Emirates Global Aluminium (EGA), the largest industrial company in the UAE outside of oil and gas, has officially begun the construction of 10 pilot reduction cells for its next-generation EX smelting technology. The groundbreaking ceremony took place on December 9 at the company’s Al Taweelah site.
The pilot project aims to demonstrate the advanced Industry 4.0 capabilities within the aluminium industry, building on EGA’s leadership in research and development (R&D) and digital transformation. EX technology is designed to produce more aluminium with less energy and lower emissions, incorporating provisions for advanced Internet of Things (IoT) sensors to enable real-time data gathering.
EGA plans to integrate all of its existing Industry 4.0 use cases into the EX technology, along with the development of new digital capabilities focused on artificial intelligence (AI) and advanced data analytics. The use of additional sensors and data will enable autonomous control of various processes, including pots, cranes, and vehicles, leading to further optimisation, reduced disruptions, and improved efficiency.
Machine learning will also play a crucial role in continuous process improvement and precise task planning, helping to reach the full performance potential of EX technology. EGA has already developed several Industry 4.0 applications, such as pot failure prediction, dynamic shift life prediction, and AI-enabled smart cranes.
The first hot metal from the pilot reduction cells is expected to be produced in the first half of 2025, with the company targeting full-scale industrialisation, including advanced Industry 4.0 capabilities, by 2028.
Abdulnasser Bin Kalban, CEO of EGA, remarked, “For over 30 years, EGA has been at the forefront of aluminium smelting innovation. Today, we stand at a transformative crossroads. The construction of our EX pilot reduction cells is not just a technological milestone; it’s the foundation for a future of smart solutions to improve efficiency and sustainability.”
He further stated, “Our bold goal is to create a self-optimising, autonomous production system that can be the most efficient in the world. This innovation is central to EGA’s growth strategy and our commitment to shaping a sustainable future for our industry.”
EGA began its digital transformation in 2021, with the goal of enhancing operations and business while improving customer and employee experiences. To date, the company has implemented over 80 Industry 4.0 use cases, unlocking approximately $100 million in value. EGA has also built critical digital infrastructure, including a digital manufacturing hybrid cloud platform in partnership with Microsoft and the region’s first fully renewable energy-powered industrial data centres at Jebel Ali and Al Taweelah.
Additionally, EGA has upskilled 3,000 employees in digital skills and methodologies, further supporting its transformation efforts.
Having completed the core design phase of EX smelting technology in June 2024, EGA is now working on the detailed engineering necessary for its installation at the Al Taweelah site.
