EGA Advances With Next-Gen Smelting Tech To Boost Sustainable Aluminium Production

Emirates Global Aluminium (EGA) has finalised the design phase of its next-generation smelting technology, EX. The company plans to construct ten pilot EX reduction cells at its Al Taweelah aluminium smelter to test and validate performance. EGA aims for EX to be ready for full industrialisation by 2028.

EX reduction cells are larger than EGA’s latest DX+ Ultra technology, allowing higher amperage and improved current efficiency. This enhancement is expected to increase production capacity by up to 22 percent. The new technology features two variants: one focused on maximising productivity and the other on minimising greenhouse gas emissions.

The more productive variant of EX is designed to reduce greenhouse gas emissions per tonne of aluminium by around five percent. The lower energy variant aims for a reduction of approximately 12 percent. Both variants are expected to consume less electricity, lower net carbon consumption, and reduce anode effects.

Innovations in the EX technology design include improvements to busbars, superstructure, and potshells. These enhancements are anticipated to deliver better pot performance, lower surrounding temperatures, and create a more favourable working environment. The development of this new technology took 18 months by EGA’s Technology Development Design team.

EGA has been developing its own aluminium smelting technology in the UAE for over three decades. Since the 1990s, the company has used its proprietary technology in every smelter expansion and retrofitted all older production lines. In 2016, EGA became the first UAE industrial company to license its core process technology internationally through a deal with Aluminium Bahrain for their Potline 6 expansion project.

CEO's Vision

Abdulnasser bin Kalban, Chief Executive Officer of EGA, stated, "Technology development has been a foundation of our global competitiveness for decades. EX technology will enable the production of more aluminium with less energy and lower emissions, unlocking opportunities for EGA’s growth and helping us to meet the increasing global demand for the low carbon primary aluminium required to reach net zero by 2050."

The pilot reduction cells are scheduled for commissioning during the first quarter of 2025. DX+ Ultra is already recognised as one of the most efficient smelting technologies in the global aluminium industry.

EGA's commitment to innovation continues with the development of EX technology, aiming to enhance productivity while reducing environmental impact. This initiative aligns with global efforts towards achieving net-zero emissions by 2050.

With inputs from WAM