Hydro plans upgrading its aluminium units with LED lights for increased energy efficiency

Hydro’s Head of aluminium plants, Ola Sæter has described how the aluminium giant is planning to curtail unnecessary operational expenditures through the instalment of sensor-based LED lighting systems in its smelters. These latest energy efficiency measures might save up to 90% of energy costs making Hydro’s journey toward sustainability more profound.

Ola Sæter, remarked: "Efficient energy use is very important for our competitiveness. With new technology and solutions within energy efficiency, we see it is possible to cut even more of the electricity consumption in the smelters. This reduces the need for power and gives an environmental benefit both for Hydro and for Norway.”

The implementation of new energy efficiency measures will occur in a phased approach. Initially, the smelters will increase the frequency of replacing older lighting with LED lights. Simultaneously, a system that regulates lighting based on needs and movement will be established. This system has the potential to provide up to 90 percent energy savings compared to traditional lighting while also improving light quality, which is essential for the working environment and safety.

Hydro in Norway has made impressive strides in reducing its CO2 emissions by 55 percent since 1990 while also decreasing electricity consumption per tonne of aluminium produced. Nonetheless, Hydro will require substantial amounts of new renewable power over the next several years to power its aluminium plants. By 2030, power contracts with an energy capacity exceeding 5 TWh will expire, necessitating their replacement.

Head of Primary Production in Hydro, Ola Sæter, commented: "Our goal is clear. We are going all the way to zero and producing emission-free aluminium. It requires more power, but also that we leave no stone unturned and look at measures to reduce consumption along the entire value chain.”

"Many of our climate measures will require more electricity. Hydro is both a major electricity producer and consumer. We will therefore upgrade our own power production, develop new renewable power ourselves and implement comprehensive energy efficiency measures," added Sæter.

Hydro has made significant progress in the last year towards achieving its sustainability goals. This includes the production of near-zero carbon aluminium from recycled post-consumer scrap, as well as the implementation of carbon-capture technology in Sunndal. Furthermore, Hydro is actively developing new solutions for green hydrogen and biogas as a replacement for traditional fossil fuels. To execute these initiatives, Hydro Rein, the company's renewable energy division, will collaborate with all five plants to implement energy efficiency measures.

The Head of Energy Solutions in Hydro Rein, Marianne Wergeland Jenssen, exclaimed: "Both energy efficiency improvements and local energy production are important contributions to free up grid capacity and at the same time making more power available. Hydro Rein offers various energy solutions to help the industry optimize power consumption. As an example, we will use existing data in a better way so the plants can more easily measure individual measures and know whether they have an energy saving effect. We look forward to contributing to this important work for Hydro's plants in Norway.”

Smart LED lights are being installed in Hydro's production halls in Sunndal, Årdal, Høyanger, Karmøy, and Husnes to achieve a total savings of 50 GWh. The Vigelands Brug aluminum plant in Vennesla was the pilot for this project, which aims to reduce compressed air consumption and implement energy-efficient pump and fan operations. These measures could contribute to additional savings of 150-200 GWh by 2030. Hydro is also focusing on heat recovery from production processes, partnering with external organizations to utilize surplus heat.