Bahrain-based aluminum producer Alba, along with Bechtel, the engineering, procurement and construction management (EPCM) contractor, has achieved a major milestone by successfully producing the first hot metal at its Potline 6 Expansion Project two weeks ahead of schedule.

Alba officially announced the commissioning of its Potline 6 with the first pot energisation on December 13, thus taking its final steps towards becoming the world’s largest aluminium smelter.

Adding 540,000 tonnes per annum (tpa) to Alba’s capacity of 1 million tpa, this new 1.4-km potline involved the construction of 424 pots in Line 6, utilising Emirates Global Aluminium’s (EGA) proprietary DX+ Ultra Technology.

On the key milestone, Alba’s chairman Shaikh Daij Al Khalifa said it not only marks the beginning of a new era for the company but also a breakthrough record as Alba brought forward the first hot metal milestone ahead of its scheduled date on January 1, 2019 – making it the fastest construction ever delivered in the aluminium industry.

“On this dual occasion, the National Day and the commissioning of Potline 6, I would like to express my sincere congratulations and utmost appreciation to Bahrain’s leadership for their guidance and wise directives, and to the government for endorsing Alba’s Line 6 Expansion Project and for trusting us to achieve this landmark project,” he stated.

 “We are also very pleased to have started the commissioning of Potline 6 safely ahead of schedule and for that I would like to thank Bechtel, our EPCM contractor for Line 6 Expansion Project – smelter, and Alba’s executive management for their hands-on orchestration as well as our employees and contractors for embracing extreme ownership,” he stated.

“This milestone precedes the gradual ramp up of 424 pots in Potline 6 which upon completion will make Alba the largest smelter in the world,” he added.

Bechtel’s Mining and Metals Global Business Unit president Paige Wilson dubbed it as a world-class achievement for Bahrain, Alba and Bechtel.

“We are very proud of this achievement. The Alba Potline 6 Project’s 24-month schedule to first hot metal, or first aluminium, is six months faster than the industry standard. This success was only made possible thanks to the very strong collaborative relationship Alba and Bechtel have formed,” stated Wilson.

As of November 30, 2018, Line 6 smelter’s overall progress exceeded 77 per cent (engineering progressed by more than 96 per cent while contracts and procurement advanced by 97 per cent. Thanks to the project’s steady progress, the Power Station 5 is nearing completion with over 80 per cent of the work already over.

Potline 6 is being executed by Bechtel as the EPCM) contractor with responsibility to design and construct Potline 6 and support industrial services. It received the notice to proceed (NTP) in January 2017. Bechtel had previously served as EPCM contractor for the Line 4 and 5 expansions as well.