Performance
Qatalum will be the largest primary aluminium plant ever built in one phase. It will be a fully-integrated primary aluminium plant consisting of a smelter, casthouse and carbon plant as well as a dedicated gas fired power plant with a capacity of approximately 1,350 MW.
Qatalum, a joint venture by Qatar Petroleum and Hydro, will have a capacity in the first phase of 585,000 tonnes of primary aluminium annually, all to be shipped as value-added aluminium casthouse products. There are already plans to boost the production to 609,000 tonnes annually from 2013.
The highest standards
The project is designed to meet the highest environmental standards. Qatalum’s Environmental and Social Impact Assessment was approved by Qatar’s Supreme Council for Environment and Natural Reserves (SCNER) in November 2006.
The Qatalum project is based on Hydro's electrolytic reduction cell technology, which was developed in-house. This technology gives a combination of low investment costs, high productivity, low energy consumption and reduced emissions.
Building on experience
HAL250 was the technology applied in Hydro's project at Sunndal, Norway. The new development in Qatar can build on the experiences gained in Sunndal, at other Hydro plants, and in the course of the company’s technology development activities.
The cell technology is a top technology product. Aluminium production takes place at 960°C and uses aggressive chemicals. This process is difficult to monitor using normal measurement methods and equipment, so Hydro has therefore developed a special microcomputer for process control.
It is vital that aluminium cell control system functions without fault 24 hours a day, every day, year after year.
The HAL275 technology to be used in Qatalum is an economical and environmental-friendly electrolytic reduction technology. A holistic approach, system knowledge, operational experience and advanced mathematical models have resulted in a compact and highly productive plant with a sound working environment. Highly efficient purification units will be installed. Due to the temperatures involved, there will also be a high degree of mechanization of operation.
Improved working environment
Hydro's recent technology development has taken place at a time when ever greater consideration has been given to local communities and the environment. This challenge has helped Hydro develop one of the most environmentally friendly and compact electrolytic reduction technologies in the world.
The removal of process gases is an important factor for the protection of operators and for ensuring a clean working environment. The patented extraction system collects 99.5 percent of the gases from the process with optimal energy use. All fluoride is recycled.
Other important environmental features of HAL275 are:
- Increased extraction from cells during change of anodes
- Closed transport systems for oxide and coke
- New, highly efficient purification units