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Manufacturing

Hydrogen and helium may be made up of small molecules but have a big role to play in the technology innovations of the future

From the natural gas that underpins power generation to the carbon dioxide emissions driving the climate crisis, there is no denying gases have a significant impact on modern life, according to Eve Pope, senior technology analyst at IDTechEx.

The two lightest gases - hydrogen and helium - may be made up of small molecules but have a big role to play in the technology innovations of the future. Key application areas include mobility, power generation, and semiconductor manufacturing.

Hydrogen power

Hydrogen is an energy carrier that could replace fossil fuels to power the future. Fuel cells can convert hydrogen gas into electricity through a chemical reaction with oxygen. Because solid oxide fuel cells have a long operating lifetime and fuel flexibility, they are well-suited to the continuous power generation required for sustainable data centres. As the AI boom continues, some data centres are already using solid oxide fuel cells running on natural gas, with plans to transition over to low-carbon hydrogen once economics and infrastructure can make this commercially feasible.

For cars, fuel cell electric vehicles can also be powered by the reactions between stored hydrogen and oxygen in the air. Markets for fuel cell electric vehicles will depend upon national investments in green hydrogen projects and rollouts of hydrogen refueling stations.

Industrial decarbonisation of iron and steel enabled by hydrogen

For iron and steel, natural gas direct reduced iron (DRI) production using shaft furnaces is already mature. Hydrogen-based DRI (H2-DRI) processes represent the next logical evolution toward greener steel production. Midrex and Energiron shaft furnace plants have successfully demonstrated the use of hydrogen or hydrogen-rich gases, as evidenced in projects like HYBRIT by SSAB in Sweden and HBIS Group in China.

The success of hydrogen-based green steel production will depend heavily upon the availability of green and blue hydrogen and supporting infrastructure, with IDTechEx’s “Green Steel 2025-2035: Technologies, Players, Markets, Forecasts” report forecasting that 46 million tonnes of steel will be produced enabled by hydrogen in 2035.

idtechx

Hydrogen isotopes for nuclear fusion

Even the heavier isotopes of hydrogen have a role to play. Deuterium and tritium are essential fuels for nuclear fusion technologies, hoped to provide energy-dense, continuous sources of green energy with no risk of meltdown. According to IDTechEx’s “Fusion Energy Market 2025-2045: Technologies, Players, Timelines” report, commercial fusion companies have raised over US$9bn to date, while an increasing number of governments see fusion as the modern day 'space race'. Players are pursuing different reactor designs and fuels, leading to various materials opportunities and supply chain challenges.

Helium required for semiconductor manufacturing

Helium is widely used in manufacturing processes due to its cooling and inert properties. It is crucial for thermal management during semiconductor production. As semiconductor manufacturing advances towards smaller nodes (essential for AI, autonomous vehicles, etc.), reliance on helium will continue to grow. Helium is a finite resource, so technologies for helium production and helium substitutes covered in IDTechEx’s “Helium for Semiconductors and Beyond 2025-2035: Market, Trends, and Forecasts” report will become increasingly essential.

Materials key to hydrogen and helium production

From the ion exchange membranes in electrolyzers for green hydrogen generation to the gas separation membranes used in helium and hydrogen production, the applications explored in this article represent significant opportunities for chemicals and materials companies. Materials for green hydrogen are needed for components such as catalysts, electrodes, porous transport layers, gas diffusion layers, bipolar plates, and gaskets. Innovations include new catalysts with less iridium content to cut costs. For gas separation membranes, the development of new palladium-alloy metallic membranes could unlock ultra-pure H2 separation.

Life cycle analysis confirms Luminy PLA’s sustainability credentials. (Image source: Total Energies)

TotalEnergies Corbion, a global leader in bioplastics innovation, has signed a strategic distribution agreement with Multi Trade Group, naming it the main distributor for Luminy PLA across the UAE, Saudi Arabia, and the wider Middle East.

Luminy PLA (polylactic acid) combines strength and durability for reusable applications with sustainable end-of-life options for disposable products.

Unlike conventional plastics, it can be reused, mechanically and chemically recycled, or industrially composted, breaking down faster than banana or orange peels.

The portfolio includes high-heat, standard, and low-heat grades, PDLA for stereocomplex compounds, and recycled PLA with 30% or 100% content.

Life cycle analysis confirms Luminy PLA’s sustainability credentials. Virgin PLA has a cradle-to-gate footprint of 0.29 kg CO2-eq per kg—an 85% reduction compared to conventional plastics. With 30% recycled content, it achieves near carbon neutrality, and 100% recycled PLA delivers a negative footprint of -0.65 kg CO2-eq per kg.

By leveraging Multi Trade Group’s regional presence and expertise, the partnership aims to expand access to Luminy PLA for converters, compounders, and brand owners, supporting Middle East government and industry sustainability goals.

TotalEnergies Corbion operates a 75,000 tons-per-year PLA facility in Rayong, Thailand, and pioneers chemical recycling of PLA via hydrolysis depolymerization, producing recycled PLA (rPLA) with food-contact approval and performance equivalent to virgin material.

With the Middle East increasingly prioritising sustainability and reducing reliance on conventional plastics, the agreement positions Luminy PLA as a scalable, high-performance alternative for industries balancing functionality with environmental responsibility.

“As a company, we are committed to delivering sustainability, recyclability, and solutions that reduce our carbon footprint and waste impact,” said Asif Iftekhar, CEO of Multi Trade Group. “This partnership with TotalEnergies Corbion reflects our mission and our responsibility to help build a sustainable future. Today’s signing ceremony at our headquarters in Sharjah marks an important step forward for the region’s polymer industry.”

“Multi Trade Group’s local expertise and market reach make them an ideal partner to expand Luminy PLA in the Middle East,” added Derek Atkinson, vice president of sales at TotalEnergies Corbion. “Together, we can help customers reduce environmental impact, achieve ambitious sustainability goals, and accelerate the shift toward a regenerative circular economy.”

 

The project centred on the installation of a third ball mill. (Image source: EGA)

Emirates Global Aluminium (EGA), the UAE’s largest industrial company and the world’s biggest producer of “premium aluminium”, has completed a debottlenecking expansion at its Al Taweelah alumina refinery, boosting production capacity by up to 50,000 tonnes of alumina per year.

The project centred on the installation of a third ball mill, strengthening operational resilience and paving the way for future output growth at the UAE’s only alumina refinery. Ball mills grind bauxite ore into fine particles for chemical processing into alumina. The additional unit enhances throughput, reduces the risk of unplanned outages, and improves overall availability alongside the two existing mills.

Executed entirely by EGA’s in-house teams, from engineering and project management to construction and commissioning, the project was completed in under two and a half years, recording over 650,000 work hours without a single Lost Time Injury.

Since its commissioning in 2019, Al Taweelah alumina refinery has consistently operated above its nameplate capacity of 2mn tonnes per year. In 2024, the facility supplied 49% of EGA’s total alumina needs, underscoring its strategic role in the company’s integrated value chain.

Abdulnasser Bin Kalban, Chief Executive Officer of Emirates Global Aluminium, said, “This expansion is a key step forward for Al Taweelah alumina refinery, unlocking additional production capacity as we reorient our bauxite supply chain beyond Guinea. It further strengthens our operational resilience and unlocks capacity growth. I thank every member of the team who contributed to this success.”

PepsiCo and DP World launch US$20mn plant in Lagos, boosting jobs, food security, and investor confidence. (Image source: DP World)

The Federal Government has reaffirmed its commitment to economic reforms and private sector-driven growth following the commissioning of a US$20 million PepsiCo and DP World production facility in Lagos

The project highlights renewed investor confidence in Nigeria’s economy and marks a significant step forward in industrial development.

The launch event was attended by senior government officials and business leaders. Speaking at the commissioning, the minister of finance and coordinating minister of the economy, Wale Edun, described the facility as evidence of Nigeria’s rising competitiveness under president Bola Ahmed Tinubu’s reform agenda.

“This is not just about two companies. It is about what is possible when global business and Nigerian ambition come together,” said Edun. “Our reforms have restored stability, unlocked investment, and are creating the conditions for rapid, inclusive growth.”

From the private sector, PepsiCo MENAPAK President Ahmed El-Sheikh emphasised Nigeria’s central role in the company’s regional strategy. He noted that the new plant demonstrates both confidence in the country’s long-term future and a commitment to sustainable investment.

Mohammed Akoojee, CEO of DP World Sub-Saharan Africa, added, “Nigeria is a key hub for Africa’s growth. Through this partnership, we are helping to build efficient, resilient supply chains that support long-term development.”

The newly inaugurated plant will produce PepsiCo’s iconic Cheetos brand, with more than 90 percent of inputs locally sourced. It is expected to generate new employment opportunities, contribute to food security, and strengthen Nigeria’s position as a manufacturing and export hub within West Africa and under the African Continental Free Trade Area (AfCFTA).

According to a statement issued by the Director of Information and Public Relations, Mohammed Manga, the investment represents a major boost for Nigeria’s economic growth. It also reinforces global investor confidence, opening fresh opportunities for businesses and citizens across the country.

Every year on 28 August, the UAE celebrates Emirati Women’s Day. (Image source: Al Gharbia Pipe Company)

Every year on 28 August, Emirati Women’s Day honours the achievements of women across the UAE who are contributing to national progress. This year, three young Emirati engineers at Al Gharbia Pipe Company reflect on how they are shaping the country’s industrial future through innovation, technology, and a passion for lifelong learning.

For Azeeza Al Ali, innovation engineer at Al Gharbia Pipe Company, integrating artificial intelligence into manufacturing is not just about efficiency. It is about aligning with the UAE’s wider industrial ambitions. “At Al Gharbia Pipe Company, we’ve integrated AI through smart systems like MES 4.0 to monitor production in real time, reduce downtime, and cut waste,” she explains. “AI also powers our automated quality checks and helps optimise energy and material use, supporting both efficiency and sustainability in line with UAE’s industrial goals.”

Azeeza Al Ali Al Gharbia

Azeeza Al Ali, innovation engineer at Al Gharbia Pipe Company

Yet the journey has not been without challenges. Azeeza notes that the lack of in-house AI expertise often requires relying on external partners. “One key challenge is that we don’t have in-house AI specialists, so for every AI idea, big or small, we need to find and work with external vendors. This takes time and coordination,” she admits. “But by choosing the right partners and starting with AI projects, we’ve been able to move forward in line with the UAE’s digital transformation goals.”

Her colleague, Meera Mansour Al Bloushi, has taken a more hands-on route in the company’s innovation drive. As assistant engineer – innovation, she built a vision-guided autonomous robot from scratch, an achievement that brought together engineering disciplines and underscored her commitment to sustainability. “The goal was to build a robot that could detect and pick up objects mainly for recycling and sorting materials like paper, plastic, and general waste using a camera, image processing, and precise motor control,” she says.

Meera Mansour Al Bloushi Al Gharbia

Meera Mansour Al Bloushi, assistant engineer – innovation, Al Gharbia Pipe Company

Although her background is in electrical work, Meera took on the mechanical design herself. “I designed the robotic arm and assembled the parts, and ensured smooth operation by integrating stepper motors, sensors, and programming the movement logic. The camera allowed the robot to ‘see’ and respond to its surroundings in real time,” she explains. In an industrial setting, she believes robots like this can “help improve efficiency and safety by automating tasks such as sorting, inspection, and material handling in hard-to-reach areas, as well as support sustainability efforts.”

Her curiosity, however, extends beyond robotics. A passionate advocate of lifelong learning, Meera continues to explore new areas that feed into her ambition of becoming a researcher and inventor. “I’m currently exploring new skills outside my main field, such as CNC turning, web application development, and electrical installation,” she says. “Even though these areas seem different, they help me grow as a well-rounded researcher and inventor. I believe being an engineer isn’t about staying in one narrow field – it’s about having broad knowledge and curiosity.”

For Mahla Mohamed Almansoori, another assistant engineer – innovation at Al Gharbia, technical competitions were the starting point of her career. She honed her skills in CNC milling while competing at the Emirates Skills National Competition, an experience that taught her the value of precision and perseverance. “My CNC milling experience and success at Emirates Skills taught me to work with precision, think creatively under pressure, and solve problems step by step,” she reflects. “At Al Gharbia, I use this mindset to find practical and efficient solutions to meet and elevate our high quality standards.”

Mahla Mohamed Almansoori Al Gharbia Pipe Company

Mahla Mohamed Almansoori, assistant engineer – innovation, Al Gharbia Pipe Company

Now, she is applying that same discipline to rethinking industrial workflows. “I’m working on making manufacturing data cleaner and faster to use by automating processes and reducing manual work,” Mahla says. “I’m also improving workflows to cut waste and boost productivity, helping support the UAE’s vision for a smarter and stronger industrial sector.”

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