Sectors
Mining & Metallurgy
Sub Sectors
Non-Ferrous Metals
Services
Design & Engineering, Project Management and Safety
Location
United Arab Emirates
Located in Abu Dhabi, UAE, the project involves the development of a 200 KTPA aluminium recycling facility within an existing industrial complex. The plant is designed to manufacture billets and T-bars using up to 75% post-consumer scrap as its principal feedstock, supporting more resource-efficient aluminium production and reducing dependence on hot metal from existing smelting operations.
The facility brings together scrap processing and sorting, melting, casting, billet finishing, storage, utilities and associated infrastructure. As the EPCM consultant, TCE is providing multidisciplinary engineering, layout development, project coordination and implementation support.
A key project requirement was integrating the complete facility within a significantly constrained brownfield site. While the feasibility concept indicated a site requirement of approximately 90,000 m², the actual available area was 58,495.26 m². TCE developed a compact plant layout that accommodates the required process systems, support facilities, storage areas and safe movement of vehicles and personnel. The project also includes a deep Vertical Direct Chill casting pit, for which TCE provided engineering and execution support to address complex ground and groundwater conditions during construction.
TCE's Scope
TCE provided EPCM consultancy for the integrated aluminium recycling facility, covering multidisciplinary planning and layout development for process, non-process and balance-of-plant systems. The scope included coordinating equipment supplier drawings, equipment disposition and operational requirements across 2D and 3D layouts, alongside space optimisation for scrap processing, sorting, recycling, casting, utilities, storage and support facilities.
TCE also planned traffic and logistics movement for trailers, forklifts, front loaders and hot metal vehicles. Pedestrian circulation, emergency egress, emergency lighting, traffic signals, signage and crash barriers were integrated into the layout. Feedback from the client’s operations team was incorporated through successive layout revisions.
For the Vertical Direct Chill casting pit, TCE provided design and execution support, including recommendations for geophysical investigation, ground treatment, dewatering, structural repairs and instrumentation. During construction, TCE coordinated with the client, execution contractor and specialist subcontractor to address site conditions and support safe execution.
Impact
TCE transformed a major space constraint into a practical and safe plant layout. Although the original plan indicated a site requirement of around 90,000 m², the complete recycling facility was successfully integrated within the available 58,495 m² area.
The compact layout accommodated the plant, storage, supporting facilities and safe movement of people and vehicles. TCE also helped the project team respond to unexpected ground and groundwater conditions during construction of the casting pit. Timely investigation and practical engineering solutions allowed work to progress safely while protecting the structure’s long-term performance.
About Us
Overview Our Leadership MilestonesSubsidiaries
- Ecofirst - Tata Consulting Engineers USA, LLC Corporate Social Responsibility Corporate GovernanceMedia
Media Kit Notices Annual Reports Marketing Collateral Videos TCExpressions Press Releases Press Coverage@tceconnect
© Tata Consulting Engineers Limited. All Rights Reserved | Site Credits:DV
