The Successful Implementation of Dubal DX Technology at Emal

Abstract

Between 2 December 2009 and 2 January 2011, all 756 DUBAL DX technology cells in Phase I of the EMAL smelter in Abu Dhabi were successfully commissioned. This represented the culmination of DUBAL DX technology fast-track development from prototyping to large scale industrialization. The process began with the design and engineering phase in 2004, followed by commissioning of five prototype pots in 2005, a demonstration line of 40 pots in 2008 and finally the commissioning of the giant smelter at EMAL Phase I in 2009/2010. The commissioning and normalization of the pots at EMAL Phase I were very smooth, without a single lining incident. This was achieved through excellent team work and coordination between the various teams at all stages (pot preparation, preheat, start-up and normalization). The rapid and stable commissioning also demonstrated the robustness of DX technology. Both potlines at EMAL Phase I are now operating at 353 kA and are achieving excellent performances: 96.0% current efficiency and 13.0 kWh/kgAl for more than 18 months since start-up.