Can Oklahoma reshape US aluminium supply? EGA’s Ziad Fares explains the project

As the US seeks to rebuild its domestic aluminium production capacity, Emirates Global Aluminium (EGA) and Century Aluminum are advancing plans for a new primary aluminium smelter in Inola, Oklahoma, targeting more than 750,000 tonnes of annual production.

In this exclusive conversation with AL Circle, Ziad Fares, Project Director for Oklahoma Primary Aluminum, discusses the project’s strategic rationale, progress towards a targeted construction start in early 2027, planned smelting technology, power and infrastructure requirements, investment considerations, and its potential impact on US aluminium supply chains. He also addresses environmental safeguards and stakeholder concerns.

Fares brings more than 20 years of experience across engineering, strategy, finance, metals and mining, and major growth projects. He joined EGA in 2015 and has held leadership roles spanning strategy, business development and finance, with experience in greenfield projects, joint ventures and strategic partnerships.

AL Circle: What was the strategic rationale behind EGA’s decision to invest in a new primary aluminium smelter in the US, and how does the Oklahoma project fit into EGA’s global growth strategy?

Ziad Fares: Oklahoma Primary Aluminum is a strategic investment in the long-term growth of the aluminium industry and in strengthening the US domestic supply of a critical material. The United States currently relies heavily on imports to meet its aluminium needs, creating a significant opportunity to rebuild domestic production capacity and expertise. For EGA, the project also represents an opportunity to bring our decades of experience in aluminium technology, project development and operations to the U.S. market. The partnership with Century Aluminum combines EGA’s global expertise with Century’s deep knowledge of the American aluminium industry.

AL Circle: The Oklahoma project is currently progressing through technical studies, engineering and permitting. What are the key milestones achieved so far, and what are the critical next steps before construction can begin?

Ziad Fares: The project has progressed significantly since its announcement, including the execution of a joint development agreement between EGA and Century, aiming to form a 60/40 joint venture between the companies to develop the project, and the selection of Bechtel to lead preparatory engineering. Bechtel is currently advancing technical design, infrastructure planning, value improvement and construction planning, while ERM is coordinating environmental and social consultation and permitting activities. The next major milestones are to complete the feasibility and permitting work, finalise the power agreement with the Public Service Company of Oklahoma and the Oklahoma Corporation Commission and make a final investment decision. Subject to those steps, the project is targeting the start of construction in early 2027.

AL Circle: The project is targeting more than 750,000 tonnes per year of primary aluminium production. What is the current timeline for construction, commissioning and reaching full production capacity, and what are the major factors that could influence this schedule?

Ziad Fares: The project is currently targeting start of construction in early 2027, with first hot metal expected by the end of the decade. Reaching full production capacity will follow the commissioning and ramp-up of the facility. As with any project of this scale, the schedule will depend on the completion of engineering, permitting, infrastructure development, procurement and construction activities.

AL Circle: What is EGA’s strategy for securing reliable, competitively priced electricity for the Oklahoma facility, and how important was Oklahoma’s power infrastructure in the site-selection process?

Ziad Fares: Reliable, competitively priced electricity is fundamental to the successful operation of a primary aluminium smelter and is therefore a central consideration in project development. Oklahoma’s abundant energy, existing industrial infrastructure, transportation connections and potential for further infrastructure development were important considerations in selecting this project location. The project team is continuing to work through the detailed power and infrastructure requirements as part of the engineering and feasibility process, as well as progressing its discussions with the Public Service Company of Oklahoma to finalise a long-term power supply agreement for the project.

AL Circle: What smelting technology and operational innovations does EGA plan to deploy at Oklahoma, and how will the facility compare with EGA’s existing smelters in terms of energy efficiency, productivity and carbon intensity?

Ziad Fares: The Oklahoma smelter is planned to use EGA’s latest EX smelting technology, which is EGA’s 10th generation of proprietary reduction technology and is designed to produce more aluminium using less energy and with lower emissions. EGA’s technology development has already reduced the electricity required per tonne of aluminium by 37.5 per cent since 1990. The Oklahoma facility will incorporate the latest advances in smelting efficiency, digital solutions, automation, environmental control technologies, and operational performance.

AL Circle: The project represents an estimated US$4 billion investment and has received significant government support. How are EGA and its partners managing the project’s capital costs, infrastructure requirements and broader economic risks in the current market environment?

Ziad Fares: A project of this scale requires disciplined capital planning, rigorous engineering and careful management of construction and infrastructure requirements. EGA and Century are working with experienced partners, including Bechtel, to optimise the project design, evaluate value-improvement opportunities and develop an efficient construction strategy. The project is also benefiting from government support that recognises the strategic importance of rebuilding U.S. primary aluminium production. Final capital commitments will be determined through the feasibility study and final investment decision process.

AL Circle: Once operational, how could the Oklahoma smelter change the US aluminium supply chain? In particular, which downstream sectors and customers do you expect to benefit most from the additional domestic primary aluminium supply?

Ziad Fares: Oklahoma Primary Aluminum will more than double current US primary aluminium production and significantly strengthen the domestic supply of a material essential to modern manufacturing. It will provide US manufacturers with a major new source of primary aluminium produced closer to their operations, helping strengthen supply-chain resilience and reduce reliance on imports. We expect the benefits to extend across industries including automotive, aerospace, construction, power transmission, packaging and other advanced manufacturing sectors. The project is also expected to catalyse an aluminium industry hub in Oklahoma and create 1,000 permanent direct jobs.

AL Circle: The project has also faced questions from some local stakeholders around environmental impact, emissions, land use and water resources. How is EGA addressing these concerns, and what environmental safeguards are being incorporated into the project from the design stage?

Oklahoma Primary Aluminum will utilise proven, world-class technology modelled after leading global aluminium facilities to minimise emissions. Environmental responsibility and operational excellence has been incorporated into the project from the earliest design stages and once operational, the plant will meet or exceed environmental requirements. Combined with modern, highly controlled operations and multiple layers of environmental safeguards, the facility is designed to set a new standard for advanced aluminium production. These safeguards include:

• Advanced Emissions Control: Fully enclosed production units, advanced air filtration and covered material handling will capture dust and gases at the source.
• Continuous Monitoring: 24/7 air quality monitoring ensures the facility operates well below state and federal safety standards.
• Rigorous Oversight: The project will be subject to strict oversight and permitting by the Oklahoma Department of Environmental Quality (ODEQ) and the U.S. Environmental Protection Agency (EPA), including opportunities for public review and input during the permitting process.