Primary aluminium production industry is the world’s larger industrial consumer of energy and ranked among the most CO2 intensive industries. It also generates enormous quantities of wastes that further decrease the exergy efficiency of its production process. However, this industry is one of the most vital sectors from economic and social point of view, not only for EU but also for the entire world. In order to remain viable and competitive, primary aluminium industry has to operate in a smarter way, be more energy efficient and meet the environmental requirements of our times. This can be achieved only through radical new technologies and novel business strategies, which will enable the industry to maintain its competitiveness and fasten its viability in the world’s markets, and explore new business opportunities. The main goal of this project is to provide primary aluminium industry with “green” innovative technological and economical solutions, focusing on the: (i) significant improvement of energy and exergy efficiencies of the production process; (ii) substantial reduction of GHG emissions; and (iii) complete elimination of the solid wastes. In order to achieve this goal within the project, novel technologies for the reduction of alumina to aluminium and the complete utilization of the red mud will be demonstrated and validated in pilot-scale. These technologies are energy-efficient and environmental-friendly, ensuring the competitiveness of the industry. A site optimization study of the new industry, integrating the novel technologies, is expected to achieve further reduction of energy and CO2 emissions and improve the energy and exergy efficiency of the whole process. It is aimed that the novel technologies will play a key-role on the sustainability, competitiveness and viability of primary aluminium production industry, so as to render it a leader industry for energy-efficient technologies and products in Europe and worldwide.