EGA is also constructing the UAE’s largest aluminium recycling plant at Al Taweelah. (Image source: EGA)

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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The two companies will collaborate on AI-powere autonomous operations. (Image source: Borouge)

Abu Dhabi-based petrochemicals company Borouge is collaborating with Honeywell to conduct a proof of concept for AI-powered autonomous operations, which is  is set to deliver the petrochemical industry’s first AI-driven control room designed for full-scale, real-time operation

The initiative aims to deploy the proof-of-concept technologies to enhance Borouge’s operations across its Ruwais facilities in the UAE. Autonomous operations will enable Borouge to optimise production, reduce energy use, and enhance safety while reducing costs at what will be the single largest petrochemical site in the world. Both companies will leverage their expertise in process technology and autonomous control capabilities to identify new opportunities to deploy Agentic AI solutions and advanced machine learning algorithms.

The project is a key component of Borouge's companywide AIDT programme, which is projected to generate US$575mn in value this year. In 2024, Borouge’s portfolio of over 200 AIDT initiatives—spanning operations, health and safety, sales, sustainability, and product innovation—generated $573mn in value

New systems

Borouge has already installed the world’s largest Real-Time Optimisation (RTO) system across three large-scale ethane crackers and 20 furnaces. The initiative analyses over 2,500 parameters per minute, enabling instant data-driven decisions, significantly enhancing productivity, optimising energy consumption and reducing emissions. The unique system minimises ethane dumping and optimises resource use, in line with Borouge's commitment to sustainable growth and operational excellence.

Borouge has invested in its state-of-the-art Innovation Centre located in Abu Dhabi and is now using advanced AI-powered tools to accelerate innovation, enabling the company to bring new grades of advanced polymers to market quicker. In collaboration with ADNOC AI Lab, Borouge has completed its first “Polymer Optimisation” programme, achieving a 97% accuracy, enabling Borouge to reduce its development timeline from months to weeks.

Hazeem Sultan Al Suwaidi, chief executive officer of Borouge, said, “Borouge's AI, Digitalisation, and Technology (AIDT) transformation programme is setting new standards in operations, innovation and business performance. By collaborating with global AI leaders such as Honeywell, we are accelerating growth, driving efficiency, and enhancing shareholder value. This project further strengthens Borouge’s competitive edge as we continue to deliver on our ambitious AIDT roadmap.”

George Bou Mitri, president of Honeywell Industrial Automation, Middle East, Turkey, Africa, Central Asia, said, “By integrating AI and automation technologies into core operations, we are helping unlock new levels of efficiency, safety, and performance. This agreement shows how advanced technologies, applied with purpose, can reshape industrial operations at scale.”

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EGA advances next-gen smelting with EX technology

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GA will integrate its existing digital use cases into the EX cells. (Image source: EGA)

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."

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Manufacturers can now use CONNECT with Databricks. (Image source: AVEVA)

AVEVA, a global leader in industrial software, has been named the 2025 Databricks Manufacturing ISV Partner of the Year. Announced at the annual Data + AI Summit, the recognition honours AVEVA’s outstanding contributions to data-driven innovation in the manufacturing sector.

Over the past year, AVEVA has partnered closely with Databricks to launch a pioneering integrative solution via its CONNECT industrial intelligence platform.

This collaboration redefines how industrial and enterprise data are unified, analysed, and actioned, solving a critical challenge in modern industry: converting fragmented OT and IT data into meaningful, trusted insights.

By combining the Databricks Data Intelligence Platform with CONNECT, users can securely integrate industrial and enterprise data in an open, scalable, and governed way, using Delta Sharing, Databricks’ open-source technology for cross-platform, cross-cloud live data sharing.

Smart solutions

This enables advanced capabilities such as AI, machine learning, and real-time analytics to be applied to previously siloed data sets.

As a result, manufacturers can now use CONNECT with Databricks to drive smarter decision-making, predictive maintenance, demand forecasting, sustainability tracking, safety improvements, and enhanced operational efficiency, while reducing development time and costs, and accelerating time-to-value.

“At AVEVA, we’re proud to have established Databricks and Delta Sharing as key foundation-stones of our strategy for our industrial intelligence platform, CONNECT,” said Bry Dillon, SVP of Partners and Commercial Strategy at AVEVA.

“Together, we’re enabling our joint customers to access real-time insights, accelerate AI, and deliver tangible outcomes across the industrial landscape. Our partnership with Databricks marks a pivotal moment in the advancement of industrial AI. This collaboration presents a powerful opportunity to accelerate the deployment of AI-driven solutions and drive greater industry wide collaboration — capabilities that are needed for companies across the industrial sector to stay relevant, remain competitive, and build efficient, sustainable businesses of the future.

"We are thrilled to name AVEVA the 2025 Databricks Manufacturing ISV Partner of the Year," said Shiv Trisal, Global Manufacturing, Transportation & Energy GTM Leader at Databricks. "As more enterprises leverage data intelligence to solve challenges across the manufacturing and energy industries, AVEVA's partnership with Databricks is essential to helping organisations everywhere harness the full potential of their data."

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