Insight – February 2016

INSIGHT
FEBRUARY 2016

07. Recognition
10. Product updates
15. Sustainability

2

CONTENTS

04. Message from the MD and CEO
07. Gaining local and global recognition for operational

excellence
10. Product update
13. Market update
14. Project update
17. Excellence in EHS
19. See you in 2016

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Message from
the MD & CEO

Welcome to the February 2016 edition of the EGA Customer Magazine. The begin-
ning of a new year brings new goals and possibilities, serving as an ideal oppor-
tunity to reflect on the achievements and lessons of the previous year. It is a time
when – as individuals and businesses – we look to the year ahead and assess how
we can do things better, create more success and bring about further progress.
As a business built on a legacy of excellence, continuous improvement is part of
our corporate culture and has been a key factor in EGA’s success across four dec-
ades. We view this as very much a team effort, encouraging EGA employees at eve-
ry level of the business to come up with innovative ideas on how we can improve
as a company; be it from an operations, technology, environmental performance or
product perspective.
At EGA, our vision and values guide the way we operate. As a team we are all
focused on one shared vision – to provide the global economy with sustainable
material of the highest quality, building a legacy of excellence for the UAE and
the world. This vision is supported by three core values: ‘protect’, ‘provide’ and
‘perform’ and in 2015, there were many examples of how we have lived up to these
values across the company.
Our commitment to ‘protect’ the environment wherever we operate can be seen
throughout the issue; from LEED and DGNB ratings for products manufactured at
EMAL to the launch of new projects at DUBAL that target energy optimization and
capacity creep. Protecting our employees is also of paramount importance and our
impressive LTI records and accreditation for our company healthcare facility are
testament to this.
To showcase EGA’s community projects, in this issue we focus on the work of GAC,
where skills programmes and the development of farmlands are making a mean-
ingful difference and helping to secure a better future for those affected by the
project. Our support of healthcare initiatives is also proving to have life-changing
affects on the local community in Guinea, providing them with vital access to im-
proved medical facilities.
In our selection of articles on operational excellence, the value of ‘perform’ is evi-
dent throughout; be it through industry certifications achieved in the past year
such as ISO 22301:2012 or award wins internationally and locally at DeutscherI-
deenPreis 2015 and the Computer News Middle East Awards (which were among
many award wins for EGA last year).
In closing I would like to wish you all a prosperous 2016 and look forward to
another successful year of business together. Enjoy this issue.

Abdulla Kalban
MD & CEO: EGA

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5

6

Gaining local and
global recognition for
operational excellence

As one of the world’s top five alu- business has gone from strength
minium producers, Emirates Global to strength, creating exciting new
Aluminium (“EGA”) is driven by a possibilities for the industry and
commitment to operational excel- economy.
lence; a value that has been firmly
rooted in the company’s DNA since EGA adheres to the highest quality
its inception in 1979. With a vision standards in all aspects of its opera-
to provide the global economy with tions and these efforts haven’t gone
sustainable material of the highest unnoticed, with the company having
quality, continuous improvement been recognised by several leading
and innovation across the busi- bodies over the years. Last year was
ness, enables the company to excel no exception with EGA receiving a
throughout its operations and drive number of accolades and accredita-
industry standards. tions for its unwavering dedication
to achieving the highest standards in
It has now been over two years since operations, product and service.
Dubai Aluminium (“DUBAL”, referred
to as EGA Jebel Ali Operations) and Industry certifications
Emirates Aluminium (“EMAL”, re- DUBAL was one of the first industrial
ferred to as EGA Al Taweelah Opera- enterprises in the UAE to develop
tions) merged to form the region’s and implement full Crisis & Business
largest aluminium provider. “The Continuity Management Systems
combined strength of both com- and in January 2015, EGA became
panies has created an even greater the first manufacturing company in
platform for technological innova- the Middle East to achieve certifica-
tion and business performance ex- tion to the ISO 22301:2012 Business
cellence,” says Abdulla Kalban (MD Continuity Management Systems
& CEO: EGA). Indeed, the integrated standard (by LRQA).

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“EGA is driven by
a commitment to
operational excellence;
a value that has been
firmly rooted in the
company’s DNA since
its inception in 1979.”

Industry certification: ISO22301 es as per the criteria defined by The Exceptional healthcare
Leadership in Energy and Environ-
“Business Continuity Management mental Design (“LEED”) green build- standards
is an integral pillar of EGA’S busi- ing programme and the Deutsche A healthy workforce promotes a
ness and provides the systematic Gesellschaft für Nachhaltiges Bauen happy and productive work environ-
approach and strategies towards op- e.V. (The German Sustainable Build- ment and to ensure the wellbeing of
erational continuity,” Kalban explains. ing Council). DUBAL’s products its employees, EGA operates on-site
“The ISO 22301 certification is testa- were declared suitable for sustain- medical facilities at both sites, where
ment to the effectiveness of our ap- able building practices by both or- the highest standards are maintained.
proach towards this area of focus.” ganisations in 2013, so EGA is now Open seven days a week, these facili-
fully certified in this regard across its ties cater for the organisation’s oc-
Continuing the company’s journey to UAE operations. cupational health needs, provide free
excellence, products manufactured medical coverage to full-time EGA
by EMAL have been declared suit- For more on this, see page 12 employees and their families as well
able for sustainable building practic- as temporary and contractual em-
ployees, and respond to emergencies
as necessary.

Attesting to this, the in-house clini-
cal laboratory at the EGA Jebel Ali
Medical Centre was audited and re-

Exceptional healthcare standards

8

EGA received the Gold Award in the ‘Safety Idea of the Year’ category at the 2015 Ideas.America International Competition

ceived Joint Commission Internation- agement, and the latest accolade is ground-breaking business value
al (“JCI”) Accreditation at the end of the 36th award EGA has received through the innovative application of
2014. JCI is an independent, non-prof- from the respected body. “This Ide- technologies. “In today’s technology
it organisation that evaluates and ac- as.America award served to further centric world, an effective I.T. opera-
credits healthcare organisations with highlight EGA’s commitment to En- tion can be pivotal to any organisa-
the aim of creating a culture of safety vironment, Health and Safety and tion’s success – especially when I.T. is
and quality. Mandated by the Dubai demonstrates our specific emphasis designed to bring about change and
Health Authority (“DHA”) to carry out on safety first and always,” Kalban innovation in the organisation,” ex-
the audit, JCI gave the EGA Jebel Ali commented following the award win. plained Ahmad Almulla (Senior Vice
Medical Centre a clean bill, making it President, I.T. at EGA).
only the third facility of its kind in the Gaining further global praise for its
world with no adverse findings. commitment to excellence through Nominees were reviewed and judged
continual improvement and innova- by a panel comprising industry ex-
An award-winning legacy tion, last year EGA also received the perts and this particular award was
Continuing a long tradition of inter- DeutscherIdeenPreis 2015 – Ideas In- assessed based on achievements in
national recognition, EGA received ternational Award for the suggestion the last 18 months on areas such as
the Gold Award in the ‘Safety Idea of “Reduce riser voltage drop in new pot supporting business integration, on-
the Year’ category at the 2015 Ideas. cells by welding aluminium strips”. time completion of I.T. projects to im-
America International Competition, prove business productivity, integrat-
which took place in Maryland, USA in Back on home soil, EGA won the “I.T. ed team work and a focus on training
September. Team of the Year 2015” award at the and continuous skills refreshment.
2015 Computer News Middle East How the team overcame challenges
Ideas.America is the leading profes- (“CNME”) Awards which recognise was also taken into consideration.
sional association that assists organi- individuals and organisations from
sations internationally in idea man- the Middle East that have delivered As EGA looks to the coming year, op-
erational excellence will remain a key
“In today’s technology centric world, an effective strategic focus to ensure that custom-
I.T. operation can be pivotal to any organisation’s ers are served with the best product
success – especially when I.T. is designed to bring first time and every time. Team work,
about change and innovation in the organisation.” problem-solving and innovation will
remain vital to ensuring continuous im-
provements throughout the organisa-
tion and help to solidify the company’s
position as a leading global player.

9

Product update
T-bars

Responding to the global upward
demand for pure grade alloys, EGA
Al Taweelah Casthouse sheet slab
casting complex added a break-
through initiative on 5 March 2015,
by introducing saleable T-bars to
the market. The specifics of the
product and production station are
as follows:
n Total capacity: 190 kpta
n Sawn to customer’s desired

length
n C ast on vertical direct casting

machine, using Low Head
Composite Mould Technology
This achievement is another dem-
onstration of EGA operations team
and management’s capability to
supply quality product to our val-
ued customers.

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Can you spot the new
additions to our product range?

RE-MELT PRODUCTS

High purity (from grade 99.90% to 99.96% purities) Open moulds ingots 10 kg; 20 kg; 22.5 kg

Low profile sow ingots 680 kg

High profile sow ingots 500 kg

Standard profile sow ingots 680 kg

T-bars 680 kg to 2,200 kg
Foundry alloys HDC small ingots 8 kg & 10 kg
(Silafont 36 and AlSi3,  A356.2; 7%, 10% and Properzi ingots 10 kg

11% silicon alloys) T-bars 680 kg to 2,200 kg

ROLLED PRODUCTS Open moulds ingots 600 mm

(1xxx, 3xxx, 5xxx,6xxx, 8xxx series alloys)

Typical widths 1,150 mm; 1,200 mm; 1,350 mm;

1,400 mm; 1,450 mm; 1,550mm;

1,600 mm; 1,650 mm; 1,700 mm;

1,750 mm; 1,800 mm; 1,850 mm,

1,950 mm, 2,000 mm; 2,050 mm, 2,200 mm

Lengths As desired, maximum 10,000 mm

Billets for extrusion and forging Diameters available 152 mm; 155 mm; 178 mm;

(homogenized using continuous

and batch homogenizers) 203 mm; 216 mm; 228 mm

254 mm; 273 mm; 279 mm;

305 mm; 355 mm; 381 mm; 406 mm

Lengths 420 mm to 7,500 mm

CASTING FACILITIES DUBAL EMAL
(Jebel Ali Operations) (Al Taweelah Operations)
Sow 95,500 tonnes/year
Standard Ingots 220,000 tonnes/year 330,000 tonnes/year
Properzi Ingots 98,500 tonnes/year 570,000 tonnes/year
Horizontal direct casting 133,000 tonnes/year
Vertical direct casting 721,000 tonnes/year –
Sheet Ingots – –
Liquid metal – 420,000 tonnes/year
380,000 tonnes/year
150,000 tonnes/year

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EGA products rated for
sustainable building by
LEED and DGNB

Products manufactured by EMAL “The international rating of suitability
have been declared suitable for sus- for use in sustainable building prac-
tainable building practices, as per tices places the products manufac-
the applicable criteria defined by tured by both DUBAL and EMAL in
two internationally acclaimed bod- a strong position to be specified by
ies, namely: end-users in the building and con-
• The Leadership in Energy and En- struction industry worldwide.”

vironmental Design (“LEED”) green LEED and DGNB sustainability rat-
building programme launched by ings also represent a key differentia-
the US Green Building Council tor in the local market, where billets
(“USGBC”); and account for the major proportion of
• Deutsche Gesellschaft für Nach- annual sales. “New laws have been
haltiges Bauen e.V. (“DGNB”, which enacted in the UAE, whereby the in-
translates as the German Sus- corporation of sustainable measures
tainable Building Council), which is mandatory in all new construction
strongly promotes sustainable and projects in the Emirates as of 2014,”
economically efficient building. Al Attar explains. “The suitability of
our products is tangible evidence of
“The LEED and DGNB ratings of our EGA’s support for the government’s
products are a major development green building agenda, simultane-
for EGA, as about 46 per cent of our ously confirming the success of our
total annual production comprises efforts to produce ‘green metal’ as
aluminium billets that are used ex- part of our overall sustainable busi-
tensively by extruders to produce ness philosophy and supporting
construction components – such as strategies to minimise the impact of
window and door frames,” says Walid our business on the environment.”
Al Attar (Chief Marketing Officer).

aplTruoomwpdinoupicrrueilmmdrawbirniily2dl0ee1t4 “The LEED and
DGNB ratings

of our products
are a major

development for
EGA, as about
46 per cent of

our total annual
production
comprises
aluminium
billets.”

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Market
update

9% 2015 Pure Metal
Production
Sheet 29%
2,464,000
22% tonnes 40%

Foundry BILLETS

Percentage total exports in 2015

THE EUROPE ASIA
AMERiCAS 25% 45%

12% GCC/
MENA

18%

13

Project
update

Guinea Alumina Corporation SA EGA Jebel Ali, Dubai
(“GAC”), Guinea
In Q1, 2015, EGA Jebel Ali launched a new project designed
In June 2015, EGA’s mining development compa- to target energy optimization and capacity creep. Good
ny, GAC signed a series of four agreements in Par- progress has already been made on the three core compo-
is, France with the Government of the Republic nents of the project, namely:
of Guinea (“GoG”) – the latter represented by the
Ministry of Mines and Geology and the National • R eplacement of D18 cells with D18+ Technology –The
Agency for the Development of Mining Structures newer technology offers a reduction in net specific energy
(“ANAIM”). Also present and party to the agree- consumption to below 13 kWh/kg Al; delivering current ef-
ments were Compagnie des Bauxites de Guinée ficiency greater than 95 per cent; and an increase in pro-
(‘’CBG’’) and Compagnie de Bauxite et Alumina duction capacity to 2.0 tonnes Al/pot-day. Construction
de Dian-Dian (“COBAD’’) of the first 32 new D18+ Technology cells was completed,
with start-up in October 2015.
The four agreements comprised:
• A Multi-User Operations Agreement covering • A dding four DX Technology cells to Potline 8 – The in-
creased operating amperage of this line, currently at 401
the access conditions and joint investment in the kA, together with the associated reduction in specific en-
railway; ergy consumption, has allowed for additional DX Technol-
• A Port Operations Agreement covering the mo- ogy cells to be added to Potline 8 in the centre passage,
dalities of operation and investment in the Port of which, in turn, will increase the line’s production capacity.
Kamsar; These four cells were in operation by end-September 2015.
• An Infrastructures Agreement covering GAC’s
access rights to the existing infrastructures; and • D 20+ Technology cells in Potline 5B – Inspired by the D18+
• A Port Agreement (now referred to as the Bulk Smelting Technology pilot project’s successful maximisa-
Materials Dock Agreement), covering the mo- tion of production with the available power, experimen-
dalities of development of GAC’s Bauxite and tal modifications were introduced to modernise the D20
Alumina Terminal. Technology cells in Potline 5B. The reduced specific en-
ergy consumption allows for additional D20+ Technology
The signed agreements relate to the access cells to be added to the line, in turn yielding higher hot
granted to GAC to the port and rail infrastructure metal production.
owned by the GoG through ANAIM in the region
of Boke and put under concession to CBG; and to D18+ cells
the development of ‘’additional infrastructure’’ in
the region of Boke, to support the expansion of
GAC’s mining activities. The work will be carried
out by the parties to the respective agreements.

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Local health centre in Sangaredi

Ensuring a sustainable
future for the people
of Guinea

As part of its social license to operate, facilities available to local people.
EGA’s mining development company, Here is a snapshot of some of GAC’s
Guinea Alumina Corporation (“GAC”) recent community work in Guinea.
works continually to improve the
quality of life of the surrounding com- Promoting skills
munity as well as those affected by
its operations. development
Aiming to foster sustainable develop-
GAC’s community engagement mentthroughvocationalskillstraining,
programmes are designed to de- GAC runs a six-month programme
liver long-term social and economic for those living in the surrounding
benefits to Guinea through employ- community. Now in its third year, the
ment (including self-employment) training is held at the Boké Vocation-
and skills training. The company also al Training Centre (CFP de Boké) and
provides expertise and resources to covers five areas of expertise: me-
construction projects, which focus chanical, electrical, plumbing, ma-
mainly on improving the medical sonry and carpentry. The most recent
session, run from June to December

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Planting crops Improving healthcare Support Services and led to the crea-
Access to healthcare is fundamental tion of 70 jobs.
2015, benefitted 95 Guineans – both to promoting a sustainable society
male and female – from the villages and GAC has supported several initia- In the district of Kawass, sub-prefec-
of Sangaredi, Tanene and Kamsar. tives aimed at improving medical fa- ture of Kamsar, GAC has sponsored
cilities in the communities surround- the construction of a modern health
Approximately 90 per cent of each ing the project. Two examples are post, to provide vital medical support
course is based on practical train- highlighted below. for those living in the district. Previ-
ing, enabling the students to gain ously, patients – including pregnant
first-hand knowledge of the skills In the city of Sangaredi, GAC has women – would have to walk three
required. On completion of the pro- funded the refurbishment of a lo- kilometres to reach the nearest health
gramme, trainees are provided with cal health centre, including the con- facility in Kakota, just to receive basic
work tools and individual protec- struction of an additional building medical care. This resulted in many fa-
tion equipment, encouraging them that will feature high quality equip- talities; illustrating the significant im-
to pursue a vocation following their ment and increase the number of pact the new health post will have on
studies. To ensure the success of this treatment rooms available. The im- the local community. The construction
initiative, a monitoring plan is carried proved facility will be able to re- contract for the project was awarded
out during and after the programme ceive 500 pregnant women for pre- to local SME STI Topographic and
by the management team of CFP de liminary medical consultations and Engineering Services and created
Boké and the village committee. healthcare, deliver at least 100 in- 30 jobs – all filled by Guinea nation-
fants and complete a minimum of als. The fully equipped infrastructure
10 operations over a one-month pe- features solar energy technology,
riod. The construction contract for providing a sustainable, low-cost
the project was awarded to Guinea source of power.

Enhancing food security Health post at Kawass
Local skills development
through agriculture
Helping to encourage food security
in the local area, GAC has developed
farmlands for the resettled villages
of Touldé and Petoun Djiga. The
GAC Community Team was involved
in helping farmers to complete pre-
liminary work for the project; which
included weeding, staking and hole
digging. The team also provided min-
eral amendments and vital equip-
ment along with 1,250 kg of ferti-
lizer. A total of 1,774 trees (including
mango, orange, avocado banana and
palm trees), donated by the Institute
for Agricultural Research of Guin-
ea, were planted on approximately
17 acres of land in Touldé and seven
acres in Petoun Djiga.

16

Excellence in
environment, health
and safety

FTP main exhaust fans showing the location of the fan and the motor

“Protect” is one of EGA’s corporate nance department to reduce green- GHG emissions. This is EGA Jebel Ali’s
values, reflecting the company’s house gas (“GHG”) emissions was ap- second initiative to be registered as a
safety-first approach. Linking to this, proved by the UAE Ministry of Energy CDM project – the first being “Regen-
one of EGA’s priorities is to build a and is to be registered as a Clean De- erative Burners for Melting Furnaces”
sustainable culture in Environment, velopment Mechanism (“CDM”) pro- which consume approximately 39 per
Health and Safety (“EHS”), a culture ject under the United Nations Frame- cent less gas than conventional cold
that focuses on encouraging positive work Convention on Climate Change. air burners.
behaviours from all leaders, employ-
ees and contractors. Be it safety at The project, titled “The 3.3 kV Main In Q3 2015, Process Control Pot-
work or the protection of the envi- Exhaust Fans energy-saving Project” room at EGA Jebel Ali notched up
ronment, EGA strives for continu- is integral to the EGA Jebel Ali car- a record 21 years without Lost Time
ous improvement and has achieved a bon management strategy and will Injury (“LTI”). One of the key factors
number of notable EHS milestones in save approximately 30 to 40 per cent enabling the team to reach 21 years
the past year. of energy consumption by using Vari- without an LTI is the high awareness
able Frequency Drive, which provides culture among team members. This,
In Q2 2015, an initiative introduced maximum efficiency. The lower ener- along with safety best practice, close
by the EGA Jebel Ali Smelter Mainte- gy consumption translates into lower working relationships with safety

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21 years LTI free at Process Control Potroom

officers and the use of insight anal-
yses for safety tools has provided a
recipe for success.

Attention to detail is key for a safe Local skills development EGA has submitted patent applica-
workplace and nothing should be left tions for several of its proprietary
unnoticed. From a leaking pipe to a bedded in the everyday working en- technologies, of which two are sum-
dusty ceiling tile – all aspects are re- vironment throughout the company, marised below:
ported, evaluated and rectified at and EGA’s industry-leading standards
EGA. With a team of 45 employees at in the field are widely respected. • Pot start-up fuse designed by a
the Technical Laboratory at EGA Jebel team of engineers at EGA for a safer
Ali, achieving 2,060,674 man-hours In Q4 2015, EGA hosted a one-day and easier way to use.
with no lost-time injury is no easy event “Innovation, Geared by Ideas”
task. However, through the persis- at each of its smelter sites in the UAE • Anode-Rod Tracking System devel-
tence of management and an unwa- to promote innovation and the pow- oped in-house to track individual an-
vering commitment to safety among er of creative thinking. The event was odes and rods at each stage of the
employees, the unit has now operated a celebration of the culture of value- process – from anode production to
a safe workplace for 25 years. adding innovation that has been a anode rodding, through the smelter
cornerstone of EGA’s successful and operation (potrooms) and back to
These projects are among many ini- sustained growth over the years. anode rodding (for recycling of the
tiatives implemented at EGA to im- “Innovation is part of our corporate anode butts and rod assemblies),
prove the company’s performance DNA – it defines who we are and how allowing for a comprehensive cycle
in Environment, Health and Safety. we operate – and has been pivotal to data collection that gives chances
Health and safety practices are em- us securing a leadership position in for improvements.
the global aluminium industry,” he
“Innovation is part of said Abdulla Kalban.
our corporate DNA – it
defines who we are and
how we operate – and
has been pivotal to us
securing a leadership
position in the global
aluminium industry.”

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FEBRUARY See you
TMS 145th Annual Meeting & Exhibition in 2016
14 to 18 February 2016
SEPTEMBER
MAY Metal Bulletin’s 31st International Aluminium
The International Aluminum Extrusion Conference 2016
Technology Seminar September 2016
2 to 6 May 2016
NOVEMBER
JUNE 19th Arab International Aluminium Conference
Harbor’s 9th Aluminium Outlook Summit (“ARABAL”) 2015
7 to 9 June 2016 November 2016

NOVEMBER/DECEMBER
Alu Dusseldorf 2016
29 November to 1 December 2016

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