Emirates Global Aluminium (EGA), recognized as the largest industrial company in the United Arab Emirates outside the oil and gas sector, has reached a significant milestone by commencing hot metal production using its pilot reduction cells for the EX smelting technology at its Al Taweelah site. This advancement marks a crucial step towards the large-scale industrialisation of what EGA brands as its next-generation aluminium smelting technology. EX technology is a cornerstone in EGA’s strategic plan to enhance low-carbon primary aluminium production, underscoring the company’s ambition to maintain its leadership position within the global aluminium smelting industry.
The EX smelting technology, which represents EGA’s 10th generation of in-house developed aluminium smelting processes, is designed to surpass the productivity and sustainability of the company’s current DX+ Ultra technology. With construction of the pilot pots having begun in late 2024, EX technology aims to deliver greater aluminium output with less energy consumption per ton and significantly reduced greenhouse gas emissions—approximately five percent lower for the higher productivity version and around twelve percent for the lower energy variant. This builds upon the already high efficiency of DX+ Ultra, which is recognised globally as one of the aluminium industry’s most advanced smelting technologies.
EGA is also harnessing the pilot project to showcase the aluminium industry’s most advanced Industry 4.0 capabilities. The company has integrated sophisticated IoT sensors within the EX cells for real-time data collection, enabling proactive maintenance and operational efficiency improvements. Existing Industry 4.0 innovations such as AI-driven pot failure prediction and smart cranes are being trialed alongside new digital tools centred on artificial intelligence and advanced data analytics to fully exploit the technology’s potential. The anticipated delivery of the first hot metal in the first half of 2025 is a prelude to planned large-scale commercialisation by 2028, which will incorporate these comprehensive digital solutions.
EGA’s commitment to digital transformation, launched in 2021, is a pivotal element in this technology development journey. The company already boasts over 80 deployed Industry 4.0 use cases, generating around $100 million in financial impact and elevating operational agility, cost competitiveness, safety, and sustainability. EGA’s efforts have been internationally recognised; it was named the first industrial company in the UAE and the world’s first aluminium company to earn designation as an Industry 4.0 global lighthouse by the World Economic Forum—a testament to its leadership in applying Fourth Industrial Revolution technologies on a global scale. The company has also upskilled more than 3,000 employees in digital capabilities to support this transformation.
EGA’s digital ambitions extend further with the recent upgrade to SAP’s S/4HANA software, enhancing data processing speeds by up to 30 times and laying the foundation for expanded use of artificial intelligence and real-time analytics through cloud-hosted solutions on Microsoft Azure. In tandem, EGA has launched one of the region’s first digital manufacturing platforms, developed in collaboration with Microsoft, which processes vast amounts of data annually to drive operational improvements across its sites. This platform enables AI at scale, optimising safety, efficiency, and quality in its operations.
Further demonstrating its forward-thinking approach, EGA has developed an Industry 4.0 centre of excellence, created comprehensive digital roadmaps, and implemented governance and agile methodologies to embed transformation within its culture. Advanced AI and computer vision technologies now support operations on the shop floor, delivering real-time visibility to managers and boosting productivity sustainably by utilising renewable energy sources to power its data centres.
Through these coordinated efforts—combining pioneering smelting technology with cutting-edge digital innovation—EGA is positioning itself not only as a major global aluminium producer but also as a leading technology provider to the aluminium industry worldwide. The successful pilot operation of the EX smelting technology marks an important chapter in EGA’s journey towards building the smelter of the future, enhancing both environmental performance and industry competitiveness.
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Source: Noah Wire Services
- https://www.gccbusinessnews.com/ega-begins-hot-metal-production/ – Please view link – unable to able to access data
- https://media.ega.ae/egas-ex-technology-pilot-to-be-used-to-prove-most-advanced-industry-40-capabilities-in-aluminium-industry/ – Emirates Global Aluminium (EGA) has initiated the construction of 10 pilot reduction cells for its EX smelting technology at Al Taweelah. This pilot project aims to demonstrate advanced Industry 4.0 capabilities in the aluminium industry, building upon EGA’s existing research and development leadership. The EX technology is designed to produce more aluminium with less energy and lower emissions, incorporating advanced Internet of Things (IoT) sensors for real-time data gathering. EGA plans to apply existing Industry 4.0 innovations, such as pot failure prediction and AI-powered smart cranes, within the EX technology. The first hot metal from the pilot reduction cells is expected in the first half of 2025, with large-scale industrialisation, including advanced Industry 4.0 capabilities, targeted by 2028. CEO Abdulnasser Bin Kalban emphasised the significance of this technological milestone in EGA’s growth strategy and commitment to sustainability. ([media.ega.ae](https://media.ega.ae/egas-ex-technology-pilot-to-be-used-to-prove-most-advanced-industry-40-capabilities-in-aluminium-industry/?utm_source=openai))
- https://media.ega.ae/ega-designated-industry-40-global-lighthouse-by-world-economic-forum-in-uae-and-world-aluminium-industry-first/ – Emirates Global Aluminium (EGA) has been designated by the World Economic Forum as an Industry 4.0 global lighthouse, marking the first such recognition for an industrial company in the UAE and the first for an aluminium company worldwide. This designation acknowledges EGA’s leadership in applying Fourth Industrial Revolution technologies to significantly improve efficiency, sustainability, and innovation. Since launching its digital transformation in 2021, EGA has implemented over 80 Industry 4.0 use cases, delivering approximately $100 million in financial impact. The company has also upskilled more than 3,000 employees in digital capabilities and ways of working. ([media.ega.ae](https://media.ega.ae/ega-designated-industry-40-global-lighthouse-by-world-economic-forum-in-uae-and-world-aluminium-industry-first/?utm_source=openai))
- https://media.ega.ae/emirates-global-aluminium-upgrades-to-saps-s4hana-software-for-key-functions-as-part-of-wider-industry-40-transformation/ – Emirates Global Aluminium (EGA) has signed an agreement with SAP to upgrade its core enterprise resource planning solution to SAP’s latest S/4HANA software. This upgrade aims to increase data processing speeds by 30 times, future-proofing EGA’s computing for key business functions and unlocking potential for digital capabilities such as artificial intelligence and advanced real-time data analytics. The new SAP S/4HANA system will be hosted in a private cloud in Microsoft Azure and will benefit from continuous updates as SAP technologies evolve. EGA’s digital transformation has already implemented over 60 Industry 4.0 use cases, delivering approximately $90 million in financial impact. ([media.ega.ae](https://media.ega.ae/emirates-global-aluminium-upgrades-to-saps-s4hana-software-for-key-functions-as-part-of-wider-industry-40-transformation/?utm_source=openai))
- https://media.ega.ae/ega-launches-one-of-the-regions-first-digital-manufacturing-platforms-to-advance-industry-40-strategy/ – Emirates Global Aluminium (EGA) has launched one of the first digital manufacturing platforms in the region to advance its Industry 4.0 strategy. Developed in collaboration with Microsoft, the platform integrates hardware, software, processes, and people throughout EGA’s global operations. Built using Microsoft’s Azure hybrid cloud, the platform enables the use of artificial intelligence at scale across EGA’s industrial operations, including Jebel Ali and Al Taweelah, to improve process efficiency, quality, and safety. The platform processes over 2.9 petabytes of real-time data annually and is expected to reduce the unit cost of running AI-based image and video analytics by more than 80%. ([media.ega.ae](https://media.ega.ae/ega-launches-one-of-the-regions-first-digital-manufacturing-platforms-to-advance-industry-40-strategy/?utm_source=openai))
- https://www.mckinsey.com/capabilities/mckinsey-digital/how-we-help-clients/rewired-in-action/emirates-global-aluminium-leading-the-industry-with-ai-driven-transformation – Emirates Global Aluminium (EGA) has undertaken a comprehensive digital transformation to enhance its operations and business. This includes creating an Industry 4.0 centre of excellence, developing digital roadmaps, and implementing governance and agile methodologies. EGA has upskilled over 3,000 employees through a digital academy and established a new data platform that democratizes data access. The company’s data centres now use half as much power as before, all of which is renewable. On the shop floor, EGA employs advanced AI and computer vision technology, supporting more than 20 apps for 1,500 users, providing managers with real-time visibility. ([mckinsey.com](https://www.mckinsey.com/capabilities/mckinsey-digital/how-we-help-clients/rewired-in-action/emirates-global-aluminium-leading-the-industry-with-ai-driven-transformation?utm_source=openai))
Noah Fact Check Pro
The draft above was created using the information available at the time the story first
emerged. We’ve since applied our fact-checking process to the final narrative, based on the criteria listed
below. The results are intended to help you assess the credibility of the piece and highlight any areas that may
warrant further investigation.
Freshness check
Score:
8
Notes:
The narrative reports that Emirates Global Aluminium (EGA) has commenced hot metal production using its EX smelting technology at the Al Taweelah site. This development aligns with previous reports from December 2024, indicating that the content is current and not recycled. The earliest known publication date of similar content is December 11, 2024. ([metalswire.net](https://metalswire.net/commodities/ega-breaks-ground-on-next-generation-smelting-technology-pilot-project/?utm_source=openai)) The narrative includes updated data on the commencement of hot metal production, justifying a higher freshness score.
Quotes check
Score:
9
Notes:
The narrative includes a direct quote from Abdulnasser Bin Kalban, CEO of EGA, stating, “The construction of our EX pilot reduction cells is not just a technological milestone, it is the foundation for a future of smart solutions to improve efficiency and ultimately sustainability.” This quote appears in earlier reports from December 2024, suggesting it may be reused content. ([zawya.com](https://www.zawya.com/en/press-release/companies-news/egas-ex-technology-pilot-to-be-used-to-prove-most-advanced-industry-40-capabilities-in-aluminium-industry-h28oshr7?utm_source=openai))
Source reliability
Score:
7
Notes:
The narrative originates from GCC Business News, a regional news outlet. While it provides detailed information, the outlet’s reputation and verification processes are not widely known, which introduces some uncertainty regarding the reliability of the information presented.
Plausability check
Score:
8
Notes:
The narrative’s claims about EGA’s EX smelting technology and its advancements are consistent with previously reported information from December 2024. The inclusion of updated data on the commencement of hot metal production adds credibility. However, the reuse of a direct quote from December 2024 raises questions about the originality of the content. ([zawya.com](https://www.zawya.com/en/press-release/companies-news/egas-ex-technology-pilot-to-be-used-to-prove-most-advanced-industry-40-capabilities-in-aluminium-industry-h28oshr7?utm_source=openai))
Overall assessment
Verdict (FAIL, OPEN, PASS): OPEN
Confidence (LOW, MEDIUM, HIGH): MEDIUM
Summary:
The narrative provides current information on EGA’s EX smelting technology, with updated data on the commencement of hot metal production. However, the reuse of a direct quote from December 2024 and the uncertain reliability of the source warrant further verification. The presence of recycled content and potential issues with source reliability suggest a need for cautious interpretation.
