Commissioning and Start-Up of Ingot Casting Machines in the Biggest Integrated Aluminum Complex in the World

This paper describes the current Maaden/Alcoa joint venture in the Kingdom of Saudi Arabia (KSA) with particular focus on the commissioning and start-up of the standard ingot casting machines. These are installed in the first standard ingot cast house in KSA built during 2012. This is part of the largest fully integrated aluminum complex in the world which starts at the mine and follows an aluminum processing chain that runs through to final products being shipped from the Cast House and Rolling Mill operations. The paper will describe Ma’aden experience in ingot casting machines: commissioning and start-up, the challenges faced particularly with de-molding machines, robots and strapping machines and the latest equipment’s and technology being implemented. The Ma’aden cast house include a TAC facility which gives the advantages of less dross and more pure metal leading to a high quality product. Ma’aden also implemented ingot height laser control which makes ingots and bundles weight control well managed, also implemented latest version of MES (Manufacturing Execution System) which is doing multiple functions including: management life-cycle, resource scheduling, order execution and dispatch, production analysis for (OEE), and materials track and trace.