Emirates Aluminium (“EMAL”) is an operating subsidiary of Emirates Global Aluminium (“EGA”). Having produced its first hot metal in 2009, EMAL celebrated its 5th anniversary in 2014.
EMAL was established as a joint venture between Mubadala Investment Company and DUBAL in February 2007 and designed to become one of the world’s largest single-site primary aluminium smelters. The EMAL complex, built on a 6 square kilometre site in Al Taweelah, Abu Dhabi, comprises a 1.3 million tpa smelter, a 3,100 MW power station, a large carbon plant, extensive casting operations (more than 1.8 million tpa), a water desalination plant, dock and other facilities. A quality-focused, customer-centred and innovation-drive organisation, EMAL holds ISO 9001, ISO 10002, ISO/IEC 27001, ISO 29990, ISO14001 and ISO/TS16949 certification; as well as OHSAS 18001 certification and NEBOSH certification in Occupational Health and Safety.
By design, EMAL was built in two phases. Phase I, which was fully commissioned by the end of 2010, is the world’s largest greenfield smelter development (800,000 tpa). Commissioning of Phase II, comprising the world’s single-longest potline (1.7 km) with a design capacity of 520,000 tpa, began mid-September 2013. Full ramp-up of Phase II was achieved mid-2014, making EMAL the largest single-site smelter in the world.
Financial Completion of EMAL Phase II was achieved on 31 December 2015. The Phase II Completion required EMAL to meet rigorous global industry standards covering construction, operational, environmental, financial and legal aspects. The Operational Test was particularly demanding, requiring the Project to operate the full plant (1.4 million tonnes of aluminium) i.e. both the Phase I and Phase II facilities, at a minimum of 95 per cent design capacity for a continuous period of 90 days. As a result of successfully achieving Phase II Completion, EMAL’s project financing is now non-recourse to Mubadala Development Company PJSC and Dubai Aluminium PJSC as their respective completion guarantees have been released.
EMAL is the anchor tenant of the Khalifa Industrial Zone Abu Dhabi (“KIZAD”), and an integral component of the KIZAD Aluminium Cluster. The development of EMAL ranks among the largest industrial projects in the UAE outside the oil and gas sector and one of the key projects supporting the diversification of the national economy, with Emiratization at the core of its employment strategy. EMAL was integrated into EGA at the latter’s official incorporation, in the first quarter of 2014.
EMAL produces high quality aluminium products in four main forms: foundry alloy (automotive applications); billet (construction, industrial, transportation and automotive forging); high purity aluminium (electronics and aerospace); and rolled products (packaging, lithographic sheets and automotive). EMAL also has a Liquid Metal Transfer facility, enabling the transfer of hot molten aluminium directly from the smelter site to downstream industry in KIZAD.
EMAL's commitment to sustainability has been evident from inception. The business has regularly participated in, led and established community engagement initiatives within the surrounding areas, including open days and support for social, sports and cultural organisations.