SUSTAINABILITY 37
Energy optimisation: A plant-wide focus In the second-part of this feature article from Emirates Global Aluminium (EGA), attention turns to energy optimisation beyond smelting operations. EGA’s focus on energy optimisation extends way beyond its smelter operations to embrace other operational areas of the business. For example, both EGA Jebel Ali and EGA Al Taweelah have captive power plants, making both operations effectively selfsufficient in terms of energy requirements. Nevertheless, the broader sustainability agenda at EGA is translated into ongoing efforts to minimise power consumption. Through on-going optimisation efforts, the thermal efficiency of the EGA Jebel Ali power plant has improved over the years and in 2013, it reached its highest-ever level of 46%. Greater thermal efficiency means increased power generation to produce hot metal, while the fuel requirement increment is proportionately less – with direct environmental benefits in terms of fossil fuel combustion and associated environmental emissions. The thermal efficiency of the EGA Al Taweelah power plant, a much newer utility, was 47.85% in 2013. After completion of the EGA Al Taweelah Phase II expansion, net efficiency has been recorded at 51.62%. Moreover, the co-generation configuration of both power plants means that a substantial proportion of the power generated is fuel-free – approximately 27% at EGA Jebel Ali; and 34.8% at EGA Al Taweelah. In addition, waste heat from the EGA Jebel Ali power plant is used to produce potable water through a sea water desalination plant. Alternative energy sources Although the location of EGA’s smelter operations in the UAE ensures an abundant source of energy, primarily natural oil and gas, EGA strongly supports national
and regional efforts to find and adopt alternative energy sources. Particular support is given to the integrated energy strategies implemented by the UAE which address (among other aspects) demand abatement, diversifying the nation’s energy mix and the adoption of renewable energy sources – which will collectively ensure a higher level of energy security. For example, EGA Jebel Ali is a member of the Dubai Supreme Council of Energy (DSCE) and, as a corporate entity, is implementing the directives issued to all DSCE member companies regarding the Dubai Government’s measures to minimise energy consumption and fulfillment of the Dubai Integrated Energy Strategy 2030 (DIES 2030). EGA Jebel Ali’s efforts in this area resulted in approximately 40,000 MWh having been saved between initial implementation of the directives in April 2011 and the end of 2014. In 2013, the absorption chiller installed at EGA Jebel Ali became the UAE’s firstever absorption chiller set-up in a power plant using excess heat to produce chilled water for comfort cooling. Installed on the rooftop of the desalination plant control building, the absorption chiller has replaced the electrically-driven vapour compression chillers used previously. It consumes less than 1 tonne/hour of steam and has reduced the site’s energy consumption by approximately 780,000 kWh per year, simultaneously reducing the smelter’s carbon footprint. EGA’s renewable energy efforts to date have included EGA Jebel Ali’s investment of AED20 million in Mohammed bin Rashid Al Maktoum Solar Park (Dubai) Phase I (13 MW); participating in a feasibility study
relating to the establishment of clean coal-fired power stations in the UAE; and building a mini solar field at EGA Jebel Ali (70 kW). Under the sponsorship of the Executive Affairs Authority in Abu Dhabi, EGA Al Taweelah is working closely with TRANSCO and ADWEA to optimise gas utilisation within the Emirates. Several initiatives that will contribute towards establishing a more efficient grid are at various stages of implementation. Conserving the environment The focus on energy optimisation is part of the bigger environmental conservation ambition at EGA, where ‘greening’ aluminium takes a prime position on the corporate agenda. “Our corporate ambition is ‘zero harm to people and the environment’,” explains Frank Briganti (Vice President of Environment, Health, Safety, Fire and Security at EGA). “We continually strive for and maintain some of the highest standards in environmental protection – from optimising raw material usage through effective energy-use management, to minimising environmental impact through stringent management of air emissions, effluent discharge and waste. We also install the best available technology for containing and monitoring our environmental impact, and continually innovate our processes and technologies to achieve better environmental performances.” Emissions In terms of air emissions, a fluoride emissions management system (FEMS) has been introduced to reduce and control fluoride emissions at EGA’s smelters, and
www.ega.ae Aluminium International Today
sustainability EGA march.indd 1
March/April 2016
3/14/16 3:11 PM