Page 28 from: Recycling International – March/April issue 2023

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STRONG AUTOMOTIVE
CONNECTION
Cassopolis is seen as the heartland of
the US automotive industry with
Michigan home to up to 90% of the
nation’s activity. ‘There was no better
location to position ourselves. We’re
right at the centre of it all.’
Delivery of the new site even sparked
an invitation to the White House to
discuss sustainable business models.
‘We know how important it is to pro-

mote recycling to legislators working
at all levels,’ she remarks. ‘They need
to know what’s going on in the indus-
try in real time. Staying in contact and
keeping key decision makers up-to-
date on our projects could attract
more backing for recyclers across the
board.’
Setting up a recycling hub in Michigan
also represents a ‘big step’ towards
providing the US with a steady stream
of high-grade aluminium scrap. She is

talking about Circal, a new product in
Hydro’s portfolio using at least 75%
scrap. ‘It was introduced on the
European market in 2019 and was met
with much enthusiasm. Our presence
in Michigan will allow us to bring
Circal to the US and Canada and we
will build from there.’
Hydro has pursued partnerships with
carmakers such as Mercedes Benz,
Volkswagen and Polestar and contin-
ues to collaborate with eco-minded
producers. ‘Ultimately, our goal is to
design a truly circular car,’ Guddal
insists. ‘We’re involved in several R&D
projects targeting this. If you look at
how vehicles were made traditionally,
we’ve already come a long way. By
providing Circal and other sustainable
aluminium products, we hope to raise
the bar even further.’
Today, the average aluminium content
of cars (including all types of power
train) stands at 179 kg with aluminium
castings making up 65%.
The rest represents sheet products
(19%), extrusions (11%) and forged
components (6%). Hydro points out
that large electric cars (EVs) have the
highest average aluminium content, at
442 kg, but that medium cars – the
C-segment – with an average 152 kg
average make up the lion’s share
(36%) of the total due to overall high-
er volumes.
Hydro expects the average aluminium
content of vehicles to increase by
approximately 20% by 2025, bringing
the overall average to 198kg across
the market. This trend is supported by
the growth in EV production. ‘This
surge in demand means we will see
more material will coming back from
our partners.’

DIGGING DEEPER
The anticipated influx of aluminium
will include both reclaimed end-of-life
cars and production scrap. ‘To ensure
we return as much as aluminium to the
loop as possible, we’re also working
on boosting our pre-consumer scrap
activities,’ Guddal says. This includes
extrusion scrap such as windows and
door frames from Hydro’s partners in
the construction sector. ‘Producers in
our network tell us it’s still necessary

HYDRO’S RECENT MILESTONES:
• December 2022: Hydro Lucé first plant in France certified by DNV to produce Hydro’s

aluminium product Circal which contains at least 75% scrap.
• September 2022: New 90 000 tonnes a year aluminium recycling plant in Szekesfehervar

(Hungary) is started with EUR 88 million investment. The site will create 80 new jobs and
is scheduled to open in Q1 of 2024.

• August 2022: Invests EUR 44 million in the upcoming Cressona (US) facility.
• July 2022: Invests EUR 13.3 million in Henderson (US) plant to expand recycled aluminium

production.
• July 2022: Aluminium recycling plant in Rackwitz (Germany) to provide automotive cus-

tomers with more post-consumer aluminium.
• In May 2022, Recycling plant in Clervaux (Luxembourg) produces 130 tonnes of alumini-

um made with 100% post-consumer scrap. This represents its first commercial volume of
near-zero carbon aluminium.

• May 2022, Recycling plant in Commerce, Texas was the first in the US to be certified by
DNV GL to produce Hydro Circal. Two months later, Hydro’s recycling plant in Henderson,
Kentucky was also certified.

• April 2022: Breaks ground on aluminium recycling plant in Cassopolis (US) with a project-
ed annual processing capacity of 120 000 tonnes.

• December 2021: Invests EUR 2.8 million in Deeside (UK) plant to increase recycling
capacity to 70 000 tonnes per year.

The construction of Hydro’s aluminium recycling plant in Michigan is now in full swing.

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