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Meeting 2016 TMS Annual Meeting & Exhibition
Symposium Electrode Technology
Presentation Title Journey towards World-Class Operational Effectiveness at DUBAL (EGA Jebel Ali Operations) Paste Plant
Author(s) Bienvenu Ndjom, Muhammad Shafiq Malik, Amer Abdul Rahman Al Marzouqi, Mohamed Fazal Ismail, Tapan Kumar Sahu, Saleh Ahmed Abdulla Ahmed Rabbaa
On-Site Speaker (Planned) Saleh Ahmed Abdulla Ahmed Rabbaa
Abstract Scope DUBAL (also known as EGA Jebel Ali Operations) has gradually increased its aluminium production capacity from 135 000 tonnes in 1979 to over 1 million tonnes today, using six different cell technologies. The associated increase in anode requirements was largely supported by the installation of a second mixing line in 1996, with the balance being outsourced. In the last 10 years, DUBAL also increased its annual hot metal production by around 90 000 tonnes through amperage increase and capacity creep, further increasing the site’s anode requirements. Simultaneously, the DUBAL Paste Plant faced other challenges such as ageing equipment, larger anode dimensions and multiple anode sizes. To overcome these challenges, DUBAL Paste Plant embarked on a journey towards best-in-class operational effectiveness. This has resulted in a 10 % increase in throughput above the design capacity and an improvement in overall equipment effectiveness of more than 15 %, while continuously improving anode density.
Proceedings Inclusion? Planned: Light Metals Volume


Anode Baking Furnace Fluewall Design Evolution: A Return of Experience of Latest Baffleless Technology Implementation
Cathode Wear in Electrowinning of Aluminum Investigated by a Laboratory Test Cell
Characterization of Carbon Anode Materials by Image Analysis
Copper Bars for the Hall-Héroult Process
Effect of Cathode Collector Copper Inserts on the Hall-Héroult Cell MHD Stability
Effect of Heating Rate during Baking on the Properties of Carbon Anodes Used in Aluminum Industry
Electrochemical Reactivity and Wetting Properties of Anodes Made from Anisotropic and Isotropic Cokes
Empirical Modeling of the Baking Furnace to Predict Baked Anode Properties
In Situ Investigation of the Behavior of Anode Assemblies
Interfacial Boundary between Carbon Anodes and Molten Salt Electrolyte
Journey towards World-Class Operational Effectiveness at DUBAL (EGA Jebel Ali Operations) Paste Plant
Low Resistance Anode Assembly Using Steel Stubhole Conductors across the Cast Iron to Carbon Interface
Measurement of the Electric Current Distribution in an Anode
MIREA: An On-line Quality Control Equipment Integration in an Operational Context
Modeling Gravity Wave in 3D with OpenFoam in an Aluminum Reduction Cell with Regular and Irregular Cathode Surfaces
Porous Carbon Anodes for the Supply of Methane during Electrowinning of Aluminium
Quantification of Sodium Present in Dry Aggregates and Anodes
Simulation-Based Decision Support in Cathode Relining Facility Scaling
Study of the Wetting of Coke by Different Pitches
The Start up & the Operation Performance of the Twin Green Anode Plant at Ma'aden Aluminium Smelter in Saudi Arabia
Uneven Cathode Wear in Aluminium Reduction Cells
Upgrade of the Firing and Control System at Egyptalum for Dual Fuel Firing

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