EGA Casthouse Operations: Aluminium Casting & HSE Safety

EGA Casthouse Operations & Safety

Operational Excellence with a Focus on HSE

Introduction to EGA

Emirates Global Aluminium (EGA) is the largest industrial company in the UAE outside oil and gas. The Casthouse is a critical facility where molten aluminium is transformed into high-quality value-added products for global customers.

Purpose in the Value Chain

Reduction Cells (Smelting)

Casthouse (Alloying & Casting)

Global Market (Extrusion, Rolling)

Casthouse Process Flow

1. Molten Metal Reception: Receiving liquid aluminium from reduction potlines.

2. Alloying & Furnace Treatment: Adding elements (Mg, Si) to meet specifications.

3. Casting (VDC): Vertical Direct Chill casting into billets or slabs.

4. Finishing: Homogenizing, sawing, cooling, and packaging.

Crucial Step: Molten Metal & Casting

At temperatures exceeding 700°C, molten aluminium is transferred from crucibles to holding furnaces. The Vertical Direct Chill (VDC) process then solidifies the metal into shapes like billets (logs) or slabs (ingots), requiring precise temperature control and water cooling.

Completing the Product: Finishing

After solidification, products undergo homogenizing (heat treatment) to equalize internal structure. They are then sawed to specific lengths, inspected for quality defects, strapped, and weighed before shipment to customers.

HSE Focus: Safety First

Zero Harm Commitment

The casthouse involves high-energy risks requiring strict protocols.

Goal: Protect our people, the environment, and our assets.

Critical Hazards in Casthouse

Molten Metal

Risk of burns and explosions upon water contact.

Mobile Equipment

Forklifts and transport vehicles interacting with pedestrians.

Heat Stress

Working near furnaces in high ambient temperatures.

Safety Measures & Controls

• Mandatory PPE: Silver suits, face shields, and metatarsal boots.

• Exclusion Zones: Strict separation of pedestrians and mobile machinery.

• Automation: Hands-off casting processes to remove operators from the line of fire.

Conclusion

EGA's Casthouse combines world-class technology with a relentless commitment to safety. By managing hazards like molten metal and heat stress through automation and strict protocols, we ensure high-quality production without compromising human life.