Dubai Aluminium Company (Dubal) has named Mott MacDonald as the engineer for the planned upgrade at its smelter complex in Jebel Ali.

The project, named Kestrel, is to replace the older reduction plant and increase aluminium production by 174,000 tonnes per annum to 710,000 tonnes.

This latest refurbishment and expansion programme involves refurbishing and extending three existing potlines and adding a further 350 MW combined cycle power generation block to the existing power facilities bringing total generation capacity to over 1700 MW. In addition, the 132/33/11 kV distribution system will be enhanced and 14 new rectifier transformer units installed.

As engineer for all works associated with the power facilities, Mott MacDonald will develop design concepts, produce technical specifications, evaluate tenders and audit designs. The consultant will also carry out detailed design of all civil works, supervise construction and commissioning of the power facilities and project manage the whole programme, which is expected to be completed in early 2006.

Mott MacDonald was also the engineer for three previous expansion projects at Dubal which is the world's largest manufacturer of foundry alloy used mainly by the automobile industry as well as being a producer of extrusion billet and high-purity aluminium. Foundry alloy accounts for 40 per cent of Dubal's production.

This latest commission builds on Mott MacDonald's impressive portfolio of projects associated with smelters. Not only was the company engineer for three previous expansion projects for Dubal - Deep 1989, Falcon 1997 and Condor 2000 - it has also recently been appointed engineering and construction manager for the power elements of a major expansion project at an aluminium smelter in Bahrain.

A Gulf Organisation for Industrial Consulting (Goic) official has said the region had plans for at least four additional aluminium smelters.