A comprehensive study into the capabilities of the five pilot DX
Technology cells, undertaken by three of the top world experts in
the aluminium industry, confirmed that the cells perform strongly
and steadily; and produce successfully at a high amperage of more
than 350 kA. In 2007, following a series of improvements to the
cell design and components, anode configuration, shell, process
control, busbars, superstructure and operational practices, the
second generation DX Technology cells was introduced.
In February 2008, we commissioned 40 of these improved DX
Technology cells at industrial scale within our Jebel Ali smelter,
in an operational area known as Potline 8. Operating stably at 380
kA, the line yielded 42,500 mt in 2010. As shown in the table
below, Potline 8 demonstrates on an industrial scale the
outstanding performance of DX technology.
| KPI |
Potline 8 |
| Amperage range |
370 kA |
| Specific energy consumption |
13.05 kWh/kg Al |
| Current efficiency |
95.2 per cent |
| Output |
2.907 mt Al/pot/day |
| AE frequency |
0.018/pot/day |
| PFC emissions |
0.012 CO2 eq mt/mt Al |
| Carbon consumption |
405 kg/t Al |
DX Technology has been installed at EMAL Phase I (756
cells in two potlines). Operating stably at 350 kA, the DX
Technology cells at EMAL Phase I were fully commissioned by the end
of December 2010, giving the plant a nominal production capacity of
740,000 mt in 2011. The amperage of the cells has been increased to
353 kA during the year, with commensurate increases in metal
production levels to 750,000 mt and associated benefits in terms of
energy-efficiency and environmental protection.
DX+ Technology
Through ongoing research and development, DUBAL's DX Technology
cells have been re-designed to enable operation at even higher
amperages. Five new generation cells, built in the pilot line at
Jebel Ali, have operated at 420 kA since the end of August
2010.
The improved technology - known as DX+ Technology - is based
directly on the proven, inherently robust DX Technology. The
industrial version is targeted to achieve specific energy
consumption of less than 13.3 kWh/kg Al, with the average yield per
pot expected to be 3.4 mt/day. The AE frequency is very low but,
more importantly, DUBAL's proprietary advanced control logic
restricts the average duration of AEs to less than 6 seconds (a
world benchmark for lowering PFC emissions).
The new generation DX+ Reduction Technology cells will be
installed in the 444 cells of EMAL Phase II.
Potline 8, DUBAL
