Widely acknowledged as the UAE’s industrial flagship and a leading player in the global aluminium sector, Dubai Aluminium (DUBAL) is leveraging its participation as a Strategic Sponsor of this year’s Water Energy Technology and Environment Exhibition (WETEX 2012) to highlight its achievements in the event’s three core areas of focus (i.e. water, energy and environment).
For starters, the DUBAL exhibition stand at WETEX 2012 features a model of the company’s world-leading, in-house developed DX+ Technology reduction cell that, by operating at higher amperages, not only offers increased productivity but also reduces the impact of a smelter’s operations on the environment through improved energy efficiency and minimised emission levels. DUBAL DX+ Technology is based directly on the proven, inherently robust DUBAL DX Technology, which has been in operation in a dedicated 40-cell line at DUBAL’s Jebel Ali site since 2008. DX Technology has also been licensed to Emirates Aluminium (EMAL) at Al Taweelah, Abu Dhabi and installed in the 756-cell EMAL Phase I, where it is currently operating stably at 353 kA.
Initially operating at 340 kA, the DX Technology cells at DUBAL now operate at 380 kA, offering several benchmark attributes that provide significant advantages, notably:.
Superb productivity of 2.91 mt Al/pot/day plus at exceptionally high purity levels of 99.92 per cent, giving rapid returns on capital expenditure; plus excellent creep potential, promising even better yields per pot.
An energy-efficient design that enables specific energy consumption of less than 13.1 kWh/kg Al and 95.1 per cent current efficiency, together contributing to energy conservation and associated operating cost reductions.
Reduced environmental impact through lower fossil fuel consumption (a direct benefit of enhanced energy-efficiency) and reduced carbon consumption (anodes) of less than 0.408 kg C/kg Al. Moreover, DX Technology cells experience minimal anode effects (less than 0.05 AE/pot/day), resulting in perfluorocarbon (“PFC”) emissions of 0.015 CO2eq mt/mt Al.
Fully engineered versatility, allowing operating capability plus inherent potential for developing even higher amperage performance capacity.
Following further modelling and extensive research, five pilot DX+ Technology cells have been in operation in the Eagle Section of DUBAL’s Jebel Ali site since 2010. Having initially operated at 420 kA and now operating stably at 440 kA, DX+ Technology cells are ultimately expected to operate at 460 kA. DX+ Technology offers similar advantages to DX Technology in terms of production efficiency, energy consumption and environmental performance indicators; as well as the added advantage of higher productivity at a lower capital cost per installed tonne of capacity. The industrial version is targeted to achieve specific energy consumption of less than 13.3 kWh/kg Al; current efficiency above 95 per cent; and an average yield per pot of 3.37 mt/day, with metal purity levels above 99.89 per cent. The AE frequency is very low but, more importantly, DUBAL’s proprietary advanced control logic restricts the average duration of AEs to less than 10 seconds (a world benchmark for lowering PFC emissions).
DUBAL DX+ Technology has been specified for and will be licensed to EMAL Phase II, an expansion project involving the construction of 444-cells in a single potline.
Sharing expertise and promoting best practices
Secondly, DUBAL will share its corporate knowledge at two forums hosted in parallel to the exhibition with the aim of promoting best practices:
Abdulnasser Kalban (General Manager: Power & Desalination Maintenance) will deliver a presentation during a Smart Grid seminar, entitled “Smart Micro Grid” in which he will demonstrate DUBAL’s continued efforts to share knowledge about its smelter micro grid and migration towards being smart micro-grid based on WETEX foundations.
Nedhal Al Rahma (Senior Support Manager: Power & Desalination Operations) will participate in a round-table discussion, his presentation being entitled “Evaporative Coolers on DUBAL’s large combined cycle gas turbines”. Nedhal will outline how DUBAL is striving toward maintaining sustainability throughout the operational process, by sharing best practice learned from installing Evaporative Coolers on the company‘s continuous duty Combined Cycle Power Plants.
Focus on energy conservation and environment protection
Held at the Dubai International Convention & Exhibition Centre from 13 to 15 March 2012, the focus of WETEX 2012 is on the advanced technologies in the areas of energy, water and environment. The event’s primary objective is to facilitate strategic partnerships between the scientific, engineering, technology, and management communities to support the efforts of governmental agencies and civic authorities in these three core areas.
Accordingly, DUBAL’s exhibition stand also highlights its corporate successes in energy conservation, specifically the fuel-efficiency enabled by the unique cogeneration configuration of the company’s captive 2,350 megawatt power station (at 30˚C); and the energy-savings achieved through implementing a combination of the initiatives mandated by the Dubai Supreme Council of Energy (“DSCE”) in terms of Dubai’s 2030 energy conservation strategy and DUBAL’s own innovations in this area. Also illustrated is DUBAL’s successful and sustained achievement of the highest standards in environmental protection, from optimizing raw material usage through effective energy-use management to minimizing environmental impact through stringent management of air emissions, effluent discharge and waste.