Name and Location
Emirates Aluminium (EMAL) smelter complex project, Abu Dhabi, UAE.

Client
EMAL.

Project Description
The smelter complex is being built on a 6 km² site in two phases.

Phase 1 was completed early in 2011 and comprised the construction of two potlines, with a total of 756 reductions cells.

Supporting units included a 2 000 MW power plant; a carbon plant encompassing an anode manufacturing plant, a baking furnace and a paste plant; a cast house; a laboratory; a dedicated berth; a reverse osmosis plant; a pitch unloading station; a raw material ship unloader, conveyer belt; and silos for storage.

Phase 2 involves the construction of an additional potline of 444 reduction cells and supporting units. The units will include a ship unloader, the current power plant will be expanded to 3 000 MW, and a new cast house facility and anode manufacturing plant will be built. Once completed, the EMAL smelter complex will be one of the largest single-site aluminium smelters in the world, with production of 1.35-million tonnes a year.

With the longest potline and largest gas treatment centre in the aluminium sector, a 2 000 V rectifier/transformer and the biggest captive gas-fired power plant in the world, the smelter complex will set many records in the industry.

Value
Phase 1 cost $5.7-billion.

Phase 2 will cost $4.5-billion.

Duration
Phase 2 is expected to be completed by the end of 2014.

Latest Developments
EMAL has achieved first hot metal (FHM) at its Phase 2 expansion.

Completed three months earlier than scheduled, the milestone FHM marks the start of production for EMAL’s Phase 2, as it heads towards a total production of 1.3-million tonnes a year of aluminium.

Using Dubai Aluminium-developed DX+ technology, Phase 2 operates with the highest amperage in the region at 440 KA and is built to reach 460 KA.

Key Contracts and Suppliers
None stated.

On Budget and on Time?
Phase 1 was completed ahead of time and within budget.

Contact Details for Project Information
EMAL, tel +971 2 509 2222 or fax +971 2 509 3333.