EGA POWER & DESALINATION EMAL – AL TAWEELAH OPERATIONS ELECTRIC POWER GENERATION

EGA POWER & DESALINATION
EMAL – AL TAWEELAH OPERATIONS
ELECTRIC POWER GENERATION
Upon completion of the Phase II expansion project
(scheduled for end2014-), the Emirates Aluminium
smelter complex at Al Taweelah, Abu Dhabi, will be
powered by an enlarged captive combined cycle
power station where the installed power generation
capacity will have increased to 3,100 MW (at design
conditions). The utility will comprise nine gas turbines
and four steam turbine generators. Eight of the nine
gas turbines will have heat recovery steam generators
to produce steam for the steam turbines EMAL’s
gas turbines are fuelled primarily by natural gas.
The combined cycle configuration of the power
plant means that approximately 34.8 per cent
of the power generated at EMAL is fuel-free.
With a vision of green aluminium and protecting
the environment, EMAL has recently upgraded the
gas turbines combustion system which resulted in
a 40 per cent reduction in NOx emissions. The termal
efficiency of the EMAL power plant in 2013 was
47.85 per cent.
EQUIPMENT
• 7 Gas turbines (GE 9FA) equipped with DLN+2.6
(less than 15 ppm NOx) and inlet air. Evaporative
Cooling system, capable of combined cycle or
simple cycle operation.
• 1 Gas turbine (GE 9FA) equipped with DLN2.0
(less than 20 ppm NOx) and inlet air. Evaporative
Cooling system, capable of combined cycle
operation or simple cycle operation.
• 1 Gas turbine (GE 9FA) equipped with DLN2.0
(less than 20 ppm NOx) and inlet air Evaporative
Cooling system, simple cycle operation only.
• 4 Steam turbines (GE condensing-type).
• 18 Rectifier transformers converting AC to DC.
• 18 Harmonic filter banks to control the harmonic
disturbance in the electrical network.
DESALINATION OF SEAWATER
The EMAL Desalination Plant operates on reverse
osmosis technology and, on completion of the
Phase II expansion project, will have an increased
production capacity of up to 3.75 million gallons
(17,000 m3) of fresh water per day. The water
produced at the EMAL Desalination Plant is
used for the company’s on-site needs.
EQUIPMENT
• 4 Sea water reverse osmosis trains each
consisting of 1 SWRO (Sea Water Reverse
Osmosis) and 1 SPRO (Second Pass Reverse
Osmosis) train. Each train is capable of producing
1.25 million gallons per day fresh water.
• Electrical energy requirement: 5.5kWh
per cubic meter of fresh water.
• Reservoir: 18 million gallons storage capacity.
‫شركات اإلمارات العالمية لأللمنيوم‬
EGA Companies
Emirates Global Aluminium PJSC, PO Box 109111, Abu Dhabi, United Arab Emirates
www.ega.ae
EGA POWER & DESALINATION
DUBAL – JEBEL ALI OPERATIONS
ELECTRIC POWER GENERATION
The Dubai Aluminium smelter complex at Jebel Ali,
Dubai, is powered by a captive combined cycle power
station with an installed power generation capacity
of 2,350 MW (at 30˚C). The utility comprises 23 gas
turbines and seven steam turbine generators. The gas
turbines have heat recovery steam generators to
produce steam for the steam turbines; and for the
DUBAL Desalination Plant’s evaporator units.
DUBAL’s gas turbines are fuelled primarily by
natural gas. The cogeneration and combined
cycle configuration of the power plant means that
approximately 36.8 per cent of the power generated
at DUBAL is fuel-free. Through on-going efforts, the
thermal efficiency of the DUBAL power plant has
improved over the years and in 2013 it was reached
the highest-ever level of 46 per cent. The fitment
of low NOx burning systems in all of DUBAL’s gas
turbines has reduced the NOx air emission rate by
60 per cent between 2000 and 2013.
EQUIPMENT
• 8 Gas turbines (six GE F9E and two Alstom 13E2)
equipped with Evaporative Coolers and Dry
Low NOx burners (less than 20 ppm NOx),
with 4 steam turbines (Alstom condensing-type).
• 1 Gas turbine (Alstom 13DM) in combined cycle
with 1 steam turbine (Alstom).
• 13 Gas turbines (eight GE F5 and five GE F9BE)
in large co-generation cycle.
• 1 Gas turbine (Alstom 13E2) in co-generation
cycle, equipped with Evaporative Coolers and
Dry Low NOx burners (less than 20 ppm).
• 44 Rectifier transformers converting AC to DC
(including 13 boosters).
• 372 Distribution transformers.
The Evaporative Coolers enhance the plant
electrical output and reduce C02 emissions
by about 200,000 tonnes per annum.
DESALINATION OF SEAWATER
Utilising the waste steam exhausted from two
free-energy driven back pressure steam turbines,
the DUBAL Desalination Plant can produce up
to 30 million gallons (136,000 m3) of fresh water
per day. The water produced is for DUBAL site
consumption and also sold to external customers.
EQUIPMENT
• 6 Multi-stage flash evaporators, each capable
of producing 5 million gallons of distilled water
per day
• Net steam requirement: 750 tonnes per hour
• Reservoir: 10 million gallons storage capacity
• Water tanker filling station: 18 million gallons
per day
‫شركات اإلمارات العالمية لأللمنيوم‬
EGA Companies
Emirates Global Aluminium PJSC, PO Box 109111, Abu Dhabi, United Arab Emirates
www.ega.ae