Emirates Global Aluminium (EGA), a global leader in aluminium production, has officially launched the construction of a groundbreaking pilot reduction cell project for its innovative EX smelting technology at its Al Taweelah site in Abu Dhabi. The development of 10 pilot reduction cells marks a major step toward the full-scale industrialization of this next generation smelting technology, which is poised to significantly transform the aluminium production industry.

EX technology is designed to dramatically improve the efficiency of aluminium smelting, reducing both energy consumption and emissions. The technology the use of Internet of Things (IoT) sensors, real-time data gathering, and enhanced connectivity. These features will enable EGA to optimize its smelting processes and push the boundaries of digital transformation within the aluminium sector.

Industry 4.0 and AI-Powered Smelting

The EX smelting technology is central to EGA’s strategy to leverage digital capabilities and artificial intelligence (AI) to create a more sustainable and efficient aluminium production system. The introduction of IoT sensors and AI technology will enable real-time monitoring and optimization of the smelting process, including gaining autonomous control of critical equipment like pots, cranes, and vehicles. This level of automation is expected to reduce operational disruptions, improve efficiency, and continuously enhance production performance.

Machine learning algorithms will play a pivotal role in process optimization, enabling the system to learn from real-time data, predict failures, and adjust production parameters autonomously.

“The construction of our EX pilot reduction cells is not just a technological milestone, it is the foundation for a future of smart solutions to improve efficiency and ultimately sustainability,” said Abdulnasser Bin Kalban, Chief Executive Officer of Emirates Global Aluminium. “Our bold goal is to create a self-optimizing, autonomous production system that can be the most efficient in the world. This innovation is central to EGA’s growth strategy and our commitment to shaping a sustainable future for our industry.”

A Step Toward Large-Scale Industrialization

The first batch of hot metal from the pilot reduction cells is expected to be produced in the first half of 2025. The large-scale industrialization of EX technology will be fully integrated into the production process by 2028.

EX technology has already shown promising results in design and early-stage testing. It is set to increase EGA’s aluminium production capacity by up to 22%.

About Emirates Global Aluminium

Emirates Global Aluminium is one of the world’s largest producers of aluminium and a leading player in the global aluminium sector. Headquartered in the UAE, EGA is committed to driving innovation, sustainability, and growth across its operations. The company is actively engaged in the development and deployment of cutting-edge technologies to reduce emissions and improve the efficiency of its aluminium production processes.