EGA breaks ground for constructing 10 pilot reduction cells for its newest smelting technology, EX

Emirates Global Aluminium broke ground today to start constructing ten pilot reduction cells for EGA-EX, the next-generation smelting technology with more advanced features than EGA’s DX+ Ultra technology.

The ten pilot cells will be constructed at Al Taweelah smelter to test and validate the technology, backed by advanced Internet of Things sensors and connections that will enable seamless real-time data gathering and application of Industry 4.0 to ensure increased production capacity by 22 per cent, improved current efficiency, and reduced greenhouse gas emissions.

EGA-EX is designed in two variants – one to maximise productivity and another to minimise greenhouse gas emissions.

EGA intends to incorporate all its existing Industry 4.0 technologies in EX to develop it as a one-stop solution for autonomous control of pots, cranes, and vehicles. EGA-EX will also be equipped with machine learning to enable continuous process improvement and increase precise task planning.

EGA expects the first batch of production from the pilot reduction cells by the first half of 2025, aiming to make its newest technology ready for large-scale industrialisation by 2028.

Abdulnasser Bin Kalban, Chief Executive Officer of Emirates Global Aluminium, said: “For over 30 years, EGA has been at the forefront of aluminium smelting innovation. Today, we stand at a transformative crossroads. 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. Our bold goal is to create a self-optimising, 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.”

EGA completed the design phase of its EX smelting technology in June 2024 and has since been working on detailed engineering for the installation at Al Taweelah.