Global aluminium deficit to widen as EV and renewable demand surges

Global aluminium

Global aluminium deficit is set to widen from 2025 as demand outruns constrained supply. Forecasts show global primary aluminium supply rising to 74.3mn t in 2025, 75.8mn t in 2026 and 76.5mn t in 2027, driven mainly by new smelter projects outside China. However, parallel demand growth from electric vehicles and renewable energy will push consumption to 74.5mn t in 2025, 76.1mn t in 2026 and 76.8mn t in 2027, creating annual deficits. These figures translate into a global aluminium deficit of 166,000t in 2025, 281,000t in 2026 and 291,000t in 2027, underscoring a steadily tightening balance.

EV and regional supply dynamics reshape global aluminium deficit

The global aluminium deficit emerges despite incremental regional capacity growth and relatively stable legacy production. Australian primary aluminium output is expected to remain flat at 1.6mn t/yr across 2025-27, highlighting limited upside from a key exporter. Meanwhile, Chinese production is expected to remain below its formal 45mn t/yr cap, reinforcing structural constraints in the world’s largest market. Additional tonnes will therefore come from newer producers, with Indonesia forecast to lift output to 700,000t in 2025 and then double to 1.4mn t by 2027.

India also plays an important role in narrowing, but not eliminating, the global aluminium deficit. Indian primary production is expected to reach 4.2mn t in 2025 and 4.7mn t in 2027, supported by recent smelter investments and captive power integration. However, growth in EV and renewable segments is highly aluminium-intensive, especially for body sheet, castings and extrusions. As a result, structural demand from auto light-weighting, power transmission, solar frames and battery casings will likely sustain the global aluminium deficit even if some projects underperform. Rising primary prices and strong interest in low-carbon metal will deepen the premium gap between conventional and certified low-carbon material.

Recycling, alumina and bauxite respond to shifting aluminium fundamentals

Recycled metal is set to play a larger role in balancing the global aluminium deficit. Global demand for recycled aluminium is expected to increase from 27mn t in 2025 to 29mn t in 2027, reflecting OEM and policy pressure to cut embedded emissions. Total recycled output is forecast to reach 40mn t in 2025 and 44mn t in 2027, driven by higher utilisation of scrap in China, the US and Europe. This shift will partly cushion primary tightness, but scrap quality, collection systems and sorting capacity will limit how far recycling alone can offset the global aluminium deficit.

Midstream markets show a different pattern, with alumina entering a cyclical surplus even as primary metal tightens. Global alumina output is expected to increase to 148mn t in 2025 and 164mn t by 2027, while demand rises more slowly to 145mn t in 2025 and 151mn t in 2027. This surplus suggests downward pressure on alumina prices as global production recovers. Australian alumina output is forecast to rise from under 17.4mn t in 2024–25 to over 18.5mn t in 2026–27, supported by higher production at the Worsley refinery. In turn, global bauxite supply is projected to reach 422mn t in 2025 and 443mn t in 2027, against demand of 373mn t and 414mn t, highlighting a modest buffer at the ore stage even as the global aluminium deficit tightens the finished metal market.

The Metalnomist Commentary

The projected global aluminium deficit through 2027 underscores how quickly EV and renewable investment can tighten a previously balanced market. For producers, stable alumina and ample bauxite create a favourable cost backdrop, but power prices and carbon policies will still define margins. For buyers, competition for low-carbon and recycled units will intensify, making long-term contracts, scrap strategy and regional diversification critical to securing supply.