ABU DHABI-based Emirates Aluminium (Emal) recently erected the first structural steel for its Phase 2 expansion, bringing it a step closer to becoming one of the world’s largest single-site aluminium smelters.

Once completed in 2014, the potline at the Al Taweelah site will be the longest in the world at 1.7 km, a statement said.

Saeed Al Mazrooei, Emal president and CEO, said: “I am pleased to see Phase 2 progressing on schedule. This milestone which was achieved as per plan is very critical to our first hot metal date.”

Yousuf Bastaki, Emal vice president, said: “The special steel structures are the first visible signs of our Phase 2 expansion and bring us yet another step closer to meeting the ambitious targets we have set ourselves. Emal is also pleased to cooperate with Emirates Steel which supplied the steel required for its expansion work.”

In total it will take 120 of the specially designed structures to facilitate the additional 444 reductions pots required to expand production to 1.3 million tonnes per year. It will take around one year to complete the installation of all 120 structures, according to the statement.

Emal was established through a 50:50 joint venture partnership between Dubal (Dubai Aluminium Company) and Mubadala (Mubadala Development Company). The joint venture agreement was signed in 2007.

The aluminium complex, a 6 sq km site, is located in Khalifa Industrial Zone -Abu Dhabi (Kizad) in the Al Taweelah area, half way between Abu Dhabi and Dubai.

Phase 1of the smelter commenced operations on December 2, 2009 and hit full production capacity on the first workday of 2011. It uses Dubal-developed DX Reduction Cell Technology to produce 750,000 tonnes of primary aluminium annually. The technology installed in Phase 1is being upgraded to increase production by 50,000 tonnes resulting in an annual production capacity of 800,000 tonnes by the end of 2012.

The $5.7 billion development resulted in 756 reduction cells arranged in two potlines, a 2,000 MW on-site power plant, an anode manufacturing plant, a purpose-built wharf and a multi-product cast house.

Work on Phase 2 of the smelter began in September, 2011. $4.5 billion will be invested to create an additional potline. The onsite power plant capacity will increase by 50 per cent to reach 3,000 MW and to power 444 additional reduction cells. This will make Emal the largest single-site producer of primary aluminium in the world.

Meanwhile, 18 UAE national students recently completed Emal’s 2012 summer training programme, gaining hands-on experience in preparation for possible careers within the industry.

The training was part of the company’s commitment and dedication to sustainable employment and in line with the Abu Dhabi 2030 vision, Emal said.