Aluminum Scrap Markets
October 20, 2025
EGA-Spectro launches Phase 2 at Rosemount, expanding secondary billet capacity
Written by Nicholas Bell
EGA Spectro Alloys has launched the second phase of a major recycling and billet plant expansion in Rosemount, Minnesota, marking another step in the company’s transition from a foundry alloy producer into a fully integrated secondary billet supplier for the U.S. extrusion market.
The project will add about 45,000 metric tons (t) of additional billet recycling capacity per year once completed in 2027.
Phase two follows the commissioning earlier this year of a 90,000-square-foot expansion that began recycled aluminum billet production for the first time at the Rosemount campus.
The first phase of the project added about 55,000t of billet capacity, while the second phase will bring that total closer to 100,000t annually, alongside existing ingot and sow operations of about 165,000t per year.
The second phase includes the installation of an additional scrap-melting furnace with automated charging, stirring, and skimming systems, along with a homogenizer – equipment that will allow greater alloy flexibility.
Once complete, total recycling capacity at the site will near 210,000t per year – about 165,000t from its legacy ingot and sow operations and about 100,000t from the new billet lines – positioning the facility as one of the largest fully integrated secondary aluminum operations in the Upper Midwest.
Spectro’s new chapter under EGA
Spectro Alloys’ transformation accelerated after Emirates Global Aluminium (EGA) acquired an 80% stake in 2024, rebranding the business as EGA Spectro Alloys. EGA has also sought to expand its footprint in the U.S. with a proposed primary aluminum smelter based in Oklahoma.
Before the recent expansion, the Rosemount plant produced ingot and sow castings of 380, 356, 319, B390, and 413, as well as marketing aluminum dross.
The Rosemount investment marks EGA’s first major operational expansion on American soil since that acquisition, with billet production marketed under the RevivAL brand, EGA’s label for billet containing a significant portion of recycled aluminum as its feedstock.
From ingot to billet
Billet shipments from phase one began this summer, with initial orders delivered to Crown Extrusions in Chaska, Minnesota for dock fabrication components.
As AMU reported earlier this month, the target scrap-to-primary melt mix ratio for its current billet operation is 80% recyclable material to 20% primary aluminum.
According to CRU data, Minnesota’s share of total U.S. secondary billet capacity will nearly double by 2027, led entirely by the expansion.
Once completed, the Rosemount facility will represent roughly 20% of secondary billet capacity in the Upper Midwest, an emerging hub for recycled billet production.
Secondary billet landscape
The broader secondary billet landscape remains concentrated in a handful of states, with Indiana, Kentucky, and Tennessee together accounting for over one-third of total domestic capacity. The Rosemount project, however, shifts some of that balance northward.
Ohio and Pennsylvania form the core of the domestic billet market, together accounting for well over a quarter of U.S. billet capacity.
Texas, Indiana, and Kentucky comprise the next quarter of domestic output potential, each hosting multiple plants but seeing mostly incremental upgrades rather than greenfield capacity.
Despite this gradual rebalancing, Ohio is still poised to retain its lead, with roughly 260,000t of additional capacity slated to come online by 2027, according to CRU data and the latest updates available from each venture.
That growth will come primarily from the Adaptiq project and the Century Aluminum-Metal Exchange joint venture, which together position the state’s total billet footprint to nearly one-fifth of the country’s secondary capacity by 2027 – even after accounting for new investments at Rosemount and other expansions across the U.S. over the same period.
