Hydro building recycled casting line in Kentucky

Aluminum and renewable energy company Hydro is spending US$85 million on a new casting line at its aluminum recycling plant in Henderson, Kentucky. The new line will become operational in 2026 and supply the U.S. automotive market with components.

The investment is backed by tax incentives from the Kentucky Economic Development Finance Authority (KEDFA) and will provide 31 new jobs in the city of Henderson. The new casting line will increase capacity by 28 000 tonnes (62 million pounds) of aluminum. 

“Recycling more end-of-life scrap reduces emissions, strengthens security of supply and enables us to deliver new, cutting-edge products to our U.S. customers,” said Hydro’s president and CEO, Eivind Kallevik.

Hydro previously announced a $15 million investment in a new baghouse and homogenization equipment at the Hydro Henderson recycling plant. These projects are now nearing completion and will enable Hydro Henderson to produce larger volumes of advanced alloys using recycled, post-consumer scrap with a lower-carbon footprint. 

Hydro's aluminium recycling plant in Henderson, Kentucky.
Hydro’s aluminum recycling plant in Henderson, Kentucky.

The new project introducing HyForge technology at Hydro Henderson follows in the footsteps of the successful implementation of the HyForge casting technology at the Hydro Husnes primary plant in Norway and the Hydro Rackwitz recycling plant in Germany.

“Hydro Henderson has been at the forefront of producing recycling based automotive products for nearly twenty years. We work closely with the automotive industry and introducing Hydro’s HyForge technology will provide Hydro and our partners with a greener advantage, Made in America,” saidKallevik.

Greener growth meets market demand

The new HyForge casthouse is slated to become operational in 2026. Hydro Henderson will serve the automotive market’s need for smaller diameter billets that can be forged directly into automotive components. This means the number of processing steps from casthouse to automotive parts are greatly reduced, leading to cost efficiency and higher product quality compared to traditional processes.

“Taking advantage of the new technology and expanded capacity cater to the specific needs of our customers within the automotive industry to create light weight car parts, helping reduce emissions from driving. This expansion significantly increases the use of end-of-life aluminum, cutting emissions from creating the products themselves, ensuring market leading sustainability performance for Hydro and our customers,” Kallevik said.

By using a high share of end-of-life scrap, Hydro Henderson will deliver HyForge billets with a low CO2 footprint.