EGA advances next-gen smelting with EX technology

Emirates Global Aluminium (EGA) has commenced hot metal production at pilot reduction cells for its next-generation aluminium smelting technology, known as EX.

The pilot programme, taking place at EGA’s Al Taweelah site, marks a major step toward scaling up the EX technology for full industrial deployment.

It lays the groundwork for EGA’s future expansion in low-carbon primary aluminium production, while also reinforcing the company’s standing as a leading provider of smelting technology to the global aluminium sector.

In addition to testing the technology’s operational readiness, the pilot will serve as a proving ground for the most advanced Industry 4.0 applications in aluminium manufacturing.

Cutting emissions

EGA will integrate its existing digital use cases into the EX cells and is also developing cutting-edge capabilities that leverage artificial intelligence and advanced data analytics to enhance operational performance.

EGA has been developing its own aluminium smelting technologies in the UAE for over 35 years.

Since the 1990s, the company has used its proprietary technology for every smelter expansion and has successfully retrofitted all older production lines.

In 2016, EGA became the first UAE industrial company to license its core process technology internationally through a landmark agreement with Aluminium Bahrain, which used EGA’s technology for its Potline 6 expansion.

EX is the 10th generation of EGA’s in-house smelting technology, with pilot cell construction beginning in late 2024.

Designed to increase output while reducing energy consumption and emissions, EX offers improved productivity per sqm compared to the company’s DX+ Ultra platform.

Depending on the variant, EX is expected to cut greenhouse gas emissions by approximately 5% to 12% per tonne of aluminium produced.

EGA’s DX+ Ultra is already considered among the most energy-efficient smelting technologies in the global market.

The company launched its digital transformation in 2021 to improve cost-efficiency, responsiveness, safety, and sustainability.

Since then, EGA has implemented more than 80 Industry 4.0 applications, generating roughly US$100mn in value. In January 2025, EGA became the first aluminium company globally, and the first industrial firm in the UAE, to be named an Industry 4.0 Global Lighthouse by the World Economic Forum.

Abdulnasser Bin Kalban, chief executive officer of EGA, said, “First hot metal from these EX Technology reduction cells is a key milestone for both our technology leadership and future growth at EGA. Our goal is to expand our primary aluminium production with the most advanced and smart aluminium smelting technology, to build the smelter of the future and to create further value for EGA through smelting technology partnerships around the world."

Also read: EGA signs agreements to produce gallium in the UAE