Emirates Global Aluminium (EGA) has recently announced a significant achievement in the development of EX, the company’s advanced smelting technology. The successful completion of the design phase has paved the way for the construction of ten pilot EX reduction cells at the aluminium smelter in Al Taweelah, demonstrating the company’s commitment to testing and validating its performance. The ultimate objective is to achieve full industrialisation of EX by the year 2028.
The new EX reduction cells surpass EGA’s previous DX+ Ultra technology in size, enabling higher amperage and improved current efficiency. This enhanced capacity has the potential to increase production by up to 22%, representing a remarkable stride in smelting technology.
An outstanding feature of EX is its dual design, with one variant focused on maximising productivity and the other on minimising greenhouse gas emissions. Anticipated benefits include a reduction in electricity consumption, net carbon consumption, and anode effects, resulting in an approximate 5% decrease in greenhouse gas emissions for the productivity-focused variant and a 12% decrease for the energy-efficient variant.
Abdulnasser bin Kalban, Chief Executive Officer of EGA, emphasised the integral role of technology development in the company’s global competitiveness. He expressed confidence in the revolutionary impact of EX technology on aluminium production, enabling increased output with lower energy consumption and emissions. This advancement is vital in meeting the growing global demand for low-carbon primary aluminium, a key factor in achieving net zero by 2050.
In terms of design, EX technology is expected to enhance pot performance through improvements to busbars, superstructure, and potshells, resulting in lower ambient temperatures and a more favourable working environment for employees. The development of EX technology is the culmination of 18 months of dedicated work by EGA’s Technology Development Design team, with the pilot reduction cells set to be commissioned in the first quarter of 2025.
Noteworthy is EGA’s extensive history of developing its own aluminium smelting technology in the UAE, spanning over 30 years. The company has consistently implemented its own technology in all smelter expansions since the 1990s and has retrofitted all older production lines. A significant achievement was EGA’s status as the first UAE industrial company to internationally license its core process technology, as evidenced by its partnership with Aluminium Bahrain in 2016 for use in the Bahraini company’s Potline 6 expansion project.
In conclusion, the completion of the design phase for EX marks a significant leap forward for EGA in the global aluminium industry. With enhanced productivity, reduced energy consumption, and lower emissions, EX has the potential to reshape the landscape of aluminium production, aligning with the increasing emphasis on sustainability.