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Karmøy technology pilot

Hydro's pilot plant in Karmøy has the most climate and energy-efficient aluminium production technology in the world. The technology pilot is groundbreaking for Hydro, Norway and the world.

female worker in protective gear on factor floor
production start 2018. annual production 75.000 tonnes aluminium. 15% more energy efficient compared to world average. World's lowest co2 footprint.
The pilot plant produces aluminium with the highest energy efficiency and lowest CO2 footprint in the world. Photo: Hydro/Multiconsult

Hydro wants to use the technology pilot in Karmøy to roll out the world's most energy and climate-efficient technology for producing aluminium.

aluminium factory hall
Using 60 new pots, the pilot plant produces 75 000 tonnes of aluminium a year. Aluminium production started in early 2018. Photo: Hydro/Marius Motrøen

Compared with the world average, the technology developed by Hydro's researchers reduces energy consumption in aluminium production by 15 percent. The low energy consumption, coupled with high productivity, means that Hydro can safely say that the technology pilot in Karmøy is world leading in primary aluminium production.

In December 2020, a two-year internal testing program successfully verified the HAL4e production technology. Twenty of the 60 HAL4e pots were selected for the final performance test, which was conducted for 75 days between October and December. During the test period, a range of additional measurements were performed on a number of parameters and exact production figures were traced and recorded. The energy results came in at 12.27 kWh/kg Al – below the set target of 12.3 kWh/kg Al.

Technology developed by Hydro

Hydro is a world leader in research and development in the aluminium industry. In recent years, the researchers in Hydro's technology centers in Årdal and Porsgrunn in Norway and Neuss in Germany have developed the next generation in electrolysis technology that will reduce energy consumption and emissions in the aluminium industry. It is this technology that is being tested in a full-scale production plant.

male worker in protective gear on factor floor

75,000 tonnes of aluminium per year for cars and buildings

The pilot facility is built at Hydro's existing aluminium plant in Karmøy in Rogaland County, Norway. The pilot adds 75,000 tonnes of aluminium production per year to the existing capacity of approximately 200,000 tonnes.

Hydro Karmøy produces aluminium products used in plates and profiles in the construction and automotive industries, and aluminium wire for high voltage lines, among other applications.