EGA introduces new technologies to improve production and optimize power consumption

EGA owned Jebel Ali smelter is introducing new technologies to its existing potlines to enhance the production of aluminium.

A groundbreaking ceremony held at EGA Jebel Ali on Thursday, February 5, 2015 marks the official start of the project that aims to achieve higher energy efficiency targets and capacity creep using a three-pronged approach.

The first change would occur in the potlines 1 to 3 where 513 pots will be introduced to D18+ Technology cells. The switch follows the pilot program started in 2012 where seven D18 Technology cells in Potline 1 were fitted with modern technologies that improved the performance and the economic competitiveness of the line.

The earlier transition had allowed the cells to consume lesser energy which remained below 13 kWh/kg Al, producing 2 tons/day and achieving 95% efficiency. EGA hopes to recreate the success by introducing the D18+ Technology cells to the remaining 513 pots in Potlines 1 to 3.

It is estimated that the new technology will increase the production by 40,000 tpa, operating at a higher amperage of 230kA instead of 205 using the same power as the existing D18 potlines. The first produce of the new technology is expected to hit the market by September 2015.

Step two would be to introduce 4DX Technology cells to Potline 8 and step 3 is to implement 6 D20+ Technology cells to Potline 5B. All these additions are expected to improve production and optimize energy efficiency inspired by the success these technologies have produced in past trials.

"For EGA, optimising energy efficiency is a key strategic objective that aims to minimise operational impact on the environment while ameliorating the significant cost of energy," says Dr Ali Al Zarouni (Vice President: Jebel Ali Operations). "These factors have underpinned the development of advanced technologies that not only increase productivity, but also reduce our operations' impact on the environment through improved energy-efficiency and reduced emission levels. Using these technologies is integral to EGA's drive to ensure long-term competitiveness in an industry that is sensitive to product quality, costs and, increasingly, environmental performance."

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