Qatalum (Qatar Aluminium Limited) is internationally known for its contributions to the development of the aluminium industry. Established in 2004, Qatalum is a joint venture between two well-established industry leaders, Hydro Aluminium and Qatar Petroleum (QP). Director of Corporate Communications, Mr Ibrahim Fakhri, spoke with Endeavour Magazine about finding success in an industry new to Qatar.

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QATALUM

While Qatar Petroleum provides a unique combination of long-term competitive energy resources and industrial infrastructure, Hydro is a global integrated aluminium

industry leader with close to a century of experience of aluminium production. Marketed by Hydro Aluminium’s extensive global networks, the aluminium products manufactured by Qatalum are used in a variety of industries including automotive, construction, and engineering.

“Qatalum’s aluminium reaches the entire global community,” says Fakhri.

Qatalum presently exports to 52 countries and 477 customers, and to date has exported more than 2 million tonnes. Its geographic location, at the heart of the Arabian Gulf, gives it convenient access to markets all around the globe, which is a perk that the downstream industries benefit from. The biggest region for Qatalum export is Asia, accounting for almost half of sales. Next is Turkey, at just over a fifth, followed by North America, at 16%. Middle Eastern countries other than Qatar account for 7% of exports. Together, Oceania, Africa, Central and South America and Europe make up a touch under 8%. Domestic sales come to about half a percent of total output.

Building and construction remains Qatalum’s largest and most important market for extrusion billets. Over the years the company has also seen a steep increase in demand for foundry alloys by the automotive sector, reflecting the exacting production standards in place. Over 50% of Qatalum’s production is destined for the global automotive sector, with an average 100 kg of aluminium foundry

QATALUM

Qatalum is ISO 9001 certified and a listed brand on the London Metal Exchange (LME). The company received its CIPS (Chartered Institute of Purchasing and Supply) Certification Award in January 2014, making it the third Qatari organisation to achieve CIPS certification. Drawing on the support and expertise of the two partners driving the project, Qatalum is perfectly placed to meet the growing demand for aluminium.

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Head Office: Serbia, 11070 BELGRADE, Bulevar Mihaila Pupina 12, P.O. Box 20Telephone No: / Fax No.: (381) (11) 310-1200, 310-1203, 310-1205 / Fax (381) (11) 311-2447; 310-1292E-mail / Web site: office@ep-entel.com / www.ep-entel.comMiddle East Offices: Qatar, UAE, Oman, jordan, BahrainQatar Office: Energoprojekt-Entel LtDAddress: 21st Floor, Palm Tower "B", West Bay, P.O.Box 4769, Doha, QatarTelephone No/Fax: Phone: (+974) 44478571, Fax:(+974)44478572E-mail: energoqt@ep-entel.com

We offer a solid foundation of know-how in many areas of environmental protection.

Our business activities in the environment sector cover: Waste management and land filling, air and water protection, environmen-tal management and environmental Studies. 

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EPE has been a consultant or a designer for more than 150 substations in the range from 400kV to 11kV during the last 25 years. Reliable expertise is available for all activi-ties related to development of the trans-mission system.

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EpE is an international Consultant for power plants, covering the wide spectrum of engineering activities from feasibility studies to the detailed design and site su-pervision during construction, revitalization and privatization within the Power Sector. EPE has been involved in every Power Plant build in Serbia and former Yugoslavia. EPE also has an active role in the Middle East region.

EPE has developed its expertise in this field by executing several major projects in GCC region (Oman and Qatar).

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STAREF is a Joint Venture Company established

by STS Oman and Aluref from Richards Bay - South Africa.

The partnership was incorporated in late 2013 to

provide specialist potshell maintenance services

to the Qatalum Aluminium Smelter in Qatar

which is inclusive of all refractory and

mechanical refurbishment

of 704 pots.

Delining

Superstructure Repair

Potshell Repair

Relining

Cathode Sealing

Pot Cut Out & Installation

Basement Cleaning

Complete Hot to Hot Reduction Services

P.O. Box. 50612 C-222, 2nd Floor C – Block, Building No 77 - Souq Mesaieed,

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QATALUM

alloys used in passenger cars. Approximately one third of foundry alloys are made from primary aluminium and two thirds from recycled.

With a base approximately 2.7 km², the size of 260 football fields, Qatalum has the ability to produce over 630,000 tonnes of high-quality primary aluminium products per annum from twin 1.2-kilometer potlines. The complex facilities include a carbon plant, port and storage facilities and a captive power plant.

Qatalum’s state-of-the-art Casthouse has been ISO/TS 16949 certified and produces customer-specified, value-added products, such as extrusion ingots and foundry alloys, that meet the stringent quality standards of Qatalum’s global customer base. Qatalum also has a vast integrated carbon plant, which produces over 1,200 anodes per day – that is around one anode per minute, or approximately 320,000 tonnes of anodes per year. Power Plant Qatalum produces its own power thanks to being capable of generating some 1,350 MW, against the smelter’s usage of 1,050 MW. Given its size and crucial importance, it has been designed using the best available technology, most specifically, the low NOx burner technology, in combination with selective catalytic reduction in order to comply with local emission standards. All this has been designed to power the largest primary aluminium plant ever built in one phase.

Qatalum has a dynamic and diversified work force representing 34 nationalities. The progressive management structure features top, mid and first-level management and although the CEO is the management head, management reporting lines are shared between the CEO and the Deputy CEO in order to reduce administrative burden and bottlenecks.

With an aim to be the employer of choice for talented Qatari graduates through training and development programs, Qatalum’s multi-national workforce brings together unparalleled international experience and expertise. The company makes sure its employees enjoy a host of excellent benefits and the highest standards of health and safety.

“Our people are our biggest asset,” says Fakhri.As well as valuing its workforce, Qatalum maintains a strong

customer focus. Its long-term marketing and sales agreement with Hydro allows Qatalum direct access to product markets by an experienced sales force and the company’s aim is for customers to recognise its services and outstanding delivery on all performance dimensions.

“We are all customers and suppliers to each other in the plant, as well as working together to deliver to our customers outside. We target customer loyalty so that they help build our business by returning to us,” commented Fakhri.

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QATALUM

Qatalum has set a new standard in environmental performance, employing the best available technologies in its processes with the aim of having minimum impact on the local environment. Qatalum’s HSE Management System guides the management of resources and the reduction of the company’s environmental impact. The company also follows its Environmental Management Manual, which includes guidelines for managing sources of environmental impact, climate change, water consumption and waste management. Qatalum’s Zero Energy and Emission Building (ZEEB) lab, located on site at the Qatalum smelter, was officially opened in March 2013. The facility, created with Hydro of Norway, is dedicated to researching and testing aluminium used in curtain wall solutions in support of creating energy, emission and carbon neutral buildings in the Middle East.

Environmental considerations are critical to Qatalum’s sustainability and the facility is one of the most environmentally friendly aluminium smelters in the world. GCCs heavily depend on their natural gas exports to meet their increasing demand, yet Qatar is an exception to this as the country enjoys huge reservoirs of natural gas, supported by a firm stand to elevate its production capacities of electricity utilising the material.

Qatalum tries to reduce and minimise its impact on the environment in every step of the production process. The Qatalum Production System has core principles that help to better protect the environment and the company’s operations emphasise efficiency, allowing it to reduce our energy consumption and GHG emissions per unit of production.

“We are keenly aware of the importance and value of our planet and its environment and we refuse to compromise on its health and long-term sustainability,” notes Fakhri.

Qatar’s National Vision 2030 continues to be a major part of Qatalum’s long-term strategic plans. Qatalum recognises that industrial diversification will be a key element of Qatar’s continued economic development, alongside environmental protection measures and social policies that will provide the platform for a sustainable tomorrow.

To achieve its ambition to be amongst the top ten most cost-efficient smelters in the world, Qatalum has recently embarked on a five year improvement programme – a complex initiative mandated by the Board of Directors involving all areas of operations. Heavily leveraging the Qatalum Production System, the programme aims to establish a strong culture of continuous improvement. The programme is designed to not just deliver impressive savings, but also to raise internal competence levels, strengthen Qatalum’s identity based on its values and contribute to its CSR agenda.

“We are pursuing industrial diversity for Qatar and its people by actively creating a future of environmental sustainability and economic opportunities.”

Aluminium− Complete Carbon sector

− Gas Treatment Centers for Electrolysis Pots

- Casthouse integrated solutions including Holding & Melting Furnaces

− Fume Treatment Centers and Firing Systems on Anode Baking Furnaces

− Bath Processing plants

− Liquid Pitch Marine terminals

www.fivesgroup.com

Aluminium

Endeavour Middle East Magazine_92x138mm_June15.indd 1 25/06/2015 17:40:07

At Qatalum, Fives supplies innovative solutions combining industrial performance with sustainable development:• (4) Gas Treatment Centers with

sea water scrubbers• A 52 tph Green Anode Plant • A Fume Treatment Center and

Firing equipment & process Control Systems on the (2) anode baking furnaces

• (11) Melting & Holding furnaces and (2) Water Cooling Systems at the casthouse