SWG collaboration: Today’s economic pathway to net-zero alumina

Sahl Regen, Worley and GEA (SWG) have collaborated to demonstrate how integrating Sahl Regen’s KX Heat Exchanger with GEA’s Mechanical Vapour Recompression (MVR) evaporation can reduce Bayer-process energy consumption by around 70 per cent. The collaboration is reinforced by Sahl Regen’s Kassofor Programme, which advances Net-Zero goals through verified carbon capture in regenerated soils.

Image source: GEA

Key highlights of the article

• ~70 per cent total energy reduction of the Bayer process and full digestion electrification with KX + MVR.
• All KX components are individually proven, with the first integrated demonstration unit ready to build.
• Reuse of Bayer-contaminated waters and environmental compatibility of MVR condensate.
• Measured and independently verified carbon offset credits: Integration of the Kassofor Programme as a complementary Sahl Regen initiative, providing ISO-verified Article 6.2 carbon offsets with extensive social and environmental co-benefits.  Making CO₂ a problem solver, not the problem.
• Solution for the whole aluminium industry: Final framing that the KX and Kassofor solutions enable Net Zero not only for alumina but for the aluminium industry as a whole.     

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In an exclusive conversation with Al Circle, Rob Clegg, Director of Projects at Sahl Regen, and Aniss Zenati, Responsable du développement commercial at GEA, explained how the SWG Collaboration—bringing together the complementary strengths of Sahl Regen, GEA, and Worley—is transforming the alumina industry’s path to decarbonisation.