Novelis Fives Voerde foundry emissions cut by 40% with furnace upgrades in Germany

Novelis

The Novelis Fives Voerde foundry emissions project delivers a major decarbonisation step in downstream aluminium. Novelis upgraded three melting furnaces with Fives at its casting site in Voerde. The Novelis Fives Voerde foundry emissions initiative targets more than a 40% carbon reduction. It also delivers significant energy savings.

The upgrade used Fives’ TwinBed II burner technology. The project deployed North American TwinBed II burners and modernised furnace performance. Meanwhile, European customers want lower-carbon inputs for transport applications. Therefore, efficient furnace upgrades are becoming a fast route to emissions cuts.

TwinBed II burners boost efficiency and cut carbon intensity

The upgrade focused on three aluminium melting furnaces. Fives supplied TwinBed II burners for the retrofit. The company managed the project through its team in Bilbao.

Operational gains support both emissions and cost goals. Novelis expects significant energy savings from the new configuration. However, the full value depends on stable throughput and scrap mix quality. Therefore, the furnace upgrade also supports tighter process control and yield.

Low-carbon billets support automotive and aerospace supply chains

The Voerde foundry produces custom-made aluminium billets. It serves automotive and aerospace manufacturers with tailored billet specifications. As a result, lower-carbon aluminium billets can help buyers meet Scope 3 and product footprint targets.

Novelis’ European leadership framed the project as practical progress. Emilio Braghi said the upgrades reduce footprint and improve efficiency. Meanwhile, industrial buyers increasingly tie contracts to carbon reporting. Therefore, the Novelis Fives Voerde foundry emissions cut could strengthen supplier positioning in premium alloys.

The Metalnomist Commentary

Retrofits often beat greenfield builds because they cut emissions faster. Meanwhile, burner upgrades can unlock savings even before grid decarbonisation completes. Therefore, downstream aluminium plants should prioritize proven furnace efficiency projects.