Shaping the future: Key projects under the primary aluminium industry in 2024

Century Aluminum & MX Holdings team up

Century Aluminum Company, a leading global producer of primary aluminium, had entered into a memorandum of understanding with MX Holdings to establish a joint venture focused on manufacturing and marketing low-carbon secondary billets. The new joint venture is set to begin production in 2026, with an anticipated output of 250 million pounds annually. It will become the largest American-owned secondary billet supplier, catering to the automotive and general extrusion industries. Both companies are currently exploring potential sites in the Ohio Valley region for the facility's ideal location. MX Holdings, a global leader in the procurement, processing, and production of non-ferrous metals, will collaborate with Century Aluminum to create high-performance, technically advanced aluminium alloys with enhanced recycled content, produced using low-carbon processes. As part of the agreement, both companies will produce billets at their existing, wholly-owned Pennex facilities, with each company manufacturing a range of alloys tailored to meet the specific needs of their customers.

Vista Metals' new aluminium casting facility in Ohio

Vista Metals, a leading manufacturer of aluminium products, is reportedly investing $60 million to establish a new aluminium casting facility in Bowling Green, Kentucky, to bolster its position as a top supplier in the U.S. market. The new plant will span over 100 acres and include a 75,000-plus-square-foot facility. The company will benefit from support provided by Kentucky's workforce service providers, including no-cost recruitment and job placement services and reduced-cost customised training and job-training incentives. Vista Metals' aluminium products mainly produce seamless rolled rings, closed die forgings, and open die forgings for aerospace, defence, and manufacturing industries. According to the report, the company has already begun initial site preparations and will soon start phase-wise construction. This new investment will create more than 50 well-paying full-time jobs in Bowling Green.

Stage 2 of the HPA First Project 

Alpha HPA has reportedly begun construction on Stage 2 of the HPA First Project following the confirmation of its fire safety technology. The facility will become the world's largest high-purity aluminium materials manufacturing plant upon completion. This project marks a significant milestone as it advances the commercialisation of Alpha HPA's proprietary solvent extraction and refining technology. The facility will focus on producing ultra-pure aluminium for high-tech sectors, including semiconductors, lithium-ion batteries, and LED lighting. Stage 2 of the project is being led by Matthew Callanan, appointed GM Manufacturing in Gladstone, alongside Lisa Roobottom, overseeing the Stage 2 development.

Hindalco Industries plans to expand its capacity

Hindalco Industries, owned by the Aditya Birla Group, announced at its annual general meeting on August 22 that it will invest $10 billion in expanding its capacity. Chairman Kumar Mangalam Birla outlined plans for various ongoing and upcoming projects in aluminium and copper smelting, including the Aditya flat-rolled product plant, a new alumina refinery in Rayagada, and the Bay Minnette expansion at Novelis. One of Hindalco's major expansion initiatives is to increase the Aditya Aluminium smelter capacity by around 200,000 tonnes in Odisha, with a significant portion of the required power sourced from renewable energy. Additionally, Hindalco is developing a greenfield alumina refinery in Rayagada, Odisha, with the first phase set to have a capacity of 850,000 tonnes, expected to be commissioned in FY2026-27. These expansion plans are in response to India's growing domestic demand for aluminium.

Vedanta plans to set up industrial parks for aluminium

Vedanta Limited, an Indian multinational mining company, is reportedly planning to establish two new industrial parks—one dedicated to aluminium and the other to silver and zinc. The announcement was made by Vedanta's chairman, Anil Agarwal, in a LinkedIn post on Wednesday, August 28, with a hint that similar parks could be developed for the oil & gas and iron & steel sectors in the future. The company has also committed to ensuring a reliable supply of raw materials and renewable energy for these industrial parks. Currently, Vedanta operates an aluminium park in Jharsuguda, which houses aluminium smelters and power plants. The park is designed to attract downstream companies, fostering the development of a comprehensive aluminium ecosystem.

600,000-tonne prebaked anode project

On August 20, Sunstone Development announced the signing of a capital increase agreement with Geely Baikuang to jointly invest 290 million yuan into Tiandong Baikuang Santian Carbon Co., Ltd. Sun-stone Development will hold a 66 per cent stake following the investment, while Geely Baikuang will own 34 per cent. The funds will be used to construct a 600,000-tonne prebaked anode production facility in Tiandong County, Baise City, Guangxi Province, at the heart of the Nanning-Guiyang-Kunming Economic Corridor. Once completed, the project will address the demand for prebaked anodes from electrolytic aluminium enterprises in Baise and Guangxi. It will also contribute to the ongoing transformation and upgrading of the aluminium industry in southwest China. Furthermore, Sun-stone Development plans to leverage Guangxi's coastal ports to expand its presence in overseas markets. The facility is strategically positioned as a "bridgehead" to the China-ASEAN Free Trade Area, benefiting from excellent transport connections, including highways, railways, waterways, and air routes, which provide optimal logistical advantages.

Akatswiri Mineral Resources' $820M aluminium project

Akatswiri Mineral Resources is optimistic about its $820 million aluminium production project, which can potentially transform Malawi's industrial landscape significantly. The company has completed a feasibility study for mining bauxite deposits in the Mulanje Mountain region. It plans to refine the ore into alumina before smelting it into aluminium—a crucial metal used across various global industries. The bauxite deposits at the Linje and Lichenya sites on Mulanje Mountain are expected to yield substantial quantities, with an annual mining target of 580,000 metric tonnes. This output is projected to be processed into 100,000 metric tonnes of aluminium each year. With current market prices at $2,600 per tonne, the project could generate approximately $260 million in annual revenue, providing a significant economic boost for Malawi.

Yunnan Yongshun Aluminium's much-awaited project

Yunnan Yongshun Aluminium Company has successfully launched its 6MW photovoltaic DC connection to power its highly anticipated electrolytic aluminium project. This follows the deactivation of vacuum contactors in prefabricated compartments for photovoltaic 1 and 2 DC power routers. The pioneering project incorporates innovative techniques, including low-voltage DC conversion and protection devices, breaking traditional power supply technology barriers. It enables direct power supply from photovoltaic DC to electrolysis series while also supporting on-site consumption of distributed photovoltaics. This enhances the company's renewable energy utilisation and overall efficiency. By implementing this advanced technology, the project promotes direct supply of green power and plays a crucial role in advancing the company's sustainability goals. The technology offers broader potential and can be adapted for other non-ferrous metal smelting industries.

Conclusion

The aluminium projects highlighted above showcase the industry's commitment to innovation, sustainability, and economic growth. From the development of low-carbon and high-performance aluminium alloys to the integration of renewable energy sources, these initiatives reflect the ongoing transformation of the aluminium sector. By embracing advanced technologies, increasing recycling efforts, and investing in local communities, these projects contribute to a greener future while meeting the growing global demand for aluminium. As industries continue to prioritise circular economy and sustainable practices, these projects set the stage for a more efficient, eco-friendly and prosperous future for the aluminium industry globally.

These were some of the key projects for 2024, to know what 2025 may hold, reserve your copy of AL Circle’s Global Aluminium Industry Outlook 2025 today. Time is ticking—don’t miss out!