2008年5月23日　日本経済新聞

中東湾岸　素材産業の拠点に　
　アルミや鉄鋼　世界最大級の設備　資源テコに存在感

　中東のペルシャ湾岸産油国が素材産業の生産拠点として台頭してきた。空前の原油高で流入する資金と豊富な原燃料を使った石油化学や鉄鋼、アルミニウムなどの大型生産計画が相次いでいる。２０１０年代には湾岸地域は石化最大の輸出拠点となり、アルミ地金の世界シェアは１割を超える見通し。天然ガスを使う製鉄所建設も相次ぎ、エネルギー資源をてこに素材分野でも存在感を高めている。
　アラブ首長国連邦(UAE)アブダビの政府系ファンド、ムバダラ開発とドバイアルミニウム社が共同出資で設立したエミレイツアルミニウム社は単一生産設備としては世界最大級の能力を持つアルミ精錬設備の建設に着手した。１０年に７０万トンの生産を開始。将来は１４０万トンへの増設も計画している。
　ほかにも年内にオマーンで３５万トンの設備が稼働、０９年にはカタールで５８万トンのアルミ生産が始まる。サウジアラビアでも複数の計画が進んでおり、現在１７０万トンの湾岸地域のアルミ生産能力は１０年代前半には４００万トン超、世界シェアは現在の５%から１０%に高まる見通しだ。

　石化分野では住友化学とサウジ国営石油会社サウジアラムコが建設中の大型プラントが年内に完成する。石化の基礎原料であるエチレンはサウジだけで日本の総生産量に相当する７００万トン規模の新増設計画が進んでいる。
　カタールやUAEなどの計画も合わせると、０５年時点で１１００万トンだった中東のエチレン生産量は、１０年代には２６００万トンを超える見通し。年率７−９%で需要が伸びる中国やインドなどの新興市場に大規模な供給余力を持つ唯一の地域となる。
　一方、UAE系の製鉄会社シャディード社はオマーンで１０月に、コークスではなく、天然ガスを使って鉄鉱石から純度の高い鉄分を取り出す製鉄原料の生産を始める。サウジ政府系のハディード社も昨年世界最大級のプラントを稼働きせた。湾岸地域では電炉や圧延設備の増設も相次いでおり、１０年の鉄鋼生産量は０６年比で７割増の３５００万トンに増える見通しだ。
　湾岸の素材増産を支えているのは「潤沢なエネルギー資源と旺盛な需要」(ドバイアルミニウムのアブドラ・カルバン最高経営責任者)。石油依存の脱却を急ぐ産油国政府は産業プロジェクトに価格を抑えた原燃料や電力を優先的に供給する政策を打ち出している。アルミの場合、生産コストは２−３割が電気代。欧米メーカーは電力コストの安い南米やアフリカヘ生産拠点を移しており、生産シフトの流れが、湾岸にも及んでいる格好だ。

湾岸地域で進行中の主な素材プロジェクト

(注)経産省、MEED誌などの情報を基に作成

湾岸地域で進行中の主な素材プロジェクト

現在170万トンの湾岸地域のアルミ生産能力は2010年代前半には400万トン超、世界シェアは現在の５％から１０％に高まる見込み。

アルミニウム

　オマーン　ソハールアルミニウム　35万トン新設　2008年稼動

December 19 2005　allbusiness.com

Oman's $2.4 Bn Aluminium JV Agreement Signed; Smelter Will Be On Stream In '08.

The Abu Dhabi Water and Electricity Authority (ADWEA), the state-owned Oman Oil Co. (OOC) and Alcan of Canada have signed a set of agreements under which a $2.4 billion greenfield aluminium smelter will be built in Oman's industrial zone as a JV. Set for completion in 2008, the smelter will have the initial capacity to produce 350,000 metric tons/year of aluminium.

Sohar Aluminium Company (SAC)will have a single AP35 pot-line built in the industrial zone, together with associated carbon and casting facilities and a 1,000 MW gas-fired power station, one of the biggest of its kind in the region which will use combined cycle turbines. The smelter, one of the biggest in the world and to be the third largest in the six Gulf Co-operation Council (GGC) countries, will be designed for a bigger capacity, so that expansion can proceed economically when markets need more aluminium.

ADWEA, the 40% leader of the SAC, will invest $900m Regional and international banks have committed $1.46 bn along with an Islamic finance component of $240m.

ADWEA　 40.00 %
OOC　　　　40.00 %
Alcan Inc　　20.00 %

SAC will be competing with larger smelters in the Arab Gulf Co-operation Council (GCC) countries, where the leader is Bahrain Aluminium (Alba). Alba's smelter has been expanded to more than 820,000 tons/year. Its capacity is to be raised to more than 1m t/y with a sixth potline to be added in the next two years. Alba is owned by the Bahrain government, Alcoa of the US, SABIC and Breton Investments of Germany.

Aluminium Bahrain B.S.C (Alba) became the largest modern aluminium smelter in the world when it commissioned its newest reduction line, Line 5, in May 2005.

Line 5,  which was built as part of a US1.7billion expansion project that includes the construction of a new power station, carbon, casthouse and other facilities, is the longest reduction line in the world and increases Alba's annual production capacity to more than 830,000 tonnes per annum (tpa).

As well as its reduction lines and cast houses, the company has a dedicated carbon department and a 1500MW power plant. A 450,000 tonnes per annum coke calcining plant and a water desalination plant are also in operation at the company's marine terminal.

The company was officially opened in 1971 and its shareholders today are the Government of Bahrain (77%), SABIC Industrial Investments (20%) and Breton Investments (3%).

Dubai Aluminium (Dubal) is the second leader in this business in the GCC. Dubal is expanding to 886,000 t/y in early 2006. It is a JV of the Dubai government (80%), Southwire Corp. of the US (7.5%), Nissho Iwai of Japan (7.5%) and local businessmen (5%). Dubal's smelter first came on stream with a 130,000 t/y capacity in 1980.

From a relatively small smelter operation utilizing three potlines which produced 136,000 tonnes of aluminium per annum in 1979, DUBAL has expanded its operations to encompass eight potlines with the capacity to produce more than 950,000 tonnes of quality hot metal aluminium each year for clients in more than 44 different countries. Hot metal volumes are expected to approximate one million tonnes by the end of 2008.

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A limited liability company, DUBAL is wholly owned by the Government of Dubai. The company’s facilities at Jebel Ali, south of Dubai, constitute one of the largest single site aluminium smelter complexes in the world. Its major operational components comprise an 890,000 metric tonne-per-annum primary aluminium smelter (making DUBAL the world’s seventh largest producer of primary aluminium), a 1,983 megawatt power station, a large carbon plant, three casthouse, a 30-milion-gallon-per-day water desalination plant, laboratories, port and storage facilities.

DUBAL was incorporated pursuant to a Decree of the Ruler of Dubai, dated 5 May 1975. Construction of the company’s smelter complex started in 1977, under the patronage of the late Sheikh Rashid bin Saeed Al Maktoum, and the first metal was produced in 1979. By 2005, DUBAL represented 28% of the contribution made by the manufacturing sector (excluding the oil and gas industries) to Dubai’s gross domestic product. The DUBAL Board of Directors is chaired by Sheikh Hamdan bin Rashid Al Maktoum, the UAE Minister of Finance & Industry and Deputy Ruler of Dubai.

In line with its corporate vision to become the world’s fifth-largest producer of aluminium by producing 2.5 million tonnes per year by 2015, DUBAL’s hot metal production capacity will expand to 945,000 tonnes per annum by mid-2008 while its power generation capacity will be increased simultaneously to 2,045 megawatts. Already, the company’s casthouse operation has the largest capacity in the world, at 1.13 million tonnes per annum.

In addition, DUBAL has entered into a joint venture with Mubadala Development Company (known as EMAL International) to develop green-field smelters using DUBAL’s in-house developed, proprietary DX reduction cell technology. Two projects have already been launched:

EMAL Taweelah Aluminium Smelter in Abu Dhabi, which involves a 1.4 million tonne smelter to be constructed in two phases, of which phase one is expected to be commissioned by 2010 and phase two by 2013.

Béni-Saf Aluminium, Algeria, where a 700,000 million tonne smelter is to be developed and commissioned by 2010.

DUBAL also holds equity stakes in two proposed green-field alumina refineries, namely:

A joint venture with Larsen & Toubro in Orissa, India, in which DUBAL holds 74%, for the development of a 3.0 million tonne per year bauxite mine and alumina refinery, to be developed in two phases of 1.5 million tonnes each.

A joint venture with Global Alumina, BHP Billiton and Mubadala to develop the Sangaredi Refinery Project (also known as the GAPCO project) in the Republic of Guinea. DUBAL has a 25% equity stake in the refinery as well as a guaranteed 40% of its anticipated annual production of 3.0 million tonnes of alumina.

UAE 　Emirates Aluminium　　70万トン（将来140万トン）　2010年

The Emal project is a vital strategic initiative for the UAE and will serve as a cornerstone of the UAE’s emerging industrialization policy.

Emal is being developed as a Greenfield aluminium smelter with an associated power generation facilities at the Khalifa Port and Industrial port, in Taweelah. The project when both phases completed, is expected to be the largest single site aluminium smelter in the world.

Phase I

Phase I will involve the construction of an Aluminium Smelter with a production capacity of 700,000 tonnes of aluminium per annum and approx. 2,000 MW combined cycle power plant over an area of 6 square kilometers. 

Emal’s process will employ DUBAL’s DX reduction cell technology operating at 340 kA and will involve high levels of automation to ensure a world-class workplace with extreme high safety standards.

The final Emal products will be remelt aluminium and the standard commodity ingot. 

Phase II

Phase II will see the initial aluminium production capacity of 700,000 tonnes per annum to be upgraded to 1.4 million tonnes per annum, while the power plant capacity will be increased to 3,500 MW to deliver a constant power supply to the smelter throughout the year.

　

11 February 2007
MUBADALA DEVELOPMENT AND DUBAI ALUMINIUM SIGN JOINT VENTURE AGREEMENT

The smelter complex in Abu Dhabi will be owned by Mubadala and DUBAL. At 1.4 million TPA capacity, it will be the largest single site smelter in the world

In a landmark joint venture, Dubai Aluminium Company (DUBAL), one of the world’s largest aluminium producers, and Mubadala Development Company, a wholly-owned investment and development vehicle of the Government of the Emirate of Abu Dhabi, have today signed the joint venture agreement (JV) for the development of Emirates Aluminium (EMAL).

The joint venture agreement entails the construction and operation of a world class green-field aluminium smelter complex which will happen in two phases.  The first phase, with a cost of USD 5 billion, and the second phase, with an approximate cost of USD 3 billion, will produce a total output of 1.4 million tonnes capacity a year at the Khalifa Port and Industrial Zone in Abu Dhabi.  This will make it the largest single site aluminium smelter in the world. The two entities will jointly develop, construct, own and operate the complex.
Plans are already under way to establish EMAL, the joint venture company with 50% stake each for Mubadala Development and DUBAL. EMAL will oversee the operation and management of the new aluminium smelter.

The JV was signed by HE Khaldoon Khalifa Al Mubarak, CEO and Managing Director, Mubadala Development and Abdullah Kalban, CEO, DUBAL.  Also present at the ceremony were HE Ahmed Humaid Al Tayer, Vice-Chairman, DUBAL, HE Mohammad Al Bowardi, Vice Chairman of Mubadala Development and members of the boards of both companies.

“This is an important strategic and historical project between DUBAL and Mubadala Development that will serve the UAE national economy and will capitalise on the excellent competencies already existing in the country.  This joint venture is the flagship and signifies the advent of several industrial initiatives between DUBAL and Mubadala Development.  The venture is under the direct support of His Highness General Sheikh Mohammed bin Zayed Al Nahyan and His Highness Sheikh Hamdan bin Rashid Al Maktoum,” said HE Khaldoon Khalifa Al Mubarak.

Abdulla Kalban said the UAE has made remarkable strides in every sphere of sustainable development, thanks to the unlimited support of President His Highness Sheikh Khalifa bin Zayed Al Nahyan and His Highness Sheikh Mohammed bin Rashid Al Maktoum, Vice President, Prime Minister and Ruler of Dubai, “who are sparing no effort to ensure economic and industrial progress and to create wealth for the people of the UAE.”

He described the signing of the JV as a historic moment that heralds the new dawn of industrial and economic growth in the country and the region at large.
The progress of this project has been swift. Since the signing of the Joint Protocol in February 2006 a detailed feasibility study, the front end engineering and design studies were completed and groundbreaking is expected in May 2007. EPCM (Engineering, Procurement and Construction Management) tendering is in process, planned to be awarded by April 2007 and financial close is expected in the final quarter of 2007.

The smelter will be developed in two phases and the first phase is expected to be operational in 2010. When completed and at full capacity, the new smelter will have a Power Plant capacity of 2,250 MW, with the required gas volume for the project already secured.

“The combination of Mubadala Development’s expertise and DUBAL’s technical know-how and 26 years experience will greatly benefit the new venture. Besides, the UAE has already been consistently diversifying the national economy and projects such as this will generate substantial number of jobs for the UAE nationals,” Mr Kalban remarked.

“We do believe there is ample room for additional capacity on the back of strong international demand. Demand is growing at an annual rate of 4% or 1.3 million tonnes a year. This demonstrates the need to establish a smelter or two every year which is not happening in the world right now,” concluded Mr Kalban.

“We are extremely pleased to have a quality partner of Dubal caliber in developing a leading edge project that will ensure effective and sustainable growth of UAE’s industrial sector. Having a partner with such experience, expertise and resource will certainly enable us to come up with a world class project. Both Mubadala Development and Dubal enjoy capabilities and resources to design, implement and run a project of that magnitude,” added HE Khaldoon Al Mubarak.

カタール　カタルム　58万トン　2009年

Qatalum will be the largest aluminium plant ever launched. Qatalum, a joint venture by Qatar Petroleum and Hydro, will have a capacity in the first phase of 585,000 tonnes of primary aluminium, all to be shipped as value added aluminium casthouse products. A dedicated power plant with an installed capacity of 1250 MW will ensure a stable supply of electricity.

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Qatar Petroleum and Hydro sign joint venture agreement for world-class aluminium plant

(March 23, 2006) Qatar Petroleum and Hydro have signed an agreement to form a joint venture for the development, construction and operation of a world-class aluminium plant in Qatar. The agreement marks an important step forward to build one of the world's largest and most competitive primary aluminium plants

Qatar Petroleum and Hydro have signed an agreement to form a joint venture for the development, construction and operation of a world-class aluminium plant in Qatar.
The agreement marks an important step forward to build one of the world's largest and most competitive primary aluminium plants.

The joint venture agreement was signed in Qatar's capital Doha on Thursday by HE Abdullah Bin Hamad Al-Attiyah, Second Deputy Premier, Minister of Energy and Industry, Chairman of the Board of Directors and Managing Director of Qatar Petroleum, and Hydro President and CEO Eivind Reiten.

The signing of the joint venture agreement follows the heads of agreement between the partners, signed in December 2004.

A joint venture company, Qatalum, will be established to build and operate the primary aluminium plant consisting of a smelter, a casthouse and a carbon plant as well as a dedicated power plant. Qatar Petroleum and Hydro Aluminium will each hold 50 percent of the new company. The plant is scheduled to start production in 2009.

The smelter will have an annual capacity of 585,000 tonnes of primary aluminium. The dedicated gas power plant has a planned installed capacity of 1,350 MW. The project, to be located in the Mesaieed Industrial City in Qatar, will be the largest initial phase greenfield aluminium smelter ever built. The plant could be expanded to an annual capacity of approximately 1.2 million tonnes.

The Qatalum project is based on strong strategic fundamentals. Qatar Petroleum is providing a unique combination of long-term competitive energy resources, an industrial infrastructure and location to accommodate this large project.

Hydro is a leading integrated, global aluminium company, and a technology leader in the aluminium industry. Hydro brings more than 80 years of operational experience, leading positions in the aluminium metal products markets and strong record in the execution of large projects.

HE Abdullah Bin Hamad Al-Attiyah stated that Qatar offers the best conditions for this kind of industrial development. The policy of the Government of Qatar is to broaden the industrial base of the country, ensuring the best environmental standards and working conditions. Qatar is an ideal location for serving growing aluminium markets in Asia, Europe and also North America. The vast gas resources of Qatar, combined with the country's ambition to diversify its industry, will ensure a long-term competitive aluminium plant.

This project represents a key element in Hydro's strategy to reposition our upstream aluminium business, expanding production in energy-rich parts of the world, said Eivind Reiten. Qatalum will be an important contributor to improve Hydro's relative cost position in production of primary aluminium and to meet the future growth in demand.

Construction is expected to begin mid-2007 with the first metal to be produced fourth quarter of 2009. Full production is expected to be reached mid-2010. The schedule is based on final build decisions to be made in 2007, following a phase of ongoing concept selection and detailed engineering.

The planned smelter will have operating costs among the most competitive in the world, resulting in a robust project economy.

The product casthouse will have the capacity to produce all of the smelter production as upgraded, value added products; extrusion ingot and foundry alloys. The marketing will be handled by Hydro.

Hydro will supply its captive potroom technology, the global environmental benchmark in the aluminium industry. Hydro will also provide resources for the planning, construction and commissioning of the project. The partners are in the process of establishing the organization needed to execute the project.

Published: October 26, 2007