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DUBAL Technologies: Serving the Gulf Region

DUBAL Technologies: Serving the Gulf Region. ARABAL 2012, Doha, Qatar Presented by Abdalla Zarouni. Content. DUBAL at a glance DUBAL Technologies – Serving the Gulf Region Optimized design for Gulf climate Benchmark KPIs High quality and experienced services, at your door step

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DUBAL Technologies: Serving the Gulf Region

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  1. DUBAL Technologies: Serving the Gulf Region ARABAL 2012, Doha, Qatar Presented by Abdalla Zarouni

  2. Content • DUBAL at a glance • DUBAL Technologies – Serving the Gulf Region • Optimized design for Gulf climate • Benchmark KPIs • High quality and experienced services, at your door step • Advancement of DUBAL Technologies • DX and DX+ Technologies • Green technologies with world-class performances • Advancement of the technologies • Retrofitting old lines • Development of D18+ Technology • Modeling, engineering and design aspects • KPIs of the demonstration cells

  3. DUBAL at a glance

  4. Site construction 1977 to 1979

  5. DUBAL at a glance • One of the world’slargest producers of primary aluminium • Smelter(>1,000,000 tpa) • Casthouses (>1,143,000 tpa) • 2,350 MW power station (30°C) • 30 million gallon/day desalination plant • Port facilities • Warehouses • Administration • Residential area

  6. Technology innovation and deployment

  7. DUBAL Technologies:Serving the Gulf Region

  8. Optimized design for Gulf climate

  9. Optimized design for Gulf climate • Open building concept has been designed and modelled to provide very good working conditions for operators

  10. Optimized design for Gulf climate • More than 40 air changes per hour (ACPH) • Most operating areas below “5oC above ambient”

  11. World-class kpis

  12. DX Technology

  13. World-class KPIs – DX Technology

  14. DX+ Technology

  15. World-class KPIs – DX+ Technology

  16. High quality and experienced services, at your doorstep

  17. High quality and experienced services • Technology Licence Agreement: • Comprehensive technology package (>700 documents) • Assistance during engineering, construction, start-up and early operation • Training of operators, supervision and management Classroom training On-the-job training Engineering and construction assistance Commissioning and start-up assistance

  18. High quality and experienced services • Tailor made optional services to meet client’s needs: • Technical Services Agreement • Workforce training, management system, IT business solution,… • Strategic Material Supply Agreement • Purchase, alumina, baked anode, petroleum coke, liquid pitch, lining material, cryolite, fluoride • Marketing and Sales Agreement • Marketing, sales and logistics services for finish product (billet, ingot, sheet ingot)

  19. High quality and experienced services • No compulsory supplier, but: • Range of recommended suppliers • Assistance in technical evaluation of new supplier • Two solutions for pot control system hardware developed by DUBAL: • DUBAL proprietary cell control unit (DCCU) • Standard PLC based cell control system

  20. Advancement of DUBAL Technologies

  21. DX, DX+ and D18+ Technologies • DX+ industrialization (EMAL II) • DX 2nd generation • D18+ development • PLC-based pot control system • AE suppression • …

  22. Green technologies • Setting the world-benchmark in PFC emissions • Extensive work to reduce PFC emissions • Very low anode effect frequency and duration • AEF reaching 0.05 ae/pd and AED reaching 10 seconds • Proactive control logic • Detect the symptoms of an anode effect and treat it in advance • Improvement of work practices • Inform the operator for rapid corrections on issues related to alumina feeding and alumina transport system

  23. Retrofitting old lines: DUBAL has a solution

  24. Development of D18+ Technology • 1979 • 360 Kaiser P69 cells at 150 kA • Production of 135,000 tpa • Today • 520 D18 cells at 202 kA • Production of 283,500+ tpa • D18 exceeded original design parameters and reaching its limits • Amperage: 202 kA (+52 kA) • Productivity: 1,512 kg/day (+370 kg/day)

  25. Development of D18+ Technology • Objective: • Improve the original DUBAL D18 cells in term of energy efficiency and reduce GHG emissions while maintaining or increasing current level of production • Minimum impact on the potline production during the live conversion process • Minimum investment cost • The new D18+ cell technology has been fully modelled, engineered and executed using DUBAL in-house resources

  26. Development of D18+ Technology • Major milestones: • Design, modelling and engineering • 8 months to produce detailed engineering package • Construction of 7 pilot pots • 28 days from cut-out to start-up of first pot • Start-up of the 7 pilot pots • 6 days from first cut-in to last pot start-up • Performance demonstration • More than 4 months of stable operation

  27. D18+ Technology

  28. World-class KPIs — 18+ Technology

  29. Thank you

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