Aluminium industry at a crossroads: Baby steps won't work anymore to achieve sustainability amidst emission challenges

Aluminium production, one of the most energy-intensive metal industries, poses a nerve-wracking challenge for global mitigation efforts. A recent study published by Nature sheds light on the evolving dynamics of greenhouse gas (GHG) emissions in the aluminium sector and highlights the urgent need for innovative technologies and policy interventions to achieve net-zero goals.

Despite advancements in technology, such as the adoption of more efficient and higher amperage cells, the proportion of aluminium production powered by fossil fuel-based captive power units rose from 37 per cent in 2012 to 49 per cent in 2021. The study reveals that retiring these power plants ten years ahead of schedule could reduce emissions intensity by 5.0–10.5 tonnes of CO2 equivalent (tCO2e) per tonne of aluminium for smelters dependent on such energy sources. Furthermore, achieving net-zero targets necessitates retrofitting at least 18 per cent of smelting capacity with inert anode technology by 2040, increasing to 67 per cent by 2050.

Encouragingly, the industry has reached a pivotal moment. In 2023, while global aluminium production grew by 2.75 per cent, GHG emissions increased by a mere 0.36 per cent. This decoupling of production growth from emissions growth marks a significant milestone. The emissions intensity of aluminium production dropped by 2.33 per cent in 2023 and has declined by 11.5 per cent since 2020.

Miles Prosser, Secretary General of the International Aluminium Institute (IAI), remarked, "The latest data reinforces our confidence that the industry has reached a turning point, with metal production growth successfully decoupled from emissions growth. We are encouraged to see that the initiatives undertaken by IAI's member companies are enabling increased production without a significant rise in greenhouse gas (GHG) emissions."