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| Background |
Emirates Aluminium (EMAL) plans to develop phase 1 of a 1.4 million t/y aluminum smelter complex at Abu Dhabi's Khalifa Port and Industrial Zone.
The complex will be built in two phases. The first phase with around 700,000 t/y capacity will cost USD 7.1 billion, and the second phase will cost approximately USD 3 billion.
The bauxite feedstock for the aluminum smelter will be sourced by MubadalaMubadala .
Emal will source the liquid pitch and aluminum fluoride from Koppers Asia LLC, and from the Italian Company Fluorsid SpA, respectively.
DubalDubal will supply its proprietary DX technology for the plant. The DX technology cell reduces the amount of energy needed for the production of aluminum.
The smelter will have a power plant capacity of 2,000 MW. The required gas feedstock for the project is already secured from the Abu Dhabi National grid. |
| Current Status |
In October 2009, almost 70% of the project construction was completed.
In April 2010, production is expected to start.
In Q4 2010, the plant is expected to reach full production capacity. |
| Previous Events |
In September 2009, 60% of the project was completed.
In August 2009, Emal and GascoGasco inaugurated a natural gas pipeline that will provide natural gas to the 2,000 MW power plant.
In May 2009, 50 % of phase one was completed.
In April 2009, 35% of phase one was completed and the installation of the prototype DubalDubal DX technology reduction cell in the potroom was accomplished and will then be replicated 756 times.
In December 2008, 30% of phase one was completed. EMAL signed a $100 million contract with ECL and Kempe to supply the technology and equipment for its Anode Rodding Plant and Hot Bath Removal at the smelter complex.
In November 2008, 20% of the phase one EPCM contract was completed.
In June 2008, EMAL awarded Al Futtaim Carillion a USD 200 million contract to undertake the infrastructure works.
In April 2008, EMAL awarded a USD 200 million contract to Alstom for the supply of gas treatment centers (GTCs).
In February 2008, EMAL awarded Prysmian a USD 33.4 million EPC contract to supply and install high voltage cables and systems for the facility. The first cable connection is scheduled for Q4 2008, the second cable connection is due in Q1 2010.
In July 2007, EMAL awarded Outotec of Finland a USD 137 million EPC contract to supply and install a green anode plant and a spent anode crushing facility for the smelter.
In May 2007, EMAL hosted a groundbreaking ceremony at the plant site and officially announced the awarding of the EPCM contract for the smelter project to a joint venture of Canada's SNC-LavalinSNC-Lavalin and Australia's WorleyParsonsWorleyParsons. The value of the contract is approximately USD300 million.
In 2006, the feasibility study was completed. |
| Scope of Work |
Construction of an aluminum smelter comprising two potlines (each with 378 DX reduction cells) an anode manufacturing plant and a multi-product cast house. |
| Financing Source |
On 16 December 2007, EMAL announced that it has closed its USD4.9 billion limited recourse bank financing for its first phase construction. Further financing for EMAL of up to USD2 billion is expected to be launched into the credit markets during the construction of the smelter, bringing the total financing of phase one to almost USD 7 billion.
EMAL received over USD15 billion of commitments for the facilities, which consist of a USD 1.8 billion, sixteen year term loan, a USD 270 million letter of credit facility and a USD 2.8 billion six year equity bridge loan.
The investment is being arranged by a syndicate of international and regional banks led by Abu Dhabi Commercial Bank, BNP Paribas, Calyon, Royal Bank of Scotland, Standard Chartered, Sumitomo Mitsui Banking Corporation, Citigroup, Emirates Bank International, Export Development Canada, Export Finance and Insurance Corporation, Goldman Sachs Credit Partners, Mashreqbank and National Bank of Abu Dhabi.
EMAL was advised by Citigroup and Sullivan and Cromwell LLP. |
| Expected Schedule |
| Phase | Schedule | Description |
| Commissioning |
Apr 2010 | Trial production expected to start
|
| Completion |
Q4 2010 | Project expected to be completed
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| Related Projects |
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| Schedule | Phase | Description |
| 2006 |
Study | Feasibility study completed
|
| May 2007 |
EPCM | Contract awarded to the joint venture of SNC Lavalin and Worley Parsons for phase 1
- Bechtel Corporation
- JV of SNC Lavalin and WorleyParsons
|
- JV of SNC Lavalin and WorleyParsons
|
|
| Jul 2007 |
EPC | Contract awarded to Outotec to provide the green anode plant and a spent anode crushing facility
|
| Sep 2007 |
FEED | Completed
|
| Feb 2008 |
EPC | Contract awarded to Prysmian to supply and install high voltage cables and systems
|
| Apr 2008 |
Supply & Installation | Contract awarded to Alstom for the supply of gas treatment centers
|
| Jun 2008 |
Construction | Contract awarded to Al Futtaim Carillion to undertake the infrastructure works
|
| Dec 2008 |
Supply & Installation | Contract awarded to ECL and Kempe to supply the technology and equipment for the Anode Rodding Plant and Hot Bath Removal
|
| Apr 2010 |
Commissioning | Trial production expected to start
|
| Q4 2010 |
Completion | Project expected to be completed
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Master Project | 
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