Constellium tests hydrogen use in casthouses

Constellium, a Paris-based aluminum recycler and product producer, is moving toward industrial testing of hydrogen in its casthouses, marking a significant step in its commitment to decarbonizing its operations.

Constellium says recycling and casting are its most energy-intensive operations, representing roughly 50 percent of its direct greenhouse gas (GHG) emissions.

Building upon successful laboratory-scale trials conducted in 2022 by C-TEC, Constellium’s main R&D center, the company demonstrated that transitioning from natural gas to hydrogen has no adverse effects on energy efficiency, oxidation rate or product quality, according to the company, which also is focused on ensuring safe operations. This first demonstration phase has paved the way for industrial-scale testing at C-TEC.

“We are excited to embark on industrial testing of hydrogen utilization in our casthouse operations, now that our laboratory trials have affirmed the viability and safety of integrating hydrogen into our production processes,” says Ludovic Piquier, senior vice president, manufacturing excellence, and chief technical officer at Constellium. “Green hydrogen is a promising lever to help the transition to carbon-neutral production, and we are proud of our progress in this important field. Our goal is to ensure Constellium is ready for the adoption of green hydrogen when it becomes more accessible and cost-effective for industrial applications.”

Green hydrogen is produced using clean electricity from surplus renewable energy sources, such as solar or wind power, to electrolyze water, while blue hydrogen is produced mainly from natural gas using a steam reforming process that brings together natural gas and heated water in the form of steam.

Grey hydrogen is created from natural gas, or methane, using steam methane reformation but without capturing the greenhouse gases made in the process, and pink hydrogen is generated through electrolysis powered by nuclear energy.

To prepare for the industrial testing phase, C-TEC has equipped one of its furnaces with a highly efficient burner capable of operating with oxygen and natural gas and/or hydrogen. The first results are expected in the third quarter of this year. 

Constellium is actively involved in various multi-stakeholder projects aimed at advancing hydrogen technologies for industrial decarbonization. One notable initiative is HyInHeat (Hydrogen technologies for decarbonization of industrial heating processes), a European Union-funded initiative exploring the substitution of natural gas with hydrogen in aluminum and steel transformation processes.

In addition to its focus on hydrogen, Constellium is exploring alternative decarbonization technologies, including direct electrification solutions compatible with existing furnaces.