As the aluminium industry faces increasing pressure to reduce carbon emissions, the need for innovative solutions to replace natural gas has never been greater. Mechatherm has long been a leading provider of advanced furnace technologies and is bringing decades of expertise to support the industry’s sustainable evolution.
The Role of Hydrogen in Aluminium Recycling
Aluminium recycling is already significantly more energy-efficient than primary production; however, furnace operations still heavily rely on hydrocarbon fuels. Hydrogen presents a sustainable opportunity for the sector, as its combustion produces water vapour instead of carbon emissions, aligning perfectly with global net-zero targets.
Yet, integrating hydrogen into aluminium production presents unique technical and safety challenges. This is where Mechatherm’s extensive experience in furnace design makes a critical difference.
Mechatherm’s Expertise in Hydrogen Fuel Switching
With over 50 years of industry leadership, Mechatherm has positioned itself as a key partner in the UK’s hydrogen fuel-switching initiatives. The transition to hydrogen requires in-depth feasibility studies and precise engineering to ensure efficiency, safety, and reliability in furnace operations.
As part of the UK government-backed Industrial Fuel Switching Programme, Mechatherm played a key role in the recent hydrogen fuel trials at Novelis Latchford.
Our team conducted advanced feasibility assessments to convert an existing furnace to hydrogen fuel, including:
- Computational Fluid Dynamics (CFD) Modelling – Predicting hydrogen’s combustion behaviour under real-world conditions.
- DSEAR Assessments – Identifying and mitigating fire, explosion, and pressurised gas risks.
- Fuel Blending and System Optimisation – Ensuring precise hydrogen integration for efficiency and performance.
Implementing Hydrogen in Aluminium Furnaces
Hydrogen has distinct properties compared to natural gas, including lower density and higher flame temperatures, requiring strategic system modifications.
To ensure safe and effective hydrogen combustion, Mechatherm implemented:
- Mass Flow Meters – Enabling accurate fuel blending and monitoring.
- UV Sensors for Flame Detection – Addressing the near-invisibility of 100% hydrogen flames.
- Optimised Pipework and Valves – Resizing components to achieve effective gas velocities.
The trial successfully tested hydrogen blends up to 100%, proving its viability as a future fuel for the aluminium sector. While these early successes are promising, industry-wide adoption will require continued investment in hydrogen supply, infrastructure, and cost management.
Driving the Future of Sustainable Aluminium Production
The UK government has committed £1 billion through its Net Zero Innovation Portfolio to accelerate the adoption of low-carbon technologies. Initiatives like the HyNet Project aim to establish a scalable hydrogen infrastructure, providing a long-term, sustainable alternative to natural gas.
Mechatherm has invested in extensive research to support this energy transition, helping the aluminium industry achieve its decarbonisation goals. With our expertise in hydrogen combustion and furnace upgrades, we are committed to delivering solutions that pave the way for a cleaner, more sustainable future.
Ready to future-proof your aluminium production? Contact Mechatherm today to explore how our hydrogen-ready furnace solutions can drive your decarbonisation strategy.
