ALBA Line 5 Expansion Projects

Project Background:

As part of the ongoing expansion of ALBA, a new smelter plant (Potline-5) has been added to the existing facilities. International Bechtel Co. was the EPC Contractor for this expansion project. MCSC executed six civil and mechanical project packages.

Project Scope & Highlights:

Anode Rodding, Butt Recycling & Rodded Anode Storage Building Civil and Structural Works: To process the Anodes, a new Anode Rodding shop, Butt Recycling and Rodded Anode Storage Building was constructed. Heavy structural building with roofing and cladding, civil works include structural foundations, equipment foundations and heavy duty paving.

  • Project Duration: 12 Months (2004-2005).
  • Man hours: 377,453 (Without LTA).
  • Preparation of Green Field Site: Area 25,000 m2.
  • Heavy concrete foundation & grade slab: 10,000 Cu.M.
  • Fabrication and installation of structural steel: 2,000 Tons.

Aboveground and Underground Services: This project scope includes various pipeline systems intended to interconnect various process units of the potline-5 plant. The network involves Natural Gas Network with pressure reducing skids, Fire Water Network with new fire water tanks, fire water pumps, pump shelters, fire hydrants and control systems, Compressed Air Network, Potable Water Network with FRP and copper piping, Sewage Network including supply and installation of pump chamber pits, electrical and control works.

  • Project Duration: 14 Months (2004-2005).
  • Man hours: 347,603 (Without LTA).
  • Design, procurement, installation, testing and commissioning of aboveground and underground pipeline and construction of fire water tank.
  • Underground and aboveground pipeline: 50,000 Inch Dia.

Mechanical Work for Anode Bake Furnace & Anode Storage Building (M15): The main functions of this unit is baking of green anodes by controlled heating to a temperature of about 1100˚C and cooling in the same manner so that all the anodes should follow the same heating and cooling curves. The anode baking shop includes 2 furnaces producing a total of 576 baked anodes at a time and an annual production capacity of the baking shop is 189,400 baked anodes. The anode baking shop is equipped with two Furnace Tending Assemblies (FTA) to carryout multi functions. It also has Anode Handling Cranes, Coke Handling System, Conveyors and other material handling systems, Burner Assemblies, Refractory Lined Flue walls.

  • Project Duration: 12 Months (2004-2005).
  • Man hours: 236,383 (Without LTA).
  • Installation, testing and commissioning of special cranes: 11 Nos.
  • Installation, testing and commissioning of piping: 6000 Inch Dia.
  • Installation, insulation and testing of fume ducts: 1 M Dai. x 400 M Long.
  • Material handling conveyor system.
  • Fabrication and Installation of Stainless Steel Piping for the Compressor Station: This includes fabrication, installation and testing of stainless steel piping.
  • Refractory work: This includes supply of skilled manpower for refractory lining work.
  • Installation of Bus-bar Rectifier System and Pre-Operational Miscellaneous Jobs: This includes supply of manpower for the fabrication, welding and installation of bus-bar rectifier system.