EGA to boost US aluminium supply with new smelter

Emirates Global Aluminium (EGA), the world’s largest producer of premium aluminium, has commenced production at its expanded Spectro Alloys aluminium recycling facility in Minnesota, USA.

The first phase of the expansion adds 55,000 tonnes of secondary billet production capacity, with full ramp-up expected by the first quarter of 2026. Once fully operational, the site will produce 165,000 tonnes of recycled aluminium billets and ingots annually.

The output from the expanded facility will be marketed under EGA’s RevivAL brand, which represents the company’s portfolio of recycled aluminium products. With this development, EGA’s total global recycling capacity now stands at 195,000 tonnes per year, combining operations in the US and Germany.

EGA is also constructing the UAE’s largest aluminium recycling plant at Al Taweelah. Set to produce 170,000 tonnes of billets annually, the facility is on track to begin operations in the first half of 2026, reinforcing EGA’s commitment to advancing sustainable aluminium production across its global network.

Addressing the global supply chain gap

Demand for recycled aluminium in the United States is projected to reach approximately 7.6 million tonnes annually by 2033, according to independent analysts at CRU. As the second largest market for recycled aluminium globally, the US plays a significant role in the transition toward more sustainable materials.

Aluminium recycling consumes up to 95% less electricity compared to primary production, resulting in dramatically lower greenhouse gas emissions. To meet growing domestic demand, Emirates Global Aluminium (EGA) is advancing plans to establish the first new primary aluminium smelter in the US since 1980. The proposed facility, to be located in Oklahoma, is expected to produce 600,000 tonnes of aluminium per year, nearly doubling the country’s current output.

At present, around 85% of aluminium used by US industries such as automotive, aerospace and construction is imported. EGA’s planned investment aims to address this gap by strengthening domestic supply chains. In 2024, EGA also expanded its recycling footprint in the US with the acquisition of an 80% stake in EGA Spectro Alloys.

Abdulnasser Bin Kalban, chief executive officer of Emirates Global Aluminium, said, “Reaching first hot metal at the expansion of EGA Spectro Alloys is another milestone in our drive to build a global aluminium recycling business to meet growing demand for this low carbon metal. It is also a milestone in EGA’s growth in the United States, already one of our most important markets and where we are progressing our plans to build a primary aluminium production plant in Oklahoma.”

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