EGA Jebel Ali starts operating a fourth HE batch furnace
Following the presentation of the new Hertwich batch furnace concept in 2010, Dubai Aluminium („DUBAL“), an operating subsidiary of Emirates Global Aluminium („EGA“) and referred to as EGA Jebel Ali, was the first company to choose the new batch furnace type. In the autumn of 2015 the fourth batch furnace of this type has been successfully commissioned at EGA Jebel Ali.
With an annual capacity of more than 1 million tonnes of aluminium, EGA Jebel Ali is one of the largest aluminium producers in the world. Together with Emirates Aluminium („EMAL“), another EGA subsidiary referred to as EGA Al Taweelah, EGA has an annual production of 2.4 million tonnes. Extrusion billets account for almost half (46 percent) of that amount. The material, predominantly intended for export, is sent for shipment in the homogenized condition after quality control. For this, EGA Jebel Ali uses both of the furnace designs by Hertwich – continuous and batch furnaces.
Monitoring on the newly installed batch furnace showed that, under operating conditions, the heating time can be reduced and temperature deviations lie within a narrow range. Thermocouples check and document the temperatures in the extrusion billets. The result shows that the uniform action of hot and cooling air produces very good metallurgical properties.A further advantageous effect is that, without having to be reversed, the drive motors and vanes of the fans are less severely stressed – a fact that results in a drastic reduction of maintenance effort and expense.On the basis of this positive experience, EGA Jebel Ali has replaced older batch furnaces with the modern units by Hertwich. In the autumn of 2015 the fourth unit, with a burner power of 5,000 kW, started operating. This most recent furnace is designed for billet diameters of between 152 mm and 406 mm.
Hertwich Engineering, a company of the SMS group is renowned for its future-oriented, energy saving technologies and outstanding service in aluminium casthouse. The company is active worldwide with design, supply, construction and commissioning of special machinery and equipment for the Aluminium industry. Hertwich is competent for supplying complete Al-casthouse on a turnkey basis (one-stop-shopping). The product range comprises melting equipment for aluminium scrap, conti and batch homogenizing plants, sawing plants, horizontal and vertical casting machines and quality inspection stations, etc. To stay ahead Hertwich relies on its own R&D and proprietary know-how. For 50 years, the advanced technology has revolutionized the industry and the company maintains its worldwide lead.