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Doing it the 'Qatalum Way'.

Qatar Aluminium, which commenced production in late 2009 and was officially opened earlier this year, has put in place its own management system called the Qatalum Way and is poised to grab a clutch of quality certificates as it proceeds to serve local and international markets. "The Qatalum Way defines our unique identity and is the framework for our approach to management and leadership and applies in every process and activity throughout Qatalum's business," a company spokesman said. "Integral to Qatalum Way is our very own quality system, the Qatalum Production System or simply QPS." As explained by the spokesman, QPS describes how best practice principles, methodologies and tools guide towards continuous improvement within Qatalum. It presents the company's principles and focus areas; use of system and technology tools, identification of critical processes and critical work processes; documenting procedures (SOP, one-point-lessons, customer-supplier agreements); and operational control to achieve targeted key performance indicators and process indicators. "QPS describes how to continuously improve the entire value chain by enhancing performance of our value drivers - cost, quality, volume and HSE," the spokesman said. Qatalum, whose production capacity is 585,000 tonnes per year, received the ISO 9001:2008 certification in July 2010 which is expected to bring Qatalum to a new horizon in terms of its market as well as meeting the registration requirements of the London Metal Exchange (LME). Nonetheless, Qatalum will also cover TS16949 (automotive standard) quality certification and pursue integrated management certification that includes ISO14001 (environment) and OHSAS 18001 (safety) in the very near future.

The Environment In general, Qatalum sees to it that environmental aspects of its operation are mitigated and keep up with the highest environmental standards through compliance with all the major Best Available Techniques (BAT) for environmental safeguard as prescribed by the EU in the IPCC Reference Document on BAT. To lower air emissions, the following are installed: * Qatalum Power Station has low NOx gas turbines with NOx emission less than 30 mg/Nm3. Additional NOx emission reduction equipment using state-of-the-art Selective Catalytic Reduction (SCR) technology is used to further reduce NOx emissions by half. * Qatalum potrooms are equipped with a double suction fume collection system in order to minimise escape of fumes. * Qatalum has four fume treatment plants which reduce hydrogen fluoride concentration in the potroom fumes from 275 mg/Nm3 to 0.1 mg/Nm3 giving 99.95 per cent efficiency. * The potroom fume treatment plants also include seawater scrubbers which reduce sulphur dioxide concentration from 275 mg/Nm3 to 35 mg/Nm3 giving 87 per cent efficiency. * The liquid pitch handling system at the port is equipped with a regenerative catalytic oxidation (RCO) unit while the Paste Plant has pitch fume scrubbing and regenerative thermal oxidation (RTO) to reduce volatile organic compounds (VOC) and PAH emission. * A special cooling chamber is provided in the Bath Cleaning Plants to cool the anode butts and the fumes are collected and treated in the potroom fume treatment plant. * Perfluorocarbon (PFC) gases are greenhouse gases generated during anode effects in the potrooms. During steady state operation, Qatalum's goal is to have nearly zero anode effects with the help of the most advanced operation and software usage.

Water and effluent standards To meet water and effluent quality standards, the company has installed an Effluent Treatment Plant to treat seawater used for scrubbing in the fume treatment plants. A large aeration system will supply oxygen and ensure at least 2 mg/l oxygen in the water before it is discharged to sea. A neutralisation system is in place for online pH monitoring and addition of neutralisation chemicals as required. Qatalum has also installed wastewater treatment units for non-saline wastewater for re-use in operation and irrigation. Complementary to the operations of the above men-tioned facilities, several other facilities are in place for environmental monitoring and measurement: A state-of-the-art environmental monitoring laboratory is established which is capable of monitoring nearly all the environmental emission sources and relevant parameters in-house. There are seven groundwater monitoring wells to regularly monitor groundwater for any contamination. The company is providing air quality monitoring in six locations outside Qatalum in the Mesaieed Industrial City area by passive sampling method. Three stations are being established using dynamic sampling techniques. Arrangements have been made for seawater quality monitoring and noise monitoring.

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Publication:Gulf Industry
Date:Sep 1, 2010
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