In a significant breakthrough, Emirates Global Aluminium (EGA), the world’s largest ‘premium aluminium’ producer, has announced the completion of the design phase for its next-generation smelting technology, EX.
This innovative technology promises to revolutionize the aluminium industry, delivering unparalleled productivity and environmental sustainability.
The EX reduction cells, designed to be larger than EGA’s most recently industrialized technology, DX+ Ultra, will enable higher amperage and improved current efficiency. This advancement is expected to increase production capacity by up to 22 per cent, helping to meet the growing global demand for low-carbon primary aluminium.
EGA has meticulously engineered two variants of the EX technology, each tailored to specific objectives. The first variant maximizes productivity, while the second focuses on further minimizing greenhouse gas emissions. The reduced electricity consumption, lower net carbon consumption, and decreased incidence of anode effects in the latter variant are projected to reduce greenhouse gas emissions per tonne of aluminium produced by around 12 per cent.
Notably, the DX+ Ultra technology, already in use, is recognized as one of the most efficient smelting technologies in the global aluminium industry. The introduction of EX technology represents a significant leap forward, solidifying EGA’s position as a global leader in sustainable aluminium production.
To validate the performance of the EX technology, EGA intends to construct 10 pilot reduction cells at its aluminium smelter in Al Taweelah. The target is for the EX technology to be ready for full industrialization by 2028, positioning EGA to meet the increasing global demand for low-carbon primary aluminium required to reach net-zero emissions by 2050.
Abdulnasser Bin Kalban, the Chief Executive Officer of Emirates Global Aluminium, emphasized the pivotal role of technology development in EGA’s global competitiveness. He stated, “EX technology will enable the production of more aluminium with less energy and lower emissions, unlocking opportunities for EGA’s growth and helping us to meet the increasing global demand for the low carbon primary aluminium required to reach net zero by 2050.”
The innovations in the EX technology design are not limited to the reduction cells; they also extend to the enhancement of pot performance through improvements to busbars, superstructure, and potshells. These advancements are expected to lead to lower surrounding temperatures and a better working environment for EGA’s employees.
EGA’s commitment to developing its own aluminium smelting technology in the UAE for over 30 years has been a driving force behind its success. The company has consistently used its in-house technology in every smelter expansion since the 1990s, and has also retrofitted all its older production lines, further strengthening its technological prowess.
Furthermore, EGA’s pioneering spirit is evident in its international technology licensing deal with Aluminium Bahrain in 2016, making it the first UAE industrial company to license its core process technology globally.
As the global aluminium industry navigates the transition towards a low-carbon future, EGA’s EX technology stands as a testament to the company’s unwavering dedication to innovation and sustainability. With the successful implementation of this groundbreaking technology, EGA is poised to redefine the future of aluminium production, paving the way for a more environmentally responsible and resource-efficient industry.
Source: EGA with additional information added by GlassBalkan