Novelis Commissions Electric Furnace
to Advance Carbon-Neutral Aluminium Production
·
Novelis has commissioned an electric pusher
furnace at its Sierre plant as part of its decarbonisation strategy.
·
The furnace is used to heat aluminium ingots
before the rolling process.
·
The project replaces a conventional natural
gas-fired furnace with an electrically powered system.
Environmental
Benefits
·
The switch is expected to reduce greenhouse gas
emissions by approximately 4,500 tonnes of CO₂ equivalent annually.
·
Overall energy consumption is projected to decrease
by around 25% compared with the previous gas-based system.
·
The lower carbon intensity of the electricity used
will contribute to a significant reduction in the plant’s:
o
Scope 1 emissions (direct
emissions).
o
Scope 2 emissions
(indirect emissions from purchased energy).
Technology
Features
·
An electric pusher furnace moves aluminium
continuously through a heated chamber using trays or carriers.
·
Key advantages include:
o
Precise temperature control.
o
Uniform heating.
o
Improved process efficiency.
o
Compatibility with protective atmospheres.
Origin of
the Innovation
·
The furnace concept emerged from the Net Zero
Lab Valais initiative launched by Novelis in 2022.
·
The initiative focuses on developing carbon-neutral
solutions for aluminium manufacturing.
Decarbonisation
Strategy
·
According to Serge Gaudin, Plant Manager of Sierre
and Director of Recycling Plants for Novelis Europe, the project represents
another step toward carbon-neutral operations.
·
The furnace supports Novelis’ long-term “3×30”
decarbonisation strategy, which aims to significantly reduce the company's
carbon footprint.
District
Heating Integration
·
Novelis has partnered with Oiken
to study expansion of Sierre’s district heating network.
·
The proposed expansion could supply approximately 20–30%
of the city's total energy demand.
·
The initiative builds on an earlier project that
supplied waste heat from Novelis’ aluminium casting operations to nearby
buildings.
Future
Plans
·
Novelis plans to:
o
Expand electrification across its operations.
o
Increase the use of low-carbon energy sources.
o
Develop additional decarbonisation technologies
throughout its production network.
Key
Takeaway
The commissioning of the electric pusher furnace
marks a major milestone in Novelis’ transition toward low-carbon aluminium
production. By replacing natural gas with electricity, the company expects to
cut emissions, improve energy efficiency, and move closer to its goal of
achieving carbon-neutral manufacturing while also supporting broader community
energy initiatives through district heating.
Operations are underway at
Novelis’ first electric pusher furnace at its Sierre plant in Switzerland.
The
pusher furnace is used to heat aluminium ingots prior to rolling. By
transitioning from natural gas to electricity, Novelis expects to cut emissions
by approximately 4 500 tonnes CO2eq per year and reduce overall energy
consumption by around 25% compared to the former gas-fired system. The
substantially lower carbon intensity of the electricity used results in net
reduction of total Scope 1 and 2 emissions.
Lab to plant floor
An
electric pusher furnace is where parts or materials are loaded onto trays and
moved continuously through a heated chamber. It is valued for its precise
temperature control, uniform heating and compatibility with protective
atmospheres.
The concept for the furnace originated from the Net Zero Lab Valais initiative,
which Novelis launched in February 2022 to develop carbon-neutral solutions for
aluminium manufacturing.
Leading the way
‘With
the commissioning of the electric pusher furnace, Novelis continues to lead the
way in sustainable aluminium manufacturing,’ says Serge Gaudin, plant manager
of Sierre and director of recycling plants for Novelis in Europe. ‘This
development moves the plant closer to achieving its goal of carbon-neutral
operations; a core component of our long-term 3×30 decarbonisation strategy.’
District heating
Novelis
has also initiated joint studies with Oiken to extend
Sierre’s district heating system, aiming to supply roughly 20%-30% of the total
energy needed by the city. This broader integration follows a project providing
waste heat from Novelis’ aluminium casting process to a nearby building
complex.
The
company plans to continue to scale electrification and low-carbon energy
integration at its Sierre plant, while also exploring broader decarbonisation
solutions across its production network.