GTX Cogeneration Project

Project Description

The Dubal Aluminium Company Limited (DUBAL) operates aluminium smelters with a production capacity of approximately 1.2 million tons per year. To ensure this production, it is necessary to provide the aluminium electrolysis reliably and without the interruption of electrical energy.

The current demand is approximately 1,880 MW and is provided by a private power plant. DUBAL's power plant was built in the 80s and has, in addition to the gas turbine plants, a desalination plant, which is operated by back-pressure turbines. Since then further combined cycle plants have been added (CCGT units). The installed electrical capacity was increased by the "GTX-project" from about 2,150 MW to 2,350 MW at 38°C.

The GTX project was developed and implemented to achieve the following main objectives:

• Increase the available power for aluminium production while increasing the reserve capacity to secure the power supply
• Increase the efficiency of the power plant from 46.2% to 48.1%
• Reduction of CO2 and NOx emissions
• Improvement of the flexibility of plant operation together taking into account the overhaul plan and reserve capacity
• Improvement in the monitoring and control of the various units from one location

The GTX-plant consists of a gas turbine type GT13E2 by Alstom and a heat recovery steam generator by CMI. The HP and LP steam generated can, on the one hand, be distributed to three CCGT units and on the other hand fed into the 20-bar steam rail for the desalination plant.

Investment volume           approximately € 112 million

Client                                 Dubai Aluminium, United Arab Emirates

Technical specifications

Electrical power                 200 MW

Fuel                                    Gas

Execution                           2006-11

VPC's services

• Feasibility studies with economic studies on the determination of the optimal approach
• Basic engineering
• Preparation of tender documents and supervision of the general contractor awarding process
• Bid evaluation and contract negotiations
• Project management
• Plan checks and documents approvals for execution
• Payment approvals
• Claim assessment and management
• Construction and site supervision