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EMAL Completes Start-up of New Potline

Not only is the new potline (Potline 3) with 1,7 km the longest in the global aluminium industry, but also the highest-ever start-up rate across the Gulf Cooperation Council (GCC) region was achieved with 6 pots per day energised for 21 days straight. The energisation of the last cell took place on 10 June 2014, witnessed by a high level delegation including members of the Board of Directors of the Emirates Global Aluminium PJSC – EGA the new UAE-based aluminium conglomerate. The new potline is expected to produce
a total of 471000 t of molten metal from start-up in 2013 to the end of 2014, approximately 77000 t more than the original FEED studies. Speaking at the cell start-up, Saeed Al Mazrooei (CEO of UAE Operations at EGA) said, “Following the completion of Phase II, the smelter at EMAL will have a nameplate capacity of 1,32 Mt/a. By energising the cells ahead of schedule, EMAL is expected to produce 1,2 Mt in 2014. This will catapult EGA into a leading position in the global industry. We are very proud of our Emirati-lead project team utilising Emirati smelter technology to achieve this mega smelter, which has placed EGA among the top five smelters in the world outside China, by tonnage; and ranked the UAE as the fourth largest aluminium producing country in the world.“ EMAL Phase II also comprised an upgrade of the 756 cells (housed in two potlines) built during EMAL Phase I, which raised the plant`s initial production capacity to 800000 t. Importantly, the EMAL Phase II project maintained and even built-on the impressive safety records achieved in the construction and operational phases of EMAL Phase I. Despite more than 20000 employees working around the clock to build and commission the additional potline, EMAL Phase II achieved 42 million work-hours without lost time injuries. EMAL Phase II incorporates DX+Technology, the best-in-class reduction technology developed in-house and proprietary to Dubai Aluminium, another operating subsidiary of EGA. Operating at 440 kA (the highest amperage in the GCC region), the DX+Technology cells at EMAL are ultimately designed to operate at 460 kA, yielding greater productivity at lower specific energy consumption levels and with reduced
environmental impact. Reflecting an on-going quest to be bigger and better, the completion of Phase II has secured EMAL a long list of industry accolades. These include the world`s largest gas treatment centre; the world`s biggest anode baking furnace; the biggest single-site captive power station (3100 MW); the highest single-line capacity green anode manufacturing plant (1,08 Mt/a); and the largest single-site casthouse (capacity of 1,65 Mt/a).

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