Implementation of D18+ Cell Technology at EGA’s Jebel Ali Smelter

Abstract

In March 2012, EGA started seven test cells to validate its new D18+ cell technology. Designed with the latest technological advances to upgrade the original D18 potlines, the test cells quickly met their design targets with specific energy of 12.75 DC kWh/kg Al and AE frequency less than 0.02/cell/day. After successful validation, a project was commenced in August 2015 to upgrade the original D18 potlines to the newly developed D18+ cell technology. Unlike previous capacity expansion at EGA, the D18+ project required construction within the existing potrooms, which continued to operate while the upgrade was underway. Despite the challenges involved, full conversion of Potline 1 was successfully achieved ahead of schedule and without injury. Through increased amperage to 235 kA and higher efficiency EGA’s production capacity will be increased by 23 kt per annum. Further conversion of 272 cells to D18+ in Potline 3 will commence in September 2016.