Reducing Emissions in the UAE Oil Industry Through Additive Manufacturing

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December 6, 2023


In the fast-paced environment of the oil and gas industry, efficiency, sustainability, and environmental conservation are increasingly becoming central concerns. The oil giants, such as ADNOC, Aramco, Shell among a few others, are at the forefront of tackling these challenges. This abstract presents a concept that could potentially lower the UAE’s emissions by approximately 3.62% through the innovative use of additive and advanced manufacturing (AM) for on-demand spare parts production.

The Case of Titanium Grade 5 Impeller

As proof of concept, we explore the production of a titanium grade 5 impeller currently being used in gas refineries across the region. Traditional methods like casting may seem cost-effective, but come with significant environmental impacts. Our analysis reveals that while the financial savings may not appear significant initially, AM leads to a substantial environmental benefit.

  • Total AM Cost: USD 1,099.75
  • Total Casting Cost: USD 1,052.54
  • CO₂ Emission Savings per Impeller: 12.93 kg

Scaling the Impact

The impact goes beyond a single impeller. Multiplying the savings by 13,500 similar parts over one-year results in a saving of 174,555 kg of CO₂. When applied to 80,000 parts per year across various entities the cumulative impact becomes even more pronounced and exceeds 7,240,800 kg of CO₂.

Additional Savings

Furthermore, the AM approach brings indirect savings by reducing the need for shipping casted parts from abroad. This not only lowers costs, but also further reduces emissions, contributing to a more sustainable and environmentally friendly supply chain.


By digitizing spare parts and enabling local production using AM, the UAE can take significant strides in lowering emissions. Although the immediate financial savings may be subtle, the long-term environmental impact is profound, as demonstrated by the example of the titanium impeller. This approach is aligned with global sustainability goals and positions the region as a leader in innovation and environmental stewardship within the oil industry.

By fostering collaboration between oil companies, technology providers, and policymakers, regional governments can further explore and expand on this concept. The shift towards AM is not just a technological advancement; it’s a commitment to a greener, more sustainable future.