We are delighted to share that DECO Group has been formally recognized by Emirates Global Aluminium (EGA) for our role in deploying the EX Max Technology pilot at the Al Taweelah smelter in June 2025. This award reflects not only engineering excellence but a shared commitment to sustainable innovation.
🌍 About Emirates Global Aluminium (EGA)
- Established in 2013 after the merger of DUBAL and EMAL, EGA is jointly owned by Mubadala Investment Company and the Investment Corporation of Dubai. It operates the world’s largest aluminium smelter at Al Taweelah, with a capacity of 1.3 million tonnes per annum, and a 2.35 GW power station
- EGA operates across the aluminium value chain: from bauxite mines in Guinea to alumina, primary smelting, recycling, and global technology licensing
- Since 2021, EGA has been advancing sustainability with CelestiAL solar aluminium, purchasing 1.1 million MWh of solar energy and contributing to low-carbon operations
🔬 What Is EX Technology and Why It Matters
EGA’s proprietary EX Technology is the 10th generation of in-house aluminium smelting systems. The pilot comprises 10 EX reduction cells that are larger than the earlier DX+ Ultra model and deliver:
- Up to 22% increase in production capacity
- 5–12% reduction in greenhouse gas emissions per tonne of aluminium, depending on variant
- Higher amperage and improved current efficiency in each potline
- Improved pot performance, busbars, and reduced ambient temperatures for better working conditions
The pilot cell construction commenced in late 2024, with the first hot metal output in mid‑June 2025, and final cell energized in July 2025 by H.E. Homaid Al Shimmari, EGA Chairman
🤖 Industry 4.0 at the Heart of EX Technology
EX is not just about scale—it’s a smart facility:
- Equipped with IoT sensors and networks for real-time process adjustments
- Enabled for AI-based autonomous controls on cranes, potlines, and supporting systems
- Incorporates machine learning, enabling predictive optimization and continuous improvement of production processes
- Demonstrates EGA’s broader commitment to industrial digitization, following its recognition as a World Economic Forum Industry 4.0 Global Lighthouse in 2025
🏅 DECO’s Role and the Award from EGA
As part of the extended execution team, DECO supported several aspects of the pilot deployment—from EPC execution to MEP works, quality assurance, and safety coordination. Our contributions helped ensure:
- Safe and timely commissioning under challenging site conditions
- Seamless integration with EGA’s digital quality control and reporting frameworks
- Precise engineering support aligned with EGA’s sustainability goals
We were honored with an award that carried the words of HH Sheikh Mohammed bin Rashid Al Maktoum:
“Innovation is an ongoing journey limitless in time and boundless in possibility.”
📈 Looking Ahead
EGA aims to fully industrialize EX technology by 2028, scaling it globally, including its first US-based deployment in Oklahoma. With EX, EGA targets low-carbon aluminium expansion, positioning itself as a global technology provider in the sector. For DECO, being part of this journey enhances our credentials as a trusted EPC partner capable of delivering innovation-aligned infrastructure solutions.
🙏 Acknowledgments
We extend our deep gratitude to:
- EGA leadership, for entrusting DECO with participation in this visionary project
- Our project partners
- Our DECO team who helped bring EX to life: Afsal Khan, Prayag Kunhikelu, Ricardo Cajape, Nasser A Bin Kalban, Shahad Ghedan, Jamal Al Hemeiri, Sylvain Dery, Ali Salameh Rashid P A, Muhammad Tanveer PMP®, Engr. Raza Bahadur, Anwar Hameed, Frank Irac, Jithin Janardhanan PMP®, and Asim Abbasi
We are proud to build—and innovate—together.
