Novacium Unveils Breakthrough Waste-to-Energy Technology for Aluminum Recycling

Novacium, a France-based affiliate of HPQ Silicon Inc., has introduced a pioneering Waste-to-Energy (W2E) technology capable of transforming Black Aluminum Dross, a hazardous byproduct of aluminum recycling, into valuable resources. This innovative solution not only produces green hydrogen but also helps achieve a fully circular aluminum recycling process, significantly enhancing sustainability and resource efficiency.

Laboratory pilot tests have validated the technology’s potential, attracting the attention of top-tier European aluminum recyclers, several of whom have signed Non-Disclosure Agreements (NDAs) to explore the technology further. HPQ Silicon Inc. holds an exclusive license for this proprietary technology in North America.

Black Aluminum Dross (BAD), a toxic byproduct of secondary aluminum manufacturing, presents serious environmental and safety challenges due to its contamination with salts, nitrides, carbides, and other compounds. When exposed to water, BAD can release hazardous gases, contributing to environmental pollution and posing significant disposal costs—up to €600 per tonne in Europe.

Novacium’s W2E technology uses BAD as feedstock to produce green hydrogen while neutralizing the waste and converting the remaining material into valuable solid byproducts. This approach offers multiple benefits, including:

• Green Hydrogen Production: Facilitates clean energy generation.
• Heat Generation: Supports industrial processes.
• On-Site Treatment: Reduces transportation and disposal costs.
• Waste Neutralization: Minimizes environmental impact.

The global secondary aluminum market was valued at $98.87 billion in 2023 and is projected to reach $150.53 billion by 2030. However, approximately 4-5 million tonnes of BAD are generated globally each year, with 95% currently disposed of in landfills.

Dr. Jed Kraiem, COO of Novacium, emphasized the environmental and economic significance of this innovation, stating, “Our process not only addresses a longstanding challenge in aluminum recycling but also offers recyclers an opportunity to reduce costs and carbon footprints simultaneously.”

Industry expert Dr. Oliver Moos, Managing Director of Casthouse Engineering and Technology AG, praised the innovation, calling it the first promising approach to tackling the black dross issue.

Novacium is now focused on scaling the technology from lab to commercial applications. According to Bernard Tourillon, President and CEO of HPQ Silicon Inc. and Novacium SAS, potential cost savings from the technology could range from C$900 (€600) to C$1,500 (€1,000) per tonne of BAD processed.

With its scalable and flexible design, Novacium’s W2E technology represents a transformative advancement in aluminum recycling, paving the way for sustainable waste management and on-site hydrogen production.