sPeCIAL ArABAL - ALUMINIUM-Nachrichten – ALU-WEB.DE

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ALUMINIUM INdUstry IN the GULf © Qatalum of the individual tasks involved for these main contracting companies and also for their delegated contractors down the line in meeting the customers total plant requirements and specifications. Middle east projects Fata EPC was EPCM contractor for the casthouse project at Qatalum SNC Lavalin: Montreal, Canada-based SNC- Lavalin is one of the leading engineering and construction groups in the world and a major player in the ownership of infrastructure, and in the provision of operations and maintenance services. The company is handling the EPCM services contract for the Emirates Aluminium (Emal) Phase II smelter expansion in Al Taweelah, Abu Dhabi. The contract covers the work to build a new aluminium facility, including a 1,000 MW power plant and a 1.7 km-long potline, the longest ever built. Once completed and fully operational in 2014, the new facility will produce 525,000 tpy of aluminium using an upgraded version of Dubal DX technology, which allows for greater operating efficiencies. This latest contract followed SNC-Lavalin’s successful completion of its EPCM mandate for Phase I of the Emal smelter, which has a production capacity of 800,000 tpy and included the construction of a 2,000 MW power plant. “SNC-Lavalin is a world leader in the design and construction of aluminium smelters, and we consider this new award as a clear acknowledgement of the leading-edge technical capabilities and experience we demonstrated with Phase I of the project,” declared Riadh Ben Aïssa, executive vice-president, SNC- Lavalin Group. “Just as important, it reflects the effort and importance SNC-Lavalin places on maintaining long-term relations with our clients. We value Emal’s relationship and trust, and we are delighted with this new opportunity to work together to build this landmark project for the United Arab Emirates.” Fata EPC: Fata EPC, a division of Italy/US outfit Fata Hunter, was the EPCM contractor for the casthouse build project at the Qatalum primary aluminium smelter in Qatar, an equal joint venture between Qatar Petroleum and Hydro Aluminium of Norway. The casthouse technology was supplied by Norsk Hydro delivering an extrusion billet VDC capacity of 350,000 tpy and 275,000 tpy from 10 and 20 kg casters. Hycast hot metal alkaline removal and in-line filters and degassers were installed along with automatic casting sequencing. The installation ensures that all equipment fumes are treated by dust collectors. In a parallel contract, Fata EPC also handled work to build an anode baking plant at the Qatalum facility with technology supplied by Pechiney to provide a total plant capacity of 368,000 anodes per year. The plant uses seven fires with 116 sections and is fuelled by natural gas with fume treatment employing dry scrubbing. Storage provision was required for 18,000 green anodes and 13,000 baked anodes – and storage and retrieval is via automatic crane and transfer. Further, Fata EPC has also elaborated a series of downstream projects in the aluminium industry including others in the Gulf region, such as the one currently in construction at Oman Aluminium Rolling Company in Sohar. As the main appointed EPCM contractor to build the planned 160,000 tpy greenfield facility, Fata EPC is managing the activities involved to procure and install complete roll plant systems to feature the latest available technology in casting, rolling and finishing. The new facility includes a Hazelett caster and a hot rolling mill along with world-class cold rolling and finishing equipment supplied by Fata Hunter, the equipment division of Fata SpA. For further project details, see report on pages 34-37. In Iran, Fata handled the second potline expansion at the Almahdi Aluminium Smelter in Bandar Abbas with key technology (provided by Imidro). The plant’s Potline 2 comprises two potrooms built 32 metres apart, each 750 metres long and 20 metres wide. A total of 228 pots, with 20 anodes per pot, employ Dubal D20 cell technology, operating at 240 kA and 13.6 kWh/kg Al and using a fluid flow alumina feeding system. Production capacity is 147,000 tpy of aluminium. Bechtel: Also in the Gulf, major EPCM organisation Bechtel is extending its long heritage of mega projects in the region by managing the greenfield construction project in Saudi Arabia for what is slated to be the world’s largest aluminium smelter. The scope of work involved in this USD4 billion project, handled by Bechtel’s Mining & Metals division, covers overall engineering, procurement, and construction management. The new smelter, a Ma’aden-Alcoa joint venture, is the cornerstone of the Ras Al Khair Minerals Industrial City, which will become the country’s aluminium and phosphate centre, north of Al Jubail in the Saudi Eastern Province. This is part of a new integrated USD10.8 billion aluminium complex, which in addition to the smelter will include a mine, alumina refinery and rolling mill. The smelter facility will have a capacity of 740,000 tpy of aluminium. Bauxite feedstock will be transported via a purpose-built rail line from a new mine at Al Ba’itha for refining and reduction at Ras Al Khair. First commercial production from the smelter and downstream rolling mill is scheduled for 2013. For further project details, see separate report on pages 46-47. Again in the Gulf region, Bechtel’s Canada operation has received a Letter of Intent (LoI) from Aluminium Bahrain (Alba) to conduct a Bankable Feasibility Study (BFS) for the smelter’s planned Potline 6 expansion project, valued at some USD2.5 billion. The study also includes an economic analysis for the construction of a fifth power station required for the plant expansion. Alba’s Line 6 is expected to produce an additional 400,000 tpy of aluminium adding to its current 881,000 tpy, with Dubal DX+ cell technology being used as the basis of the study. Bechtel has considerable specific industry 44 ALUMINIUM · 9/2013
sPeCIAL ArABAL ALUMINIUM INdUstry IN the GULf © Bechtel Construction work at the Ma’aden-Alcoa joint venture early this year, with Bechtel the EPCM contractor. From left to right: field engineers Fadi Elmourad, Muthukumaran Kuppusamy, Mohamad El Samad and planner Lamont Berry. Fluor Corporation’s Greenville, South Carolina office is elaborating a design and procurement contract awarded by the aforementioned Ma’aden-Alcoa joint venture to build an integrated automotive sheet manufacturing plant that forms part of the aluminium complex. The scope of Fluor’s work will include design, construction and commissioning of the plant, which will have the capability to produce a range of products suitable for further downstream manufacturing in the aluminium complex. Once complete, the automotive sheet facility will produce lightweight aluminium to be used in vehicle manufacturing. These products will include automotive heat-treated and nonheat-treated sheet, building and construction sheet, and foil stock. “This new manufacturing facility will help meet the global automotive industry’s growing demands for new, lighter materials,” said Fluor head of Mining & Metals business Rick Koumouris. experience in the region having operated as the EPCM contractor for the previous Line 4 and 5 expansions. The BFS is expected to be completed by the third quarter this year, and Alba projects that the new line could be completed by early 2015. Alongside Bechtel, BNP Paribas is acting as the financial adviser for the project. further ePCM projects HRV Engineering / Hatch: In Iceland, Rio Tinto Alcan is updating equipment, increas- ANODE BAKING FACILITIES The Riedhammer anode baking facility is a key component in a modern anode production plant. Our plants offer many advantages such as: • Customised design • Excellent anode quality • Extended furnace lifetime • Low energy consumption • High productivity • Flexible equipment supply • Safe operation RIEDHAMMER CARBON BAKING TECHNOLOGY RIEDHAMMER GmbH Klingenhofstraße 72 90411 Nürnberg Phone: +49 911 5218 0 Fax: +49 911 5218 231 www.riedhammer.de
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