Emirates Global Aluminium (EGA) has announced that it has completed a three-year, $300m (AED1.1bn) project to replace older production lines at its Jebel Ali aluminium smelter with its own UAE-developed technology.
The company said in a statement that all of its 2,777 reduction cells now run on home-grown technology, improving EGA’s production capacity by more than 58,000 tonnes of aluminium per year.
The new reduction cells, according to EGA, each has the capacity to produce 20% more aluminium than those they replaced, and uses 10% less specific energy to make each tonne of metal.
In addition to boosting production capacity, the new technology reduces emissions of perfluorocarbons, a greenhouse gas generated in the aluminium smelting process from anode effects, by 96%.
Six million man-hours reportedly went into the project, with zero lost time injury (LTI).
Abdulla Kalban, managing director and chief executive officer at EGA, said: “This project to replace older reduction cells with UAE-developed technology boosts our competitiveness as one of the largest premium aluminium producers in the world, as the new reduction cells can produce more aluminium with less energy and with lower emissions.
“The most important achievement for me though was that a continuous focus on safety meant this challenging project was completed without [anyone getting hurt].”
Originally built in 1979, the 520 reduction cells at Potline 1 and Potline 3 at EGA Jebel Ali were the company’s oldest.
EGA said that replacement work done on Potline 1 and Potline 3 was carried out in 16 separate sessions to minimise the amount of time that reduction cells were out of production.
According to the company, its latest technology is the 10thgeneration since EGA started its technology development programme.
Last year EGA became the first UAE industrial company to license its technology internationally, with Aluminium Bahrain selecting it for its new Potline 6 following a competitive tender.