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Industry Highlights 

EMAL – The World’s Largest Single Site Aluminium Smelter

EMAL, a joint venture between Dubal and Mubadala, is building the world’s largest single‑site aluminium smelter at Al Taweelah in the UAE. With an ultimate capacity of 1.4 million tonnes per annum, the facility will showcase the Dubal developed DX smelting technology, providing a highly competitive smelter to position EMAL in the top echelon of aluminium producers.

WorleyParsons, in joint venture with SNC Lavalin, is providing the engineering, procurement and construction management services for this multi‑billion dollar project, which also includes a 2,000 MW gas‑fired power plant and associated facilities on a 500 hectare site. The project schedule is fast, with first metal planned for 2010.

To deliver this challenging project, WorleyParsons has drawn on its global Minerals & Metals, Infrastructure & Environment and Power groups to establish a multi‑discipline project management office at Al Taweelah, which is anticipated to peak at around 500 personnel. This team is further supported by our extensive workshare capability, with the cast‑house, carbon plant and port engineering being completed in Melbourne and Geelong, and additional detailed engineering services provided by our Beijing High Value Engineering center.

Currently, the project remains on schedule with an on-site workforce of 2,800 personnel, and 2.7 million man‑hours have been achieved without a lost time incident. On-site manning is forecast to peak at around 10,000 personnel in 2009. Throughout the project a number of value improvement programs have been successfully implemented and substantial cost savings have been achieved in all areas of the plant.

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