DUBAL is first customer for GE’s new high performance platforms to strengthen efficiency of its installed gas turbines

Dubai Aluminium Company (DUBAL), which powers one of the world’s largest aluminium smelters with a 2,350 MW power station, has placed the first order in the Middle East for innovative, high-performance platforms by GE that enhance the flexibility, performance and value of its existing gas turbine assets. 

This was announced at GE’s Powering Efficiency Forum, a thought leadership summit focused on meeting future energy efficiency needs in the Middle East. Government officials, power generation company representatives and industry leaders attended the event. 

At the Powering Efficiency Forum, GE announced the expansion of its high-performance Advanced Gas Path (AGP) solution for its 9E and 9F-3 gas turbine customers in the Middle East. Proven to deliver industry-leading upgrade performance, AGP marks the first-of-its-kind solution available for comparably sized gas turbine assets in both classes. 

The AGP solution is part of GE’s LifeMax* Advantage portfolio for installed B/E-Class gas turbines, which along with the FlexEfficiency* Advantage portfolio for F-Class gas turbines apply the collective power of hardware innovations, advanced software and data analytics in ways that enable its customers to unleash the full performance and value of their existing gas turbine assets.

AGP technology advancements feature hardware design and materials improvements to the components of GE’s gas turbine hot gas path system. These innovations are coupled with GE’s OpFlex* advanced controls software to expand gas turbine performance and enable GE customers to operate their power plants more dynamically. 

The LMA solutions help customers with installed B/E-Class turbines to reset the clock on their ageing assets with custom-fit upgrade packages. Customers can achieve improvements in output, efficiency and reliability with a suite of upgrades that enable B/E-Class units to recapture lost performance and lower operating costs. 

DUBAL installed GE’s Advanced Gas Path  solution, which includes OpFlex* advanced controls software, on one 9E unit in April 2013 to expand the performance of its power station’s output, efficiency and maintenance intervals. Since completion of the upgrade, the gas turbine’s output increased by 3.4 per cent, generating an additional 5.88 MW and improving fuel efficiency by about 1.5 per cent. 

DUBAL will also upgrade two additional 9E units using GE’s LifeMax* Advantage technologies. The output capacity across all three units is expected to increase by 17.64 MW, reduce fuel use by 1.5 per cent and extend maintenance intervals to 32,000 hours, the equivalent of approximately one additional year of operation. 

“Incorporating these new technologies into our power station is central to our long-term strategy of producing aluminium products as efficiently and cost-effectively as possible for our customers,” said Tayeb Al Awadhi, Vice President, Power & Desalination of DUBAL. “Our success going forward will depend on increasing our production levels while lowering our operational costs. The solutions GE has customized for our unique power demands will allow us to achieve such levels of efficiency.” 

Mohammed Mohaisen, CEO, Power Generation Equipment and Services Sales of GE Power & Water, Middle East, said: “Power generation entities in the Middle East are expected to experience significant growth in energy demand over the next decades. By 2040, demand for energy is expected to grow by 76 per cent, which makes it important for the companies to focus on enhancing their energy generation efficiencies. 

“A focus on energy efficiency also complements the regional governments’ focus on sustainable development. GE’s innovative solutions tap into a three-way collaboration between our customers, machines and our professional team, thereby enabling our customers to meet future needs by unlocking the potential of their existing assets. We are thankful to DUBAL for adopting our new platforms and highlighting the strong partnership we share and their trust in our capabilities.” 

DUBAL has also ordered software upgrades, including GE’s OpFlex* AutoRecover and Peak Fire technologies, along with a Mark* VIe controls upgrade, to drive further output and efficiency improvements, while containing overall maintenance costs. Installation of all five LifeMax* Advantage solutions on DUBAL’s second 9E gas turbine is scheduled for November 2013, with installations on the remaining unit scheduled for 2014. 

With natural gas-fired power generation expected to surpass oil-based fuel sources in the Middle East region by 2040, and a projected decline from 34 per cent to 14 per cent in oil-fired power generation, GE’s AGP technology enables customers with existing gas turbine assets to expand their power capacities without investing in new infrastructure or to complement new power plant construction. 

GE’s LMA portfolio also includes a Dry Low NOx1+ (DLN1+) combustion solution, which allows operators to run their gas turbines up to 32,000 hours between scheduled maintenance intervals; a broader suite of OpFlex* advanced controls, which help expand operating profiles across all modes of power plant operation; and Flange-to-Flange replacements of core engine components including the compressor and combustion systems to rejuvenate installed gas turbine assets. 

FEA solutions for GE F-Class gas turbine customers are configured to expand performance including output, efficiency and operating windows. GE customers also can benefit from an extension of maintenance intervals, asset and parts life through more durable hardware components and software technology that automate operational adjustments to reduce stresses on parts.  

Solutions delivered through the LMA and FEA platforms are part of GE’s Predictivity* portfolio. GE Predictivity solutions tap into the power of the Industrial Internet, a combination of mind and machine assets that collectively bring industrial-strength capabilities to GE customers.

DUBAL produces more than one million metric tons of aluminium products per year, including foundry alloy for automotive applications, extrusion billet for construction, industrial, forging and transportation, and high purity aluminium for the electronics and aerospace industries. The company delivers products to more than 300 customers in 57 countries. 

Active in the Middle East since the 1930s, GE’s presence today comprises an array of established projects across the region via strategic partnerships, investments and solutions, with a focus on infrastructure development and major challenges such as cleaner energy and water scarcity. Through business offerings that include power, water, health, aviation and more, GE is able to be a partner in the UAE’s quest to solve its toughest challenges.