
ore imported into Indonesia in 2022. 
The percentages of the aluminium ore 
imported into the country in that year 
were 50.9% from Guyana, 15% from 
China, 10% from Brazil, 9.2% from South 
Korea, and 4.6% from the UK.
In 2018, the Netherlands, India, China, 
and Germany were the four major sources 
of aluminium ore imported into Indonesia. 
The nation imported (US) $313,000 in 
aluminium ore from the Netherlands in 
that year, (US) $136,000 from India, (US) 
$96,000 from China, and (US) $23,000 
from Germany.
The four nations represented 93.5% of 
all aluminium ore imported into Indonesia 
in 2018. The percentages of the aluminium 
ore that the country imported in 2018 
were 51.5% from the Netherlands, 22.4% 
from India, 15.8% from China, and 3.8% 
from Germany.
Whilst Indonesia has been a modest 
importer of aluminium ore, the nation is 
one of the major exporters of this product.
Indonesia was the 3rd largest exporter 
of aluminium ore in 2022; the country 
was the 4th largest exporter of this 
product in 2018. Exports of this product 
more than doubled during that five-year 
time period. Total exports of aluminium 
ore were (US) $263,601,000 in 2018 and 
(US) $623,001,000 in 2022.
These exports represented 8.2% of 
all aluminium ore exported worldwide 
in 2022 and 5.3% of all of this product 
exported globally in 2018.
China, according to the ITC, was the 
destination of the aluminium ore exported 
from Indonesia during each year from 
2018 to 2022.
Scrap Aluminium
Pic 7. According to the ITC, Indonesia 
was the 22nd largest importer of scrap 
aluminium in 2022. In that year, the 
country imported (US) $284,862,000 in 
scrap aluminium; this amount represented 
1.1% of all global imports of scrap 
aluminium.
Five years earlier, the country was the 
17th largest importer of this product. 
In 2018, Indonesia imported (US) 
$204,332,000 in scrap aluminium. 
Globally, this represented 1.3% of all 
imports of scrap aluminium.
Indonesia increased its importation of 
scrap aluminium from 2018 to 2022 from 
the USA, Australia, Taiwan, Germany, and 
Singapore, whilst amounts of this product 
imported into Indonesia decreased from 
the UK. Imports of scrap aluminium from 
Australia almost more than doubled, 
whilst the levels of imports of this product 
from Taiwan and Germany increased 
substantially in 2022 from small amounts 
in 2018.The USA, Australia, Taiwan, Germany, 
the UK, and Singapore were the top six 
nations from which Indonesia imported 
scrap aluminium in 2022. The amounts of 
this product imported from these countries 
were, respectively, (US) $128,649,000, 
(US) $40,906,000, (US) $27,509,000, 
(US) $27,255,000, (US) $26,283,000, and 
(US) $6,815,000.
Together, these six countries represented 
90.4% of all scrap aluminium imported 
into Indonesia in 2022. The percentages 
of the scrap aluminium imported into the 
country in that year were 45.2% from the 
USA, 14.4% from Australia, 9.7% from 
Taiwan, 9.6% from Germany, 9.2% from 
the UK, and 2.4% from Singapore.
In 2018, the USA, Australia, and the 
UK were the three major sources of scrap 
aluminium imported into Indonesia. The 
country imported (US) $112,711,000 in 
scrap aluminium from the USA in that 
year, (US) $32,214,000 from the UK, (US) 
$20,273,000 from Australia, and (US) 
$5,064,000 from Singapore. The amounts 
imported from Germany and Taiwan were 
relatively modest compared to the levels 
of other nations – (US) $1,728,000 and 
(US) $801,000, respectively.
These six nations represented 84.6% 
of all scrap aluminium imported into 
Indonesia in 2018. The percentages of 
the scrap aluminium the country imported 
in that year were 55.2% from the USA, 
15.8% from the UK, 9.9% from Australia, 
and 2.5% from Singapore; imports of this 
product were less than 1% from both 
Taiwan and Germany.
Pic 8.
Indonesia was a relatively small source 
of scrap aluminium exports in both 2022 
and in 2018, according to the ITC. In 
2022, the country ranked as the 75th 
largest exporter of this product worldwide. 
Indonesia exported (US) $19,019,000 in 
scrap aluminium in that year, representing 
less than 1% of all global exports of the 
product.
In 2018, Indonesia exported (US) 
$15,376,000 in scrap aluminium. The 
country was ranked as the 67th largest 
exporter of this product in that year. As 
in 2022, the nation represented less than 
1% of all exports of scrap aluminium 
throughout the world.
Indonesian exports of scrap aluminium 
more than doubled to South Korea and 
Thailand from 2018 to 2022; this type 
of exports also increased to Japan during 
the five-year time period. The amount of 
exports of scrap aluminium to Singapore 
decreased by more than 40%, whilst 
exports of this product to Saudi Arabia 
decreased substantially from 2018 to 
2022.
South Korea, Thailand, Japan, and 
Singapore were the top four export 
destinations for scrap aluminium produced 
in Indonesia in 2022. The amounts of 
this product exported to these countries 
were, respectively, (US) $10,050,000, (US) 
$4,541,000, (US) $1,529,000, and (US) 
$1,320,000.
The four nations represented 91.7% 
of all scrap aluminium exported from 
Indonesia in 2022. The percentages of 
the scrap aluminium exported from the 
country in that year were 52.8% to South 
Korea, 23.9% to Thailand, 8% to Japan, 
and 6.9% to Singapore.
In 2018, those four countries plus Saudi 
Arabia were the major destinations for 
scrap aluminium exported from Indonesia. 
The country exported (US) $4,858,000 
in scrap aluminium to South Korea in 
that year, (US) $3,926,000 to Saudi 
Arabia, (US) $2,448,000 to Singapore, 
(US) $1,667,000 to Thailand, and (US) 
$1,290,000 to Japan.
The five nations represented 92.3% 
of all scrap aluminium exported from 
Indonesia in 2018. The percentages of 
the scrap aluminium exported from the 
country in that year were 31.6% to South 
Korea, 25.5% to Saudi Arabia, 15.9% to 
Singapore, 10.8% to Thailand, and 8.4% 
to Japan. �
Richard alumina chronicles.indd 5Richard alumina chronicles.indd 5 26/02/2024 15:45:4826/02/2024 15:45:48
AUTONOMOUS 
CHARGING & 
SKIMMING 
MACHINES
Aluminium International Today March/April 2024
EUROPEAN UPDATE16
European Aluminium calls for a real 
“Industry Decarbonisation Deal” 
*Director of Climate Change & Energy, European Aluminium.
The European Commission unveiled its Communication ‘Securing our future: Europe’s 2040 climate 
target and path to climate neutrality by 2050 building a sustainable, just and prosperous society’ 
outlining the needed climate and energy policy framework post-2030. European Aluminium provided 
Aluminium International Today with an exclusive interview with Emanuele Manigrassi*.
The Industry Decarbonisation Deal: 
The framework recommends an ambitious 
greenhouse gas (GHG) emissions reduction 
target of 90% by 2040, compared with 
1990 levels. This presents a significant 
opportunity and challenge for the 
aluminium industry, as demand is set to 
surge in support of the green transition. 
European Aluminium emphasises the 
pressing need for coherent energy, trade 
and industrial policies that facilitate 
the industry’s decarbonisation and 
incentivising recycling while remaining 
competitive on global markets. This will 
enable the industry to meet the growing 
demand with sustainable aluminium 
‘made in Europe’.
The EU is significantly ahead of 
other countries and regions in climate 
ambition, mandating substantial emission 
reductions in every sector and installation. 
Achieving this goal requires a harmonised 
policy approach across various domains, 
including trade, energy, and industrial 
strategy, ensuring that Europe remains 
competitive while progressing towards 
decarbonisation. Aluminium is the 
most used non-ferrous metal globally, 
delivering energy and CO2 savings in 
leading sectors, including mobility and 
transport, packaging, consumer goods, 
and building and construction. Large 
volumes of aluminium will also be required 
to produce solar panels, batteries, electric 
vehicles, wind turbines, heat pumps and 
hydrogen electrolysers. To satisfy the 
EU’s targets for a fast energy transition, 
the additional demand for aluminium in 
Europe will reach 5 million tonnes per year 
by 2040, equivalent to an increase of 30% 
compared to Europe’s total aluminium 
consumption today[1].
However, Europe’s higher climate 
ambitions cannot be achieved at the 
expense of its manufacturing capacity 
nor increase import dependencies across 
the aluminium value chain. Energy costs 
in Europe are still too high compared to 
our global competitors, hindering the 
possibility to invest in the decarbonisation 
and recycling processes needed to achieve 
climate neutrality by mid-century [2 and 3].
“The link between climate, trade and 
industrial policy must be strengthened 
and at the forefront of the agenda of 
the next EU Commission. We are ready 
to work with the EU Commission and the 
Member States on bridging solutions to 
bring down the cost of energy and boost 
the transformation of our industry while 
remaining competitive on global markets,” 
notes Paul Voss, Director General of 
European Aluminium. The EU needs to 
therefore step up its overall energy security 
by scaling up investments in decarbonised 
energy systems, clean technologies, and 
infrastructure, while making full use of 
the provisions of the Critical Raw Materials 
and Net Zero Industry Acts, which both 
recognise aluminium as a strategic raw 
material and component for Europe’s 
green transition. Both pieces of legislation 
will have to be thoroughly implemented 
to ensure aluminium manufacturing, 
processing and recycling remains and 
grows in Europe.
Last year, the EU27 lost 50% of its 
primary aluminium production as a result 
of the energy crisis. Prior to the crisis, 
the EU had already lost one-third of its 
primary aluminium production capacity 
over the preceding 15 years due to 
uncompetitive operating conditions in 
Europe. This European production was 
replaced by production in other countries, 
with a much higher carbon footprint.
“The proposed ‘Industrial 
Decarbonisation Deal’ will have to 
include strengthened carbon leakage 
protection measures that go well beyond 
existing untested mechanisms such as the 
Carbon Border Adjustment Mechanism 
(CBAM). We regret to see that in the 
Communication, there is no reference toany additional carbon leakage protection 
measures complementing the CBAM. 
These will be urgently needed to ensure 
our industry can remain competitive while 
delivering on our commitment to reach net 
zero by 2050. The European Aluminium 
value chain needs enhanced carbon 
leakage measures beyond the unproven 
CBAM. The current tool has numerous 
loopholes and avenues for circumvention, 
which are insufficient to safeguard the 
European aluminium industry against 
carbon leakage and to effectively reduce 
global emissions[4]” he concludes.
In response to these policy challenges, 
European Aluminium has published a 
study identifying technological pathways 
for which more research and financial 
resources will be urgently needed to 
achieve net-zero emissions by 2050.
European alu.indd 1European alu.indd 1 26/02/2024 15:48:3426/02/2024 15:48:34
17
European Aluminium emphasises the 
pressing need for coherent energy, trade 
and industrial policies that facilitate 
the industry’s decarbonisation and 
incentivising recycling while remaining 
competitive on global markets”. Could 
you expand on ‘coherent energy’ policy, 
in light of the energy crisis of 2023? What 
do you wish to see from the European 
commission with regards to energy 
policy, will this focus on energy security 
over renewability and/or vice versa? 
In Europe, energy costs for aluminium 
producers remain excessively high 
compared to other regions worldwide. 
The energy crisis of 2022-2023 
highlighted the vulnerability of European 
producers, resulting in approximately 50% 
curtailments of EU27 primary aluminium 
capacity. This trend followed a 15-year 
period during which the EU lost one-
third of its primary aluminium production 
capacity due to uncompetitive operational 
conditions because of the too high-power 
prices in Europe. Furthermore, the spike 
in gas prices severely hit the recycling and 
transformation sectors. While gas prices 
in Europe are lower than last year, they are 
still too high compared to other regions. 
Consequently, European production is 
replaced by production from countries, 
which tend to have significantly higher 
carbon footprints.
So what we really need is cost-
competitive, low-carbon energy, at a price 
that allows us to compete with other 
global players. This issue is particularly 
sensitive in Europe due to variations 
in energy cost structures, especially on 
electricity, among EU Member States. 
The variations are due to the countries’ 
electricity mix, national surcharges, and to 
what extent the indirect carbon costs of 
the EU Emissions Trading System (ETS) are 
passed on in the power price by electricity 
suppliers. Additionally, the possibility to 
enter long-term contracts varies across 
the Union, depending on whether 
An Interview with 
Emanuele Manigrassi:
Member States have State Aid schemes 
to support their national champions, 
storage, infrastructure, and level of grid 
interconnections.
The recent energy crisis highlighted 
this reality: countries with deep pockets 
could support their industrial champions, 
whereas others faced challenges. Notably, 
82% of total national aid approved by 
the EU Commission was allocated to 
just three Member States: Germany 
(53%), France (24%), and Italy (7.6%). 
Therefore, a “coherent” energy policy 
should encompass measures to align with 
Europe’s broader industrial, trade, and 
security objectives. This means diversifying 
energy sources to mitigate overreliance on 
any single source, implementing a unified 
European approach to boost investments 
in renewable energy infrastructure, 
incentivising renewable energy projects, 
fostering research and development in 
renewable energy technologies, and 
finding ways to reduce the cost of 
consuming low-carbon energy for trade-
exposed industries like aluminium.
“The proposed ‘Industrial Decarbonisation 
Deal’ will have to include strengthened 
carbon leakage protection measures 
that go well beyond existing untested 
mechanisms such as the Carbon Border 
Adjustment Mechanism (CBAM).” How 
do you suggest CBAM is strengthened? 
How will a strengthened CBAM benefit 
EU industry? 
We have always opposed the idea of the 
Carbon Border Adjustment Mechanism 
(CBAM). In our view, it cannot be designed 
in a way that would offer us the same 
level of protection provided by the existing 
carbon leakage protection measures in 
place in Europe. Additionally, we identify 
many unaddressed loopholes, ranging 
from the potential risk of resource shuffling 
(i.e. redirecting low-carbon aluminium to 
Europe while exporting carbon-intensive 
aluminium to other regions) to the 
manipulation of declared trade codes 
at the border, the over declaration of 
scrap content to lower costs, or simply 
importing higher value-added products 
further down the value chain that are not 
yet covered by the CBAM’s product scope.
This is why it is vital for our industry 
that the EU does two things: firstly, 
acknowledging that the CBAM cannot 
serve as the sole carbon leakage 
protection measure for European industry, 
and secondly, exploring alternative tools 
to safeguard industry interests should 
the CBAM fail to achieve its intended 
objectives. Even with the implementation 
of the CBAM, our low-carbon producers 
will continue to pay the indirect carbon 
costs embedded in power prices due to the 
ETS and the marginal pricing mechanisms 
applicable to European electricity markets. 
Conversely, low-carbon imports will 
remain unaffected. So, we need to look 
at alternative carbon leakage protection 
measures that can truly level the playing 
field.
Interestingly, the need for alternatives 
was initially included in the first draft of 
the 2040 target plan but was subsequently 
removed, probably because of the fear 
that mentioning “alternatives” could 
undermine the credibility of one of the 
EU’s flagship climate policies.
“In response to these policy challenges, 
European Aluminium has published a 
study identifying technological pathways 
for which more research and financial 
resources will be urgently needed to 
achieve net-zero emissions by 2050.”
More research and financial support are 
easy to request, but what is the likeliness 
that this will come about? How can 
EU industries support your call for an 
“industry Decarbonisation Deal”? 
The report is much more than a 
request for financial support. It marks the 
beginning of a journey and dialogue with 
energy and technology suppliers, as well 
as other industrial value chains, national, 
European, and international organisations, 
on how we can truly deliver a net-zero 
aluminium value chain in Europe. While 
European producers are already leading 
the way in decarbonisation, regulatory 
constraints and carbon costs in Europe are 
eroding the resilience of the value chain. 
The EU has only 16 years left to achieve 
its ambitious 90% Greenhouse Gas (GHG) 
reduction target, yet this imperative should 
not lead to deindustrialisation, a stark 
reality faced by industries in Europe. Our 
report reveals that without intervention, 
the necessary enabling conditions for a 
fully decarbonised energy system and 
most of the technologies required to 
achieve a fully decarbonised value chain 
will not be available before 2035. Every 
sector of the economy must contribute, 
and we propose three main lines of 
action: accelerating the decarbonisation 
of power generation and hydrogen at a 
competitive price for industry, prioritising 
and increasing investments in R&D for 
low-carbon technologies, and increasing 
scrap recovery and recycling in Europe. �
European alu.indd 2European alu.indd 2 26/02/2024 15:48:3926/02/2024 15:48:39
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CCR Aluminium Rod lines with smaller
production output for E.C. grade and
most common alloys: 1.5 tph to 3.5 tph
CCR Aluminium Rod lines with medium
production output for E.C. grade and
most common alloys: 4.5 tph to 6 tph
CCR Aluminium Rod lines with medium
production output for E.C. grade