Backed by the UK Department for Energy Security & Net Zero (DESNZ) under the Industrial Fuel Switching (IFS) Competition, the two-week trial involved converting a natural gas furnace to operate flexibly on hydrogen.

“It demonstrated that we can adapt our existing infrastructure to run on hydrogen without compromising safety, quality, or performance. It’s a practical step forward in reducing our site’s carbon footprint and preparing for a low-carbon future,” explained Allan Sweeny, Plant Manager at Novelis Latchford.

The trial proved hydrogen can be safely used in aluminium recycling, according to the UK firm, giving Novelis confidence it could cut up to 45,000 tonnes of CO2 a year at Latchford.

Broader deployment hinges on either a HyNet connection from 2031 or on-site electrolyser production.

Novelis stated that the existing infrastructure was successfully adapted, product quality remained consistent, and dual-fuel burners enabled operational flexibility.

Novelis partnered with Progressive Energy to deliver the project over a two-year period.

The milestone follows a series of successful tests earlier this year at the company’s Warrington site, where hydrogen was blended with natural gas at levels from 30–100% to assess infrastructure compatibility, product quality and emissions.

Additionally, Novelis is investing approximately $90m to double the recycling capacity for used beverage cans at Latchford. This expansion will increase capacity by 85 kilotonnes per year and reduce Novelis Europe’s CO2e emissions by more than 350,000 tonnes annually.