Oslo, Norway-based Norsk Hydro has started producing the first aluminum metal at its technology pilot in Karmøy to demonstrate its low emission and energy-efficient HAL4e process. Compared to the world average, the Hydro-developed technology will use 15 percent less energy in aluminum production and has the lowest carbon dioxide footprint.

The company launched the HAL Ultra R&D initiative in 2010, with the long-term vision of being able to produce aluminum at a specific DC energy consumption of only 10 kWh/kg without net CO2 emissions. The technology pilot is designed with an annual production capacity of approximately 75,000 tons, consisting of 48 cells running on the HAL4e technology (12.3 kWh/kg) and 12 cells using the latest HAL4e Ultra technology (11.5-11.8 kWh/kg). This is well under the world average of 14.1 kWh/kg aluminum and Hydro’s own average of 13.8 kWh/kg aluminum.

Compared with the technology used in Hydro plants in Sunndal and Qatar, the new pots will be 50 percent larger and produce 50 percent more metal from each pot, while also using less energy per kilo produced.

Total costs are estimated at NOK 4.3 billion (US$557 million), consisting of net project costs of NOK 2.7 billion (US$350 million) and around NOK 1.6 billion (US$207 million) in support from Enova.

Source: Norsk HydroSource: Norsk Hydro

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