Constellium & PyroGenesis ally to revolutionise aluminium melting with plasma burner process

PyroGenesis Canada Inc., a leading high-tech firm specialising in designing, developing, and commercialising advanced plasma processes and sustainable solutions to reduce greenhouse gas emissions, is excited to reveal the signing of a collaboration agreement (the "LOI") with Constellium.

Constellium is one of the world's largest aluminium transformation and recycling companies. Together, the two entities will focus on developing cutting-edge plasma torches and associated processes designed as efficient heating sources for aluminium remelting furnaces.

How does a plasma torch operate

A plasma torch generates an intense electric arc that ionises the gas, forming superheated plasma. This plasma, characterised by temperatures exceeding those of traditional methods, promises a faster, more efficient, and environmentally friendly alternative to conventional burners.

"PyroGenesis was proud to host and work with the scientific team from Constellium during this important test campaign over the last several quarters. The results from this campaign have led to today's agreement to move forward with a planned scale-up to a full-size furnace at one of Constellium's casthouses," said Mr. P. Peter Pascali, President and CEO of PyroGenesis.

About the agreement

PyroGenesis and Constellium have agreed to deploy an industrial-scale aluminium remelting furnace, aligning with Constellium's decarbonisation strategy. The project will be executed in two distinct phases: conducting feasibility studies and engineering assessments and installing a demonstration plasma-heated furnace system within one of Constellium's aluminium casthouses.

This announcement builds upon PyroGenesis Canada Inc.'s earlier press releases, dated April 20, 2022, and March 31, 2023, which detailed updates on its expanding aluminium business offerings. The collaboration follows a recent, highly successful completion of an initial joint evaluation of plasma technology in aluminium melting test furnaces.

"PyroGenesis is quickly becoming the go-to plasma solution company for key players in heavy industry as they seek solutions to meet their global decarbonisation strategies. Constellium is one of the best examples of a global industry leader who is evaluating PyroGenesis' electric plasma torches as a fuel-switching possibility. We expect that with the energy transition trend only getting started, that others will follow the lead of influential and respected companies like Constellium," added Pascali.

Following successful initial laboratory trials, Constellium and PyroGenesis have solidified their collaboration by committing to test this cutting-edge technology at an industrial scale. This will involve implementing a demonstrator plasma-heated furnace system within one of Constellium's casthouses.

PyroGenesis – the go-to plasma company

PyroGenesis is quickly becoming the go-to plasma solution company for key players in heavy industry as they seek solutions to meet their global decarbonisation strategies. Constellium is one of the best examples of a worldwide industry leader who is evaluating PyroGenesis' electric plasma torches as a fuel-switching possibility. We expect that with the energy transition trend only getting started, that others will follow the lead of influential and respected companies like Constellium."

"As part of our decarbonisation roadmap, Constellium has been evaluating various solutions to support the decarbonisation efforts within our aluminium cast houses. We are delighted with the robust research and development collaboration alongside PyroGenesis, which culminated in a successful plasma test campaign at their facility. Our technical experts, hand in hand with their PyroGenesis peers, were able to demonstrate the highly promising potential of plasma torch applications in our cast house furnaces. This fruitful collaboration has paved the way for our next phase of partnership as we transition to a significantly larger furnace and facility," commented Mr. Ludovic Piquier, Senior VP Manufacturing Excellence and Chief Technical Officer of Constellium.

The Company's advancement of plasma torch technology for high-temperature furnaces is an integral component of its three-tiered solution ecosystem, designed to align with critical economic drivers within the global heavy industry sector. The development of plasma torches for aluminium melting furnaces falls under the Company's Energy Transition & Emissions Reduction tier. This initiative focuses on fuel switching by leveraging the Company's electric-powered plasma torches, enabling heavy industries to significantly reduce their reliance on fossil fuels and greenhouse gas emissions.