The laboratory conducts metallographic analyses and mechanical testing of EGA Spectro’s finished products to ensure customers receive the highest quality recycled aluminium at the precise specifications needed. The facility will offer sample testing from customer castings or extrusions to help troubleshoot and optimise downstream quality. The lab adds improved and faster sample analysis services for customers.

EGA Spectro’s expansion adds 55 thousand tonnes of secondary billet production capacity in the first phase. The expansion takes EGA Spectro Alloys’ total production capacity to 165 thousand tonnes per year of recycled aluminium ingots and billets.

Abdulnasser Bin Kalban, Chief Executive Officer of Emirates Global Aluminium, said today: “The new laboratory strengthens EGA Spectro Alloys’ ability to meet the quality expectations of our customers and support them in improving their own products. As demand for low-carbon aluminium grows, our focus is on delivering the metal our customers need with the quality and reliability they expect from EGA.”

The ramp-up to full production at EGA Spectro expansion is expected to be complete in the first quarter of 2026.

Demand for recycled aluminium in the United States is expected to reach some 7.6 million tonnes per year by 2033, according to CRU, an independent business intelligence organisation. The United States is currently the world’s second biggest recycled aluminium market.

Recycling aluminium requires 95 per cent less electricity than making new metal, and generates a fraction of the greenhouse gas emissions.

EGA acquired 80 per cent of EGA Spectro Alloys in 2024.

The pilot is a key step in readying EX smelting technology for large-scale industrialisation, making the project an important foundation of EGA’s future growth and the further strengthening of EGA’s position as the technology provider of choice in the global aluminium industry.

EX is EGA’s 10th generation smelting technology and produces more aluminium with less energy and lower emissions.

Homaid Al Shimmari, Chairman of Emirates Global Aluminium, said: “EX technology enhances EGA’s ability to remain at the forefront of the global aluminium industry. Our aim is to apply this technology in our planned facility in Oklahoma, the first new primary aluminium production plant to be built in the United States since 1980. As part of this effort, we will test the technology using alumina refined from bauxite sourced from multiple locations, to further prove its potential for global deployment.”

Abdulnasser Bin Kalban, Chief Executive Officer of Emirates Global Aluminium, said: “The pilot of our new EX technology is a strategic project for EGA, and is the latest chapter in our long history of industry leadership through technology innovation. The performance of EX reduction cells during start-up and in the first weeks of production has been even better than expected, and I am excited about what this technology will achieve. I thank each colleague who worked so hard to develop this new technology and build the pilot in Al Taweelah.”

EGA has developed its own aluminium smelting technology in the UAE for more than 30 years. All EGA smelter expansions since the 1990s have used EGA technology, and the company as retrofitted all its older potlines. EGA’s technology development, and earlier work since 1980, has reduced the amount of electricity required to make each tonne of aluminium by 37.5 per cent.

EGA was the first UAE industrial company to license its core process technology internationally, in a deal with Aluminium Bahrain in 2016 for the use of EGA’s DX+ Ultra technology in the Bahraini company’s Potline 6 expansion project.

The EX pilot in Al Taweelah will also be used to prove the most advanced Industry 4.0 capabilities in the global aluminium industry.

EGA launched its digital transformation in 2021 to boost cost competitiveness, agility, and flexibility, and to improve safety and sustainability. Since then, EGA has implemented more than 80 Industry 4.0 use cases, generating around $100 million in financial impact.

In January 2025, EGA became the first industrial company in the UAE and the first aluminium company in the world to be designated an Industry 4.0 global lighthouse by the World Economic Forum.

Construction of the 10 pilot pots began in late 2024, and the first reduction cell was energised in mid-June.

The pilot at Al Taweelah is a key step in readying the technology for large-scale industrialisation, making the project a key foundation for both future low-carbon primary aluminium production growth at EGA and the strengthening of EGA’s position as the smelting technology provider of choice for the global aluminium industry.

The pilot will also be used to prove the most advanced Industry 4.0 capabilities in the aluminium industry. All EGA’s existing Industry 4.0 use case will be deployed in the new technology and the company is developing new state-of-the-art digital capabilities centred on artificial intelligence and advanced data analytics.

Abdulnasser Bin Kalban, Chief Executive Officer of Emirates Global Aluminium, 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."

EGA has developed its own aluminium smelting technology in the UAE for more than 35 years. EGA has used its own technology in every smelter expansion since the 1990s and has retrofitted all its older production lines.

EGA was the first UAE industrial company to license its core process technology internationally, in a deal with Aluminium Bahrain in 2016 for use in the Bahraini company’s Potline 6 expansion project.

EX is EGA’s 10^th generation smelting technology. Construction of the pilot pots began in late 2024.

EGA’s EX has been designed to produce more aluminium with less energy per tonne and lower emissions. EX reduction cells provide higher productivity per square meter compared to our latest DX+ Ultra technology.

The next generation technology is expected to reduce greenhouse gas emissions per tonne of aluminium produced by around five per cent for the more productive variant and around 12 per cent for the lower energy variant.

DX+ Ultra is already one of the most efficient smelting technologies in the global aluminium industry.

EGA launched its digital transformation in 2021 to boost cost competitiveness, agility, and flexibility, and to improve safety and sustainability. Since then, EGA has implemented more than 80 Industry 4.0 use cases, generating around $100 million in financial impact.

In January 2025, EGA became the first industrial company in the UAE and the first aluminium company in the world to be designated an Industry 4.0 global lighthouse by the World Economic Forum.

EX has been designed to produce more aluminium with less energy and lower emissions. The design incorporates provisions for advanced Internet of Things sensors and connections to enable real-time data gathering and even greater application of Industry 4.0.

EGA intends to utilise all its existing Industry 4.0 use cases in EX technology, and develop new state-of-the-art digital capabilities centred on artificial intelligence and advanced data analytics.

With more sensors and data, the goal is to deploy artificial intelligence for autonomous control of pots, cranes and vehicles, enabling further optimisation and integration of all potline processes, reducing disruptions and improving efficiency. Machine learning will enable continuous process improvement and increasingly precise task planning to reach the full theoretical performance capabilities of EX technology.

EGA’s already-developed Industry 4.0 use cases include pot failure prediction, dynamic shift life prediction, and the use of artificial intelligence vision-enabled smart cranes.

First hot metal from the pilot reduction cells is expected in the first half of 2025. The target is that EX is ready for large-scale industrialisation, including advanced Industry 4.0 capabilities, by 2028.

Abdulnasser Bin Kalban, Chief Executive Officer of Emirates Global Aluminium, said: “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 is the foundation for a future of smart solutions to improve efficiency and ultimately sustainability. 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 launched its digital transformation in 2021, aiming to enhance every aspect of its operations and business, while upgrading customer and employee experience and ultimately creating new revenue streams.

So far, EGA has implemented more than 80 Industry 4.0 use cases, unlocking some $100 million in value.

EGA has also built important digital foundations, including one of the region’s first digital manufacturing hybrid cloud platforms with Microsoft, and the region’s first 100 per cent renewable energy-powered industrial data centres at Jebel Ali and Al Taweelah, reducing the emissions from EGA’s computing. EGA has also upskilled some 3,000 employees in digital capabilities and ways of working.

EGA completed the core design phase of its new EX smelting technology in June 2024, and has since been working on detailed engineering for the installation at Al Taweelah. EX reduction cells are larger than EGA’s most recently industrialised technology DX+ Ultra, enabling higher amperage and improved current efficiency.

DX+ Ultra is already one of the most efficient smelting technologies in the global aluminium industry.

EGA’s EX technology aims to increase production capacity by up to 22 per cent and has been designed with two variants - one for maximum productivity and the other to minimise greenhouse gas emissions.

The next generation technology is expected to reduce greenhouse gas emissions per tonne of aluminium produced by around five per cent for the more productive variant and around 12 per cent for the lower energy variant.

EGA was the first UAE industrial company to license its core process technology internationally, in a deal with Aluminium Bahrain in 2016 for the use of DX+ Ultra technology in the Bahraini company’s Potline 6 expansion project.

This state-of-the-art facility will be located at Khalifa University’s Main Campus in Abu Dhabi and is expected to significantly expand high temperature materials research in the UAE both for practical applications in industry and academic study. Currently, research in high temperature materials for institutions and the industries in the UAE can only be conducted abroad.

The goal is to build long-term strategic partnerships where academia and industry are proactively engaged and committed to success in collaborative and multidisciplinary advanced R&D efforts.

EGA expects to use the laboratory and programme for practical research into refractories, carbon-based materials, anode baking furnaces, and waste.

EGA’s research is expected to focus on capturing and recovering heat energy generated from the company’s industrial processes, improving energy efficiency and reducing greenhouse gas emissions. In aluminium smelting, approximately half of all energy is lost as waste heat.  

Abdulnasser Bin Kalban, Chief Executive Officer of Emirates Global Aluminium, said: “At EGA, one of our core values is to continuously improve our business and operations through innovation. This new state-of-the-art laboratory and research programme will strengthen the UAE's position as a leader in industrial technology development and drive forward the country’s Operation 300bn industrial growth strategy. For EGA, it means we can conduct even more of our practical research here in the UAE, solving challenges locally and contributing to the UAE’s research capabilities. I look forward to some ground-breaking results from this collaboration.”

His Excellency Prof. Ebrahim Al Hajri, President, Khalifa University, said: “We are glad to see the enduring and fruitful relationship with Emirates Global Aluminium, Mubadala Investment Company, and Strata. Manufacturing remains cemented through the development of capability and capacity at Khalifa University. The trust of the industry in Khalifa University to provide localized solutions and adapt to their unique industrial challenges is a testament to the advanced and applied research competencies that the university offers. This achievement is a result of over a decade of collaboration with our industrial partners, which has enabled us to build capacity and gain a deeper understanding of industrial needs. Today, we are cementing that trust and confidence from the industry by localizing research, development, and innovation in the UAE. We look forward to seeing industries across the region and globally follow suit as we continue to provide tailored solutions and adapt to industry trends."

Mubadala Investment Company is committed to launching advanced R&D programs aimed at developing capabilities in areas critical to Mubadala and of national priority. Priority will be given to applied research and providing solutions in areas of critical technical need. Additionally, it aims to develop capable UAE scientists, technologists, and innovators for careers in R&D.

EGA is committed to reaching net zero by 2050 in line with the UAE’s Net Zero by 2050 Strategic Initiative, and has a roadmap to decarbonise its operations.

EGA has worked for more than a decade with other industries in the UAE to find productive uses for by-products from aluminium production. EGA has already developed re-uses for many waste streams from its industrial activities, including bauxite residue, spent pot lining, carbon dust and dross.

EGA’s technology and development team works extensively with universities in both the UAE and internationally, with academic partnerships that include Khalifa University, the American University of Sharjah, Rochester Institute of Technology, Abu Dhabi University and American University in Dubai in the UAE, as well as the University of Auckland, University of New South Wales, and MIT.

The digital connection automates the process of submitting certificates of analysis, which are key specification and quality assurance documents that must accompany shipments of metals into and out of London Metal Exchange warehouses around the world.

The London Metal Exchange is the world centre for trading industrial metals. Trading on the London Metal Exchange sets the global benchmark price for aluminium. Warehouses approved by the London Metal Exchange support physical delivery and ensure price convergence. All metal delivered into London Metal Exchange warehouses must conform to specifications on quality, shape and weight as well as the Exchange’s responsible sourcing requirements.

The digital certificates of analysis will allow for greater traceability, accessibility and transparency to the process by eliminating paper documentation, which can often be damaged or lost as metal travels around the world.

Abdulnasser Bin Kalban, Chief Executive Officer of Emirates Global Aluminium, said: “Our digital transformation is a core part of achieving EGA's bold aspiration to innovate the future of aluminium production. Leading our sector in digitally providing certificates of analysis to the LMEpassport platform is just one way we are using big data and analytics to transform the efficiency of our operations and business at EGA.”

London Metal Exchange Head of Physical Markets, Georgina Hallett, commented: “We are delighted that EGA has made the first direct connection to LMEpassport, taking advantage of a digital solution that in time will entirely replace the need for paper certificates of analysis across all physically delivered LME metals, bringing greater security, traceability and operational efficiency to the trading of physical metal.”

All primary aluminium smelters that produce London Metal Exchange brands must digitise their certificate of analysis submission process by October this year to the exchange’s digital register, LMEpassport.

EGA launched its digital transformation in 2021, aiming to enhance every aspect of its operations and business, while upgrading customer and employee experience and ultimately creating new revenue streams.

In its wider digital transformation, EGA has so far implemented over 65 Industry 4.0 use cases, ranging from using artificial intelligence vision to quality check carbon anode production in real-time, to developing predictive tools for market movements in key commodities. To date, almost 2,000 EGA employees have been upskilled in digital capabilities and ways of working, and the transformation has delivered some $85 million in financial impact.

EGA and Microsoft have launched on the of the first digital manufacturing platforms in the region to unlock additional value through Industry 4.0 applications.

At Jebel Ali and Al Taweelah, construction is nearly complete on the region’s first 100 per cent renewable energy powered industrial data centres.

EX reduction cells are larger than EGA’s most recently industrialised technology DX+ Ultra, enabling higher amperage and improved current efficiency, increasing production capacity by up to 22 per cent.

EX has been designed with two variants – one to maximise productivity, and the other to further minimise greenhouse gas emissions. Reduced electricity consumption along with lower net carbon consumption and the reduced incidence of anode effects is expected to reduce greenhouse gas emissions per tonne of aluminium produced by around five per cent for the more productive variant and around 12 per cent for the lower energy variant.

DX+ Ultra is already one of the most efficient smelting technologies in the global aluminium industry.

EGA now intends to construct 10 pilot EX reduction cells at the company’s aluminium smelter in Al Taweelah to test and validate performance. The target is that EX is ready for full industrialisation by 2028.

Abdulnasser Bin Kalban, Chief Executive Officer of Emirates Global Aluminium, said: “Technology development has been a foundation of our global competitiveness for decades. 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.”

Innovations in the design of EX technology are expected to deliver enhanced pot performance with improvements to busbars, superstructure and potshells, leading to lower surrounding temperatures and better working environment.

The new technology was developed over 18 months by EGA’s Technology Development Design team. The pilot reduction cells are expected to be commissioned during the first quarter of 2025.

EGA has developed its own aluminium smelting technology in the UAE for more than 30 years. The company has used its own technology in every smelter expansion since the 1990s and has retrofitted all its older production lines.

EGA was the first UAE industrial company to license its core process technology internationally, in a deal with Aluminium Bahrain in 2016 for use in the Bahraini company’s Potline 6 expansion project.

The visit is part of EGA’s FURSA platform, developed by the EGA Youth Council and the company’s Learning and Development team to provide youth access to curated courses and experiences to enhance skills in leadership, Industry 4.0, sustainability, science and technology.

EGA youth engaged with leading technology companies in Silicon Valley, including Google, Apple, Tesla, Amazon, Microsoft and Standford University, to gain insights on the transformative potential of emerging technologies and best practices for enhancing organisational adaptability and driving innovation.

Abdulnasser Bin Kalban, Chief Executive Officer of Emirates Global Aluminium, said: “Empowering the next generation of leaders is crucial for the future growth of our business. Through these programmes, we ensure young people are able to learn from others and are equipped to drive transformative change. Industry 4.0 is already transforming the competitive landscape in our industry and at EGA, and will be central to the success that today’s youth will deliver during their careers.”

Hala Alhashmi, Chair of EGA Youth Council and Product Owner in the Digital Transformation & Industry 4.0 Department at EGA, said: “Exploring global innovations and emerging technologies is essential to enhance our competitiveness, drive growth, and remain relevant in today's digital economy. As young people at EGA, we are proud to be playing an active role in shaping a dynamic and progressive future for our company.”

FURSA is an exclusive platform for EGA employees under the age of 35. It includes 26 academic courses, from prestigious universities such as Harvard, Oxford and London Business School, and wide range of tailored experiences in volunteering, and collaboration.

The EGA Youth Council hosted and participated in over 20 events during 2023 including 11 nation-wide impact initiatives.

Founded in 2018, the EGA Youth Council empowers aspiring young employees to enhance their leadership skills and become pacesetters for change in the nation. The council operates under three main tenets as a foundation of its five-year strategy - empowering youth, engaging them, and fostering their development.

The Agreement was signed between Alba’s CEO Ali Al Baqali and EGA’s CEO Abdulnasser Bin Kalban in the presence of top officials from both companies.

The Agreement encompasses both onsite and remote assistance wherein EGA will provide Alba’s Reduction Line 6 with technical support services, monitoring services as well as operational consultation. The agreement also covers operational and process audits, technical training workshops, as well as hands-on operation support among others.

Commenting on this occasion, Alba’s CEO Ali Al Baqali stated: “Alba’s Reduction Line 6 is a success story built upon the foundation of our exceptional local talent and bolstered by EGA’s DX+ Ultra technology playing a role in it.

We are excited to build on our partnership with EGA through this technical services agreement as it will enable our human talent to continuously benefit from EGA’s DX+ Ultra advancements and achieve our sustainability objectives.”

Commenting on this occasion, Abdulnasser Bin Kalban, Chief Executive Officer of Emirates Global Aluminium, stated: “EGA’s longstanding partnership with Alba reflects the vision of our wise leadership to deepen the dynamic relations between our two countries. We are pleased to extend our technology and know-how provision to Aluminium Bahrain and further build on the success of Reduction Line 6 built with EGA technology. Our partnership is grounded in shared values and commitment to advancing sustainable development. At EGA, we have been developing our own technology for more than 30 years. EGA’s bold aspiration is to innovate the future of aluminium production and cement our position as the technology partner of choice for our industry.”

Commissioned on 13 December 2018 and gradually ramped up over the course of 2019, Alba’s Reduction Line 6 has brought the Company’s nameplate production capacity to more than 1.6 million metric tonnes per annum.

The new data centres will enable EGA to further deploy artificial intelligence and automation solutions at the heart of the company’s industrial operations, while reducing EGA’s total IT energy consumption by 50 per cent through real-time Artificial Intelligence-optimised power, cooling management and latest generation computer infrastructure.

EGA is developing the new data centres with local technology provider, Scientechnic. The construction is a key part of EGA’s digital roadmap, which is transforming EGA’s operations through Industry 4.0 adoption and broader digital transformation.

The data centres will improve the resilience of EGA’s computing and will be certified to the Uptime Institute’s Tier III standard, a global benchmark for data centres.

Around the world, computing accounts for approximately seven per cent of global electricity consumption, and this is forecast to rise to 13 per cent by 2030, according to the European Commission.

Abdulnasser Bin Kalban, Chief Executive Officer of Emirates Global Aluminium, said: “EGA’s bold aspiration to innovate the future of aluminium production is a source of our global competitive advantage, and this includes leading our sector in the implementation of Industry 4.0. Our new data centres, combined with our existing cloud computing resources, transform our data processing capacity. Improving the environmental sustainability of EGA’s computing infrastructure is part of our commitment to embed sustainability in everything we do. The construction of EGA’s new on-site data centres is an important milestone in our goal to establish a thriving manufacturing innovation ecosystem in the UAE.”

Carlo K Nizam, Chief Digital Officer of Emirates Global Aluminium, said: “Our new data centres will optimise the resilience and sustainability of EGA's digital manufacturing platform which supports data-heavy artificial intelligence and advanced automation solutions. This will help enable EGA’s future ambition of self-optimising artificial intelligence driven plant operations, such as fully-autonomous crane and vehicle operations.”

Last year, EGA announced a strategic collaboration with Microsoft UAE to progress the company’s digital roadmap, shifting two thirds of EGA’s server and applications infrastructure to Microsoft Azure Hybrid Cloud. The hybrid cloud combines computing resources both on-site at EGA and in Microsoft’s data centres.

Both Microsoft and EGA are members of the UAE Ministry of Industry and Advanced Technology’s Industry 4.0 Champions Network, which aims to accelerate Industry 4.0 adoption across UAE industry.

The development of the data centres and the use of the hybrid cloud together increase EGA’s data processing capacity by 2,300 times while significantly reducing unit processing costs, future proofing EGA’s computing for the company’s digital transformation.

EGA has developed technology in the UAE for more than 30 years and is focused on improving the efficiency of the aluminium smelting process. EGA’s latest home-grown technology is among the most efficient and competitive in the global aluminium industry.

Scientechnic is headquartered in Dubai and is one of the region’s leading integrated solution providers of electrical, mechanical, power, automation, and mobility technologies.

In 2022, EGA spent some $2.18 billion on goods and services from local UAE suppliers, accounting for 39 per cent of the company’s total global procurement spend. EGA is actively working to grow its local supply chain further in line with the UAE’s Operation 300bn industrial growth strategy and ‘Make it in the Emirates’.

ICSOBA is the largest annual technical forum in the global aluminium industry.

The three-day event in Dubai - the biggest edition ever - brings over 190 international contributions and 168 technical presentations in four, parallel streams focusing on advancing sector decarbonisation and further sustainability.

As a global leader in aluminium smelting technology development, EGA will share over 20 papers detailing findings and solutions to address complex industrial challenges, including both EGA papers and papers co-authored with academics or suppliers.

Abdulnasser Bin Kalban, Chief Executive Officer of Emirates Global Aluminium, said: “Technology development has for decades been a source of global competitive advantage at EGA, and a commercial opportunity. Our bold aspiration is to innovate the future of aluminium production, and that is why we are hosting ICSOBA in the UAE. Convening the best technical minds in aluminium in Dubai will help our industry tackle some of its most complex challenges.”

The conference is taking place between 5 - 9 November 2023 in Dubai. This edition marks the second time ICSOBA takes place in Dubai and the fifth time in the Middle East.

EGA has developed its own aluminium smelting technology in the UAE for more than 30 years. EGA was the first UAE industrial company to license its core process technology internationally. DX+ Ultra, EGA’s latest fully-industrialised technology, was licensed to Aluminium Bahrain in 2016 for their potline 6 expansion project,. EGA technological know-how was used for the upgrade of five pilot reduction cells at Indonesia’s INALUM.

All EGA’s aluminium smelter expansions since the 1990s have used the company’s own UAE-developed technology. EGA has retrofitted all its older production lines.

For more information about the 41st International Conference and Exhibition of ICSOBA, please visit https://icsoba.org/2023/

This year’s edition welcomes seven MIT PhD and master's student engineers at EGA, to work with EGA teams on innovative solutions to some of the most pressing technical challenges facing the aluminium industry.

Over the course of eight weeks, MIT students will be embedded into departments at EGA to combine the latest academic thinking with EGA’s practical industrial expertise. EGA and MIT will focus on addressing industrial challenges in areas including Reduction, Technology Development, Carbon, and Power.

Initiated in 2015, EGA’s partnership with MIT has led to over a million dollars in annual cost savings through performance and efficiency improvements. The programme has since seen EGA's Jebel Ali and Al Taweelah facilities hosting over 54 student engineers from MIT’s David H. Koch School of Chemical Engineering Practice.

Abdulnasser Bin Kalban, Chief Executive Officer of Emirates Global Aluminium, said: "Our long-standing partnership with MIT reflects EGA’s commitment to innovate the future of aluminium production globally. By leveraging the knowledge of academia and industry, we are able to make further progress addressing complex industrial problems to achieve more effective and sustainable solutions. We anticipate valuable outcomes from this year’s collaboration."

MIT’s David H. Koch School of Chemical Engineering Practice has been sending students to industry leading companies around the world to apply their academic knowledge and expertise to the development of innovative solutions to industrial challenges for more than 100 years. EGA was the first company in the Middle East to participate in the programme.

EGA’s technology and development team works extensively with universities in both the UAE and internationally, with academic partnerships that include Khalifa University, the American University of Sharjah, Rochester Institute of Technology, Abu Dhabi University and American University in Dubai in the UAE, as well as the University of Auckland, University of New South Wales, and MIT.

Heat-related illness is a hazard for anyone working outside in the UAE summer, and can be fatal if left untreated. It is, however, preventable. EGA has focused for more than a decade on eliminating heat-related illness every summer.

Kenzen’s wearable technology offers the potential to further protect outdoor workers in the UAE, by continuously reporting core body temperature, heart rate, activity and other body indicators in real time allowing both the wearer and EGA’s safety team to detect heat strain in the body before the early signs can be felt. EGA used wearable devices for the first time in a trial of 50 volunteers last summer.

Despite industrial processes that generate further heat, and which must run and be tended around the clock, EGA achieved zero heat-related illnesses in 2019 and 2022. In 2021, EGA recorded two cases of heat-related illness requiring treatment at the company’s on-site medical centres. In both cases, the employees received rehydration via intravenous drips and fully recovered within hours.

Abdulnasser Bin Kalban, Chief Executive Officer of Emirates Global Aluminium, said: “Heat-related illness is a serious threat to health and even life in our region, and increasingly around the world. Our work has shown that heat-related illness is entirely preventable, even in challenging industrial environments like ours. Wearable technology offers the potential to protect people even more, and I am looking forward to the results of the wider trial we are conducting this summer.”

EGA‘s ‘Beat the Heat’ programme is an intense, summer-long effort across the company’s operations. Employees are trained to detect the early signs of heat stress in themselves and others. EGA conducts hydration tests before and during shifts, and employees are encouraged to take regular breaks and cooling showers. Cooling booths, drinking stations, icemakers, and portable air conditioning units in EGA production areas help keep people cool.

Kyle Hubregtse, CEO of Kenzen, shared his thoughts on the partnership, stating, "We are delighted to support Emirates Global Aluminium in their mission to prioritise employee health and safety and contribute to cutting-edge research on thermal physiology. By combining Kenzen's wearable technology with EGA's dedication to workforce well-being, we are setting new benchmarks in heat stress management and advancing the frontiers of occupational health."

EGA’s metal has been formed in Jebel Ali into parts for MBRSC’s MBZ-SAT, the region’s most advanced commercial satellite in the field of high-resolution satellite imagery, which is due to be launched in 2024.

The partnership is a space sector milestone for Make it in the Emirates, supporting the UAE’s Operation 300bn ambition to more than double the size of the industrial sector by 2031, and for the UAE’s goal of being a leader in space exploration.

The first fully UAE-made parts have already been delivered to the Mohammed Bin Rashid Space Centre at Al Khawaneej in Dubai.

His Excellency Salem Humaid AlMarri, Director General of the Mohammed Bin Rashid Space Centre, said: “At MBRSC, our mission is not only to explore the vast potential of space but also to drive the diversification of the UAE's economy. We recognise the immense value of joining forces with diverse partners to leverage their unique expertise and capabilities. By forging strategic partnerships with innovative entities such as Emirates Global Aluminium and Gulf Extrusions, we are able to expand the horizons of the UAE's space sector. Together, we are committed to pushing the boundaries of innovation and fuelling the growth of this vital industry.”

Abdulnasser Bin Kalban, Chief Executive Officer of Emirates Global Aluminium, said: “At EGA, we have been making it in the Emirates since 1979. We are proud to now provide CelestiAL solar aluminium, together with Gulf Extrusions, to another UAE champion which will use it to reach beyond the sky on behalf of our nation. Aluminium is an essential material for modern life, including space travel, and the UAE’s production through EGA is a global contribution to human progress.”

Omar Shegem, Chief Executive Officer of Gulf Extrusions, said: “Our parts, made in the UAE with EGA’s aluminium, are already found in everything from cars to skyscrapers around the world. We are now honoured that our work will leave the Earth’s atmosphere for the first time as part of MBZ-SAT. Together we are making it in the Emirates for the world and beyond.”

MBRSC has been dedicated to the advancement of space science, technology, and exploration, playing a pivotal role in the UAE’s space ambitions. The Centre’s main activities encompass the UAE Satellite Programme, the UAE Astronaut Programme, the Emirates Mars Mission, and the Mars 2117 Programme which includes the Emirates Lunar Mission and Space Ventures, among others. Recognising the importance of collaboration, MBRSC actively engages in partnerships with private entities, fostering innovation and driving the growth of the space sector.

Since the first satellite launch in 1957, aluminium has been the leading material in space exploration due to its lightweight, strength and resistance to corrosion.

EGA’s aluminium is the largest made-in-the UAE export after oil and gas and is shipped to more than 50 countries worldwide. In 2021, EGA became the first company in the world to produce aluminium commercially using solar power through a partnership with Dubai Electricity and Water Authority, which operates the Mohammed bin Rashid Al Maktoum Solar Park in the desert outside Dubai. Electricity generation accounts for around 60 per cent of the global aluminium industry’s greenhouse gas emissions. The use of solar power significantly reduces these emissions.

Last year, EGA hosted UAE astronaut Hazzaa AlMansoori for a virtual discussion with employees about the uses of aluminium in space.

EGA is one of the UAE’s most innovative companies and has developed its own aluminium smelting technology in the UAE for more than 30 years. EGA’s latest technology, DX+ Ultra, is amongst the most efficient in the global aluminium industry. The company has used its own technology in all its smelter expansions since the 1990s has retrofitted all its older production lines and was the first UAE industrial company to license its core process technology internationally.

Gulf Extrusions, a subsidiary of Al Ghurair Group, is one of 26 UAE customers of EGA which make everything from car parts to window frames for the local market and global export. EGA supplies some 10 per cent of its metal to local companies, and the aluminium sector as a whole accounts for 1.5 per cent of the entire UAE economy.

The winning team members from American University in Dubai were Mostafa Aboelnaga, Mohammad Rashwan, Mohammad AlHadi, Yassin Abdelmeguid and Bilal Serieh. They were coached by Dr. Salem Haggag.

In this year’s competition, students were challenged to design and build a robot that can measure the thickness of materials within EGA’s reduction cells, a task that is currently performed manually. Through this challenge, students were able to apply their academic knowledge in the field of robotics and automation to think creatively and develop a practical solution for the aluminium industry.

The American University of Dubai team’s winning entry was called Robot for Anode Cover Thickness (R FACT). It uses artificial intelligence to interpret images.

Five teams were shortlisted and received funding of AED 50,000 each from EGA to design and build their robots, and three teams proceeded to the finals. The other finalist teams were from Heriot-Watt University and Abu Dhabi University.

Abdulnasser Bin Kalban, Chief Executive Officer of EGA, said: "I congratulate the American University in Dubai team for their win. The skills students practice in EGA’s Al Robot competition are important for the UAE’s industrial future and the achievement of Operation 300bn. I hope these students will now be inspired to pursue careers in UAE industry."

EGA's technology and development team works extensively with universities in both the UAE and internationally, with academic partnerships that include Khalifa University, the American University of Sharjah, Rochester Institute of Technology, and Higher Colleges of Technology in the UAE, as well as the University of Auckland, University of New South Wales, and the Massachusetts Institute of Technology.

Through the EGA Ambassador Programme, EGA also collaborates with universities to bridge the gap between academic studies and workplace experience. This initiative is spearheaded by young Emirati engineers and professionals, who demonstrate the practical applications of science, technology, engineering, and mathematics in UAE industry.

With the goal of reaching 45 per cent in-focus Emiratisation, EGA plans to create 500 additional opportunities for UAE Nationals by 2026 to secure talent for the future and provide opportunities for young UAE Nationals in the industrial sector. By the end of 2022, EGA had achieved an in-focus Emiratisation rate of 42 per cent, one of the highest of any major company.

Since its inception in 2017, the Al Robot competition has provided students with the opportunity to develop their Industry 4.0 skills by practicing the application of their academic learning in the real world. The competition encourages the use of innovative and creative engineering skills which are fundamental to the UAE’s industrial future. 

For this year, students are required to design and build a robot that can measure the thickness of materials within EGA’s reduction cells, a task that is currently performed manually.

EGA’s Chief Executive Officer, Abdulnasser Bin Kalban, said: “The EGA Al Robot competition is now in its fifth year, and we are proud to look back at the innovative solutions university students have submitted throughout previous editions which are now in operation in our smelters. Developing the skills of our youth, and encouraging them to apply these skills in industry, is vital to the achievement of the UAE’s Operation 300bn industrial growth strategy. I look forward to seeing this year’s entries from the best students in science, technology, engineering, and mathematics in our country.”

Each selected team will receive AED 50,000 to design and build a prototype of their robots for testing at EGA. Winners will be announced in 2023, with finalist teams winning cash prizes worth AED 100,000 in total.

Last year’s edition of Al Robot required students to develop a robot capable of cleaning silt and mud from the aeration basin at EGA’s Al Taweelah site. The competition was won by a team from UAE University. Aeration increases the amount of oxygen in the water, safeguarding the marine environment.

EGA’s technology development team works extensively with universities in both the UAE and internationally to combine EGA’s industrial expertise with the latest academic thinking. EGA’s academic partnerships include Khalifa University, UAE University, Abu Dhabi University, Heriot Watt University, the American University of Sharjah, Rochester Institute of Technology and Higher Colleges of Technology in the UAE, the University of Auckland, University of New South Wales, and the Massachusetts Institute of Technology.