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University of Bahrain
College of Engineering
Chemical Engineering Department
CHENG 462 – FINAL PROJECT
ALBA LINE 6 EXPANSION PROJECT
STUDENT NAME
Husain Yusuf Ahmed
Salman Yusuf Salman
ID
20166225
20167572
SECTION
01
01
Table of Contents
Table of Contents ........................................................................................................................................... i
List of Figures ............................................................................................................................................... ii
1
Introduction ........................................................................................................................................... 1
2
Overview ............................................................................................................................................... 2
3
4
5
2.1
2012............................................................................................................................................... 2
2.2
2015............................................................................................................................................... 2
2.3
2016............................................................................................................................................... 2
2.4
2017............................................................................................................................................... 3
2.5
2018............................................................................................................................................... 3
2.6
2019............................................................................................................................................... 3
Alba Line 6 Major Units ....................................................................................................................... 4
3.1
Power Plant ................................................................................................................................... 4
3.2
Carbon Plant.................................................................................................................................. 4
3.3
Reduction Line .............................................................................................................................. 5
3.4
Cast house ..................................................................................................................................... 5
Alba Products ........................................................................................................................................ 6
4.1
Extrusion Ingots (Logs and Billets) .............................................................................................. 6
4.2
Foundry Alloy Ingot (Properzi and Standard Ingot Form) ........................................................... 6
4.3
Liquid Metal.................................................................................................................................. 7
4.4
Primary Aluminium Tee and Standard Ingots .............................................................................. 7
4.5
Sheet Ingot (Rolling Slab)............................................................................................................. 7
4.6
Calcined petroleum coke............................................................................................................... 8
4.7
Water ............................................................................................................................................. 8
Markets ................................................................................................................................................. 8
5.1
6
Bahrain Downstream Industries .................................................................................................... 8
Social and Economic Environment ....................................................................................................... 9
6.1
Impact on GDP, current account, and trade balance ..................................................................... 9
6.2
Employment .................................................................................................................................. 9
6.3
Bahrainisation ............................................................................................................................. 10
6.4
Community Investment ............................................................................................................... 10
6.5
Environment................................................................................................................................ 11
7
Conclusion .......................................................................................................................................... 11
8
Reference ............................................................................................................................................ 12
i
List of Figures
Figure 1 Alba Line 6 expansion project ........................................................................................................ 1
Figure 2 The final and approved schedule of the Project.............................................................................. 2
Figure 3 Majesty King Hamad bin Isa Al Khalifa inaugurates the Alba line 6 milestone ............................ 3
Figure 4 The carbon plant ............................................................................................................................. 4
Figure 5 Mechatherm 165t tilting melting/holding furnace – during 1st cast ............................................... 5
Figure 6 The percentage of each Alba products. .......................................................................................... 6
Figure 7 The primary aluminium Tee and standard ingots ........................................................................... 7
Figure 8 The percentage export of the product to the world ......................................................................... 8
Figure 9 The employee benefits .................................................................................................................... 9
Figure 10 The community investment percentage ...................................................................................... 10
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1
Introduction
The line 6 project at Alba as shown in the figure below is a quantum leap for the company and the beginning
of a new era of growth and prosperity for the Kingdom of Bahrain. The cost of the project is estimated at 3
Billion US dollars. it is the largest project in the region that makes it the largest aluminum smelting plant
in the world, excluding China.
This report is going to give an overview in several periods about the Alba line 6 expansion project until the
startup. Then, the report going to study the technical details of the major units which are the power plant,
carbon plant reduction line, and cast house. Moreover, the final products will be explained in detail with
downstream industries in Bahrain for Alba. In the end, the socio-economic benefits of the Alba line 6 project
for Bahrain also will be explained.
Figure 1 Alba Line 6 expansion project
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2
Overview
2.1 2012
On 5 Dec 2012, the board of directors of Alba approved the launch of a bankable feasibility study for the
sixth line, which will enhance productivity to a great level. At that time they expect that Alba line six will
increase the production by 400,000 MT/year to reach 1.3×10^6 MT/year. After that, Alba chooses Dubal
DX+ technology for their study. Then, the feasibility study plan went to Bechtel Canada.
2.2 2015
Gulf International Bank and National Bank of Bahrain have been appointed as financial advisors for the
project. Also, Alba announces that it has obtained an environmental license from the Supreme Council for
the environment in the Kingdom of Bahrain.
2.3 2016
At the beginning of 2016 Alba upgrade the technology from EGA DX+ to EGA DX+Ultra for their line 6
project. Then, Alba hiring Bechtel to take charge of engineering, procurement, and construction operation.
subsequently, Alba announces a reduction in the amount of capital spending from $3.5 billion to $3 billion.
Afterward, Alba hired GE and Gamma group to handle the engineering construction and procurement for
(PS 5). Later, Alba awards Siemens the electrical distribution system contract. Thereafter, Alba announces
its success in closing the distinguished syndicated loan facility. The final and approved schedule of the
Project is given in the below figure.
Figure 2 The final and approved schedule of the Project
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2.4 2017
$700 million was secured to finance the project from export credit agencies. Moreover, the design study
for the expansion project has been completed. Afterward, Alba starting the concrete works of the foundation
of the melting line. Fabrication of 100 pot shell has been completed. Next, signing an MoU with General
Electric company for power generation.
2.5 2018
Alba produced the first sealed cathode for line 6 smelter. After that, the world's largest reformer has been
received. Alba completes the hiring process for its expansion project. Subsequently, Alba successfully
completed 427 pot shells. Turn On the new switch house 7 that was 33 Kv. later, Alba signs an agreement
with Fluocid, the leading Italian company in the production of fluorochemicals. Alba conducted the first
fire of the general electric 9HA gas turbine in (PS 5). Last but not least, Alba on 13 Dec 2018 starts operating
line 6 smelter instead of 1 Jan 2019. Finally, the biggest furnace in Alba history which is Cast House 4 has
been stated.
2.6 2019
Alba announces successful testing of 40 fully operational smelting cells. Thereafter, they turn on around
50% of the pot line. Afterward, Alba celebrated 30 million working hours without injury. In March 2019
Alba marks 25% on line 6 startup. Then, 5 weeks later they successfully start 50% of line 6. Finally, his
majesty King Hamad bin Isa Al Khalifa inaugurates the Alba line 6 milestone as shown in the figure below.
Figure 3 Majesty King Hamad bin Isa Al Khalifa inaugurates the Alba line 6 milestone
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3
Alba Line 6 Major Units
3.1 Power Plant
Alba hiring GE and Gamma group to construct and operate the power Station 5 which generates 1792
megawatt of electric power using gas turbine power by combined cycle technology. This leading-edge
technology offers 54% to 60% efficiency. Moreover, GE company offered 3 gas turbines of type 9HA, 3
steam turbines, and 3 heat recovery for steam generation. The first fire of gas turbine in power Station 5
was on 30 Oct 2018. Lastly, this Power Station helps alba to be self-sufficiency in terms of extensive energy
requirements without the need for government or any private company.
3.2 Carbon Plant
This plant produces the carbon anode which is the positive charge of the electrolytic cell in the potlines.
First stage is producing the green anode in paste plant. Then, convert the green anode to baked anode by
heating it up to 1100 oC in 14 days in the section of the kiln. Afterwards, the rodding plant where the rod
fix in anode and we recover the bath, cast iron and the return butt. Moreover, we produce new anode since
it should be replaced every 28 days. Finally, the process control where it checks the quality of the anode by
taking samples and making data analysis to carry out different tests for optimization. Mentioned that Alba
have four carbon plants that produce around 550,000 MT/year of anodes. Also, Alba set new world record
by produced 404 sealed anodes in one shift. The figure below shows the carbon plant.
Figure 4 The carbon plant
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3.3 Reduction Line
This line is considered one 9f the longest reduction lines in the world with 1.35 Km. This line adds 540,000
MT/year to the total production to reach 1.54 million MT/year, this makes a huge difference in Alba since
in 1971 Alba was producing 120,000 MT/year. EGA is the technology supplier for this reduction line. The
technology used is called DX+Ultra. This technology is characterized by high productivity and energy
saving. Reduction line 6 is the highest production smelting line in Alba since it is supplied with a current
around 440 kA.
3.4 Cast house
This is the biggest furnace in Alba history and it started on 26 Dec 2018. Cast House 4 is a major unit of
the line six expansion project. It was designed with a total production capacity of 530,000 tons per year.
The cold charge of furnace 3 is considered a part of Cast House 4 startup. Mechathern supplied three 165
tonne capacity tilting holding/melting furnaces, three 85 tonne capacity furnaces, and two under the hearth
electromagnetic stirring system as shown in the figure below. Moreover, a fully integrated and
interconnecting hot metal delivery system to deliver the metal from each furnace to any newly casting
machines. The furnace can supply hot metal to three different casting machines by launder system. Which
165 tonnes VDC rolling ingot, 85 tonne VDC billet, and 10 Kg continuous casting machine. This gives
Alba optimum casting flexibility based on their production. Furthermore, Mechatherm supplied degassing,
refining, and filtration to each casting line.
Figure 5 Mechatherm 165t tilting melting/holding furnace – during 1st cast
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4
Alba Products
Alba is one of the largest companies in the world with a reputation and prestige in the production of primary
aluminium and providing it to customers with high quality. There are more than 25 countries that Alba
products exported to it. Alba is distinguished by its high-quality metal with purity levels above 99.7%. After
the opening of Line 6, Alba annually produces more than 1.54 million metric tons of aluminium. The figure
below shows the percentage of each Alba products.
Figure 6 The percentage of each Alba products.
4.1 Extrusion Ingots (Logs and Billets)
Alba annually produces about 350,000 tons of extrusion ingots. Alba provides extrusion ingots in the form
of logs and billets featuring high surface quality, internal durability, dimensional variability, and a high
level of internal safety. It also has a good surface coating that facilitates surface polishing, making it a
favorite in all global markets. Alloys are used in products of medium and high strength. Alloys provide
many of the production needs of manufacturers due to their extrusion capacity that provides ease and high
quality during the extrusion process. They are used in many applications such as building, construction,
engineering, and transportation.
4.2 Foundry Alloy Ingot (Properzi and Standard Ingot Form)
Alba can produce 100,000 tons of foundry alloy ingot annually. Alba provides alloys in the form of Properzi
and Standard. They are available in two different content depending on the percentage of silicon (Si) which
they are: Al-7% Si-Mg Alloy and Al-11% Si-Mg Alloy. Alloys are available in high quality modified and
unmodified forms to facilitate the process and quality of production. Alba is added Strontium (Sr) to meet
customers’ which makes customers prefer it to meet their production needs, as ALBA offers 29 different
types. They are used in many applications such as transportation and cars. Clients prefer the Properzi alloy
form due to its improved quality with its unique design which provides greater convenience during packing
and storing which reduces transportation costs.
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4.3 Liquid Metal
Alba has six pot lines that produce about 1.54 million tons annually of high-quality aluminium with the
highest levels of purity and is considered the preferred among the downstream industries in Bahrain. Before
supplying customers, aluminium passed through the Treatment of Aluminium in Crucible (TAC) by using
MTV’s (Metal Transfer Vehicles) to improve its quality by reducing alkali metals, especially sodium (Na).
It is used in the production of electrical wires, welding, transportation, and aluminium powders and pellets.
4.4 Primary Aluminium Tee and Standard Ingots
Alba annually produces about 400,000 metric tons per year of standard ingots. Primary aluminium is used
in casting standard alloys according to international specifications of the London Metal Exchange (LME)
using a modern technical process used by ISO. There are two types of standard alloys (10 kg and 22.5 kg)
as shown in the figure below. The production process is monitored by the quality assurance departments to
ensure that the production is following international specifications. Tee Ingots It is a standard T-shaped
alloy to facilitate handling and storage and reduce cost. For customers who need re-melting, this shape is
ideal for their furnaces and final products. They are used in many household and electronic products,
buildings, and cars.
Figure 7 The primary aluminium Tee and standard ingots
4.5 Sheet Ingot (Rolling Slab)
Alba annually produces 140,000 metric tons of rolling slab. The base metal from the pot room is used to
produce high-quality alloys and sheets that are subject to quality and safety standards. Inline vacuum and
filter equipment such as ACD, ceramic foam filtration, and TKR cartridge filters are applied to ensure metal
cleanliness and utilize the latest metal level control technology and Wagstaff molds. They are used in many
products such as aluminium foil, cooking utensils, construction, construction, and transportation industries.
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4.6 Calcined petroleum coke
Alba produces 550,000 metric tons of calcined coke annually. It is the main raw material in the aluminium
smelting process to produce carbon anodes. Alba produces high-quality calcined coke with high purity,
which enhances the production value of aluminium. Alba is distinguished by its automated plants, indirect
cooling mechanisms, and the only covered storage facility in the world. Alba uses 65% of calcined coke to
make anodes to produce basic aluminium, which has made it very popular in the world due to the high
quality of calcined coke.
4.7 Water
In 2001, the Alba Desalination Plant which is part of the calciner plant was commissioned to contribute to
sustainable and environmental practices. Water is used in the cooling process during aluminium production.
The steam produced by the high temperatures used to generate additional energy that helps to save the value
of natural gas. Alba contributes large quantities of potable water to the Bahrain Electricity and Water
Authority for public consumption
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Markets
Alba exports its products to more than 25 countries around the world. It enjoys a reputation for producing
high-quality aluminium. Alba aims to provide the customer with fast service and a satisfaction guarantee.
As shown in the figure below it exports about 17% of the production to the Middle East and North Africa,
24% to Asia, 24% to Europe, and 11% to the Americas.
Figure 8 The percentage export of the product to the world
5.1 Bahrain Downstream Industries
About 25% of Alba's production is consumed by the refining and petrochemical sector in Bahrain. Alba
provides customers whose work is in Bahrain with transportation services within hours, which enables them
to directly pour aluminium products, saving time, operation, and cost. The major downstream industries in
Bahrain are Midal Cables, Bahrain Alloys Manufacturing Company (BAMCO), Bahrain Welding Wire
Products Mfg. Co. (BWP), Bahrain Atomisers International (BAI), AluWheel, and others
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6
Social and Economic Environment
There are many benefits to opening Line 6, and it is considered one of the main links in the transformation
of Bahrain and its people. Alba strives to contribute to Bahrain's economic diversification and create
opportunities to work so that people can enjoy a good life.
6.1 Impact on GDP, current account, and trade balance
Alba is one of the largest companies contributing to Bahrain's GDP. The opening of the line 6 led to a
tangible transformation in the country, where Alba contributed 12 percent, and after the line 6, it became
15 percent of the country’s GDP. The cost of the project is estimated at 3 Billion US dollars, but the project
is bankable, so there will be no capital inflows that affect the trade balance. In addition, it will contribute
to increasing the rate of production, which will increase the economy and development of the country. The
6-line savings exceeded 16 percent, with more than 370 million dollars, which is one of the major
achievements of the project
6.2 Employment
The project in the construction phase created many great opportunities for work. The average number of
workers at the smelter was 2,600 and the power plant had 750 workers. Although the work is temporary, it
still provides great job opportunities for citizens. The line 6 expansion project contributes to creating about
500 permanent job opportunities through direct employment in the company and enhancing productivity in
manufacturing companies, which leads to the indirect creation of thousands of job opportunities. The
company trains all new employees regularly to ensure they are ready to take on the operational duties and
responsibilities. All employees in the company enjoy many benefits as shown in the figure below.
Figure 9 The employee benefits
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6.3 Bahrainisation
Alba follows the Bahrainisation program, which aims to employ a large percentage of Bahrainis and seeks
to reduce the unemployment rate among citizens. The line 6 will provide many job opportunities for
Bahraini citizens. Alba seeks to raise the percentage of Bahrainisation to 90 percent by training Bahraini
graduates.
6.4 Community Investment
Alba supports the Bahraini community with many social programs and activities. Alba aims to reduce its
dependence on oil and establish industries that provide valuable export revenues to develop the country's
resources and create training and employment opportunities. all that will increase with the opening of line
6. Alba also supports local community initiatives and events such as World Juniors Table Tennis
Federation, the 10th H.M. King Hamad Trophy Golf Championship, and the annual F1 Grand Prix
Weekend. The figure below shows the community investment percentage by category.
Figure 10 The community investment percentage
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6.5 Environment
The highest environmental standards are adhered to at Alba where the products are not of high quality at
the expense of the environment. Alba has invested more than 13.2 million Bahraini Dinars in conservation
projects that focus on pollution control, waste management, and greenhouse gas reduction. Line 6 was
manufactured with the latest technologies related to efficiency and environmental performance, which led
to a reduction in the intensity of emissions.
Also, Alba supports the local community by providing safe drinking water generated through the process
of aluminium. It also supports environmental initiatives such as the redevelopment of Al-Malikiyah beach,
which is a successful partnership between the government and industry
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Conclusion
In the end, the Line 6 project at Alba is a quantum leap for the company and the beginning of a new era of
growth and prosperity for the Kingdom of Bahrain. Thus, making Alba the largest aluminium smelter in
the world, excluding China, by boosting annual productivity, bringing the total output capacity to 1.54
million metric tons annually. The project contributed to raising Bahrain's GDP from 12 to 15 percent. Also,
it contributed to providing very great job opportunities for citizens in the company directly and other
companies indirectly, which reduced the unemployment rate in Bahrain. Also, using modern advanced
technologies has resulted in preserving the environment by reducing the severity of greenhouse emissions.
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Reference
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Social%20Impact%20Assessment.pdf.
[7] “HM King inaugurates Alba Line 6 milestone,” Bahrain News Agency. [Online]. Available:
https://www.bna.bh/en/HMKinginauguratesAlbaLine6milestone.aspx?cms=q8FmFJgiscL2fwIzON1+DgF9
eDBuERutpaWKiqPXKyw.
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https://www.idom.com/project/ps5-combined-cycle-power-plant-bahrain/.
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