HH Sheikh Hamdan officially inaugurates Potlines 7B & 9B at Dubai Aluminium Company

The expansion programme has resulted in an increased capacity of 100,000 tonnes per annum, raising the total annual production capacity of DUBAL - one of the world's largest producers of premium quality aluminium - to 861,000 tonnes a year.

An official gala ceremony was organized to mark this occasion at the sprawling DUBAL complex, which was attended by dignities, VIPs and guests in the UAE His Highness Sheikh Hamdan, HE Mr. Ahmed Humaid Al Tayer, Vice-Chairman of the board of directors of DUBAL, Mr. Mohammed Al Ghurair, Managing Director, DUBAL, Mr. Abdullah J. M. Kalban, CEO, DUBAL, dignitaries, members of the board, senior management team and other employees.

Addressing the audience, HE Mr. Ahmed Humaid Al Tayer said: "The expansion programme and other initiatives could not have been possible without the continuous support of HH Sheikh Hamdan, who has always stood by us to ensure that DUBAL's international status as one of the leading global players in the production of primary Aluminium is maintained."

"DUBAL already contributes more than 7% to Dubai's GDP and plays a key role in the manufacturing sector. This is the result of HH Sheikh Hamdan's vision to expand Dubai's and consequently the UAE's manufacturing base, which will further expedite the overall growth of the country," said HE Mr. Al Tayer.

HE Mr. Al Tayer congratulated the board of directors, the senior management team responsible for expansion project and asked all the employees to work hard and strive towards achieving the targets specified in the 10-year future growth program.

Mr. Yousuf A. Bastaki, General Manager, Engineering, Expansion & Technology Development, DUBAL, who was the Master of the Ceremony, gave the welcome address.

The official ceremony began with a reading from the Holy Quran after the arrival of HH Sheikh Hamdan, the board members and other dignitaries. This was followed by speeches from HE Mr. Ahmed Al Tayer and Mr. Abdullah Kalban. A six-minute video presentation highlighting the various stages of the expansion was shown after the speeches at the program.

After the video presentation, HE Mr. Al Tayer presented a memento to HH Sheikh Hamdan, who then toured the sprawling smelter complex.

Complimenting the core management team and all those who worked towards completing the expansion programme, Mr. Kalban, said: "On this momentous occasion, I am honoured to point out that the AED1.04-billion (USD289-million) expansion programme was completed below the budgeted, saving the company around AED220.37 million (USD60 million)."

"The board of directors approved the expansion plan on June 6, 2005 and the first concrete was laid on December 31, 2005 for Potline 7B and November 15, 2005 for Potline 9B. The first metal was produced from 7B on September 24, 2006 and from 9B on June 15, 2006. In other words, Potline 7B expansion was completed in nine months whereas Potline 9B was finished in six month's time from the date of the first concrete" Mr. Kalban said.

"Potline 7B expansion covered creating 128 cells in addition to installation of a USD30 million environmental protection plants. The Environmental Protection System, one of the most advanced in the world, not only purifies but recycles the impact of effluents in the atmosphere," Mr. Kalban pointed out.

"Potline 9B expansion involved creating 36 additional cells, maximizing the use of assets to support existing cells through providing anodes and electricity and upgrading of the existing fume treatment plant system," added Mr. Kalban.

DUBAL also achieved 4.2 million man-hours without LTA (loss time due to accident) in a total of 5.2 million man-hours that was needed for the execution of the expansion. Moreover, the pot cut-in rate at 6.25 cells a day was another record for DUBAL.

A total of 2,000 contracted workers were involved in the implementation process and the job was awarded to 75 contractors who oversaw 116 main packages. In its continuing support to UAE-based businesses, DUBAL awarded a total of 40% of the packages to local contractors.

A group of SNC-Lavalin engineers supported by a team of DUBAL engineers played a crucial role in the completion of the expansion. Among the DUBAL Project Managers, 40% were UAE nationals.

"Probably one of the biggest objectives that DUBAL achieved during the process was involving UAE nationals so that they are trained to manage such huge projects in the future," remarked Mr. Kalban.

"Another key feature that helped in DUBAL achieving this milestone is the in-house D20 technology. DUBAL has developed and tested its own advanced reduction technology to achieve efficient smelting performance," pointed out Mr. Kalban reiterating once again that the commitment and devotion shown of the employees brought this project to a successful completion.

"With the completion of the Potline 7B and 9B expansion phase, DUBAL is entering its next growth trajectory .With our in-house technology and local talent, we at DUBAL are optimistic that the company will reach greater heights," concluded Mr. Kalban.

DUBAL is the industrial flagship of Dubai. The company produces and exports high quality, value added primary aluminium products to more than 44 countries world-wide.