• HSBC

UAE flagship technology places Dubal on world map

  • United Arab Emirates: Saturday, February 20 - 2010 at 13:26
  • PRESS RELEASE

DX Reduction Cell Technology — an in-house developed innovation proprietary to Dubai Aluminium Company Limited ('Dubal'), the entirely state-owned enterprise that owns and operates the world's largest modern smelter with a captive power station — has achieved exposure to international industry experts, with extremely pleasing results.

So says Ali H A M Al Zarouni (Vice President: Smelter Operations), who presented a technical paper on the technology at the TMS Annual Meeting and Exhibition ('TMS 2010'), held at the Washington State Convention Centre in Seattle, USA from 14 to 19 February 2010.

"As demonstrated by the information contained in my presentation, DX Reduction Cell Technology has the proven capacity to operate at higher amperages, with associated business, operating and environmental benefits. This is because DX Technology cells are inherently more energy efficient, more productive and more environmentally friendly. These benefits have been documented at our Jebel Ali smelter where the technology has been implemented at industrial scale, earning third party endorsement in the process. Also, DX Technology cells have also been specified and installed at new Emirates Aluminium ("EMAL") green-field smelter, where commissioning of phase 1 commenced in December 2009,"

says Al Zarouni.

Al Zarouni also presented a technical paper on reduction cell start-up process that has been tried, tested and implemented at Dubal. The technique, which involves hitherto unheard of cell pre-heat on full line current, offers techno-economic benefits of higher productivity at lower cost and lower energy consumption. Waste generation is practically nil and the process is environmentally friendly. It also offers an accelerated start up rate of cells; and therefore has great potential for application in expansion projects and in restarting a potline following a power outage.

Dubal's technological progress was further promoted through an exhibition stand at TMS 2010, the theme and key messages being projected across all media, including the exhibition graphics and collaterals. Special emphasis was placed on the benefits offered by Dubal's DX Reduction Cell Technology, which is fully a saleable and bankable innovation that we are proud to offer to the market place.
'TMS 2010'.
'TMS 2010'.
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About Dubai Aluminium Company ('Dubal'):
Dubai Aluminium Company Limited ('Dubal') owns and operates the world's largest modern aluminium smelter with a captive power station. Built on a 480-hectare site in Jebel Ali, the complex's major facilities comprise a one million metric tonne per annum primary aluminium smelter, a 2,350 megawatt power station (at 30°C), a large carbon plant, casthouse operations, a 30 million gallon per-day water desalination plant, laboratories, port and storage facilities.

The Jebel Ali site has the capacity to produce more than one million metric tones of high quality finished aluminum products a year, in three main forms: foundry alloy for automotive applications; extrusion billet for construction, industrial and transportation purposes; and high purity aluminium for the electronics and aerospace industries. More than 300 customers are served in at least 45 countries predominantly in the Far East, Europe, the ASEAN region, the Middle East and Mediterranean region, and North America.

The company holds ISO 9001, ISO/TS 16949, ISO/IEC 27001, ISO/IEC 20000, ISO 14001 and OHSAS 18001 certification at its Jebel Ali site; and has twice won the Dubai Quality Award in the Production and Manufacturing sector (1996 and 2000). More than 4,100 skilled operators, tradesmen, administrative staff, technicians, professionals and managers are employed by Dubal. Some 24% of the total workforce is drawn from the local population, with UAE nationals holding over 70% of Senior Management positions.

Dubal also holds a 50% share in Emirates Aluminium ("EMAL"), a green-field smelter development at Al Taweelah, Abu Dhabi. Commissioning of the first phase of EMA (comprising a 756,000 metric tonne per annum smelter plus associated power generation, reduction material and casting infrastructure) began in December 2009.

Driven by a quest for continuous improvement and ongoing innovation, Dubal has invested substantial sums of money over the past 25 years in developing advanced reduction cell technologies that not only improve productivity but also reduce the operations' impact on the environment through improved energy efficiency and minimized emission levels.

This has culminated most recently in Dubal's proprietary DX Technology - a UAE flagship technology that operates at 370kA plus and therefore ranks among the best in its class. Developed in 2006, DX Technology has been implemented in a dedicated 40-cell potline at Dubal's Jebel Ali smelter complex; and is being installed at EMAL, which will ultimately produce 1.5 million metric tones per annum using DUBAL's DX Technology.

Entirely state-owned, Dubal is one of the largest non-oil contributors to the economy of Dubai and is widely regarded as the industrial flagship of the UAE. Having begun to tap metal at the Jebel Ali site in November 1979, Dubal celebrated its 30th anniversary in 2009.

Contact:
Yasser Fathy
Managing Director
T +971.4.391.1200
F +971.4.390.4511

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