Aluminium, one of the world’s most versatile and recyclable metals, is a fitting symbol of Ma'aden evolution as a company. Just as aluminium is shaped and changed into a wide range of goods, its development has transformed Ma’aden into a world-class, future-focused company.
After oxygen and silicon, aluminium is the third most abundant element and the most abundant metal in our planet’s crust. It is also the most widely used non-ferrous metal, its production exceeding that of every metal but iron. Its properties – including low weight, high strength and conductivity, corrosion resistance and adaptability – make it a staple in industry and commerce around the world, used in everyday objects from soda cans and frying pans to power lines and aircraft.
The vision behind Ma’aden’s move into aluminium production is to maximize the minerals and metals value chain. Ma’aden’s ‘mine-to-metal’ vision resulted in the development of a new homegrown and sustainable industry and transfer of knowhow associated with it, and positioning Saudi Arabia as a supply-side player in a global industry with strong prospects to grow and diversify in the future.
In 2009, Ma’aden established a joint venture with Alcoa, the world’s third-largest aluminium producer, to build the world’s most efficient and integrated aluminium complex in Saudi Arabia. This USD 10.8 billion (SAR 41 billion) project includes a Bauxite Mine, a Refinery, a Smelter, a Casthouse, a Can Recycling Unit and the world’s most advanced Rolling Mills. This complex was given the name of the world’s first Fully Integrated High Efficiency Aluminium Production Complex. Ma'aden’s Fully Integrated High Efficiency Aluminium Production Complex, and is the largest and most efficient vertically integrated aluminum complex in the world. Its products, aluminium of the highest international standards, is sold to both domestic and global markets and is encouraging the development of additional downstream aluminium-based industries in Saudi Arabia and neighboring countries.
Ma'aden’s Fully Integrated High Efficiency Aluminium Production Complex involves the development, design, construction and operation of mutib plants in two sites that are integrated into a single mine-to-metal network. These two locations are Al Ba’itha Mine in the Qassim Province of Saudi Arabia, linked to Ma'aden integrated aluminium complex in Ras Al Khair Industrial City in the Eastern Province of Saudi Arabia.
Through the Natural Engineered Wastewater Treatment Initiative, by the Complex, Ma’aden aims at achieving Zero Liquid Discharge via 100% Water Recycle and Reuse.
Ma’aden Bauxite and Alumina Company (MBAC)
Ma'aden feedstock comes from large bauxite deposits in Al Ba’itha Mine, which includes the mine as well as the ore-crushing and handling facilities. The mine’s estimated production is 5 million tonnes per year of dry weight bauxite. The ore is then transported via the new North-South railway line to Ras Al Khair Industrial City, feeding the Ma’aden’s Refinery. The Refinery is the first alumina refinery in the Middle East; it can produce 1.8 million tonnes per year of alumina, all of which almost 80% are processed in Ma'aden’s Smelter, while the rest exported globally. The bauxite and alumina is under the operation of Ma’aden MBAC. The technology used in Ma’aden’s Refinery is using Bayer Process Technology, while our Boilers use Natural Gras for heat generation.
Ma’aden Aluminium Company (MAC)
The heart of the Ma'aden’s Fully Integrated High Efficiency Aluminium Production Complex is the Smelter, located adjacent to the Refinery. The entire facility construction was completed within 26 months and the first hot metal was produced on 12 Dec. 2012. Smelter commercial production was declared in the beginning of Sep 2014 while the Environmental Permit to Operate was obtained for the 1st time on Sep 5th, 2013. Ma’aden’s Smelter consists of 2 Pot lines with 1.2 KM long , totaling of 720 pots and has adopted Aluminum Pechiney Technology.
Ma’aden’s Refinery production is fed into the Ma'aden’s Smelter. The Smelter’s annual production capacity is 780,000 tonnes per year of primary aluminium. The technology used in Ma’aden’s Smelter is AP Technology. The electrical power is supplied from one of the world’s largest gas-fired Power Generation (2.4 G) and Sea Water Declination Plant (1 mil Qm / day), located also in Ras Al Khair Industrial City. Both are major strengths in today’s carbon-constrained world.
Ma’aden has gained a strong reputation in regional and global markets as a supplier of high quality primary aluminium products. Ma'aden is continuously expanding MAC’s global market footprint.
Ma’aden’s Casthouse is integrated with the Smelter, with a Total Design Capacity of 1.2 M tons per year, producing Standard Ingot, Extrusion Billet, T-Bar and Rolling Slab, produced according to customer requirements.
Ma’aden Rolling Company (MRC)
MRC is wholly owned by Ma’aden and has a capacity of 460,000 tons per year. It currently produces Can Sheets, End and Tab Stock for beverage can manufacturing and Auto Sheet for the automotive industry. Ma’aden Rolling mill uses state- of- the art rolling technology to manufacture highest quality flat rolled products to serve its ever expanding customer base across the globe. MRC is the best in class in rolling mill technology sphere anywhere on the globe.
MRC is also equipped with a Can Recycling Unit which has the capacity to recycle 120,000 metric tons per year of primarily Used Beverage Cans. MRC is an example to follow in fostering the beginning of the new technologically-based recycling industry in Saudi Arabia.
Ma’aden has been gaining a strong reputation in regional and global markets as a supplier of high quality Flat-Rolled Products and Solutions. Ma'aden is continuously expanding MRC's global market footprint. Proximity to local markets ensures tailored service and quick response times, while Ma'aden favorable logistics also enables high-quality service for national and international customers.
Sahara and Ma’aden Petrochemicals Company (SAMAPCO)
Caustic Soda is an essential feedstock needed for the refining of bauxite to alumina. Ma’aden sources Caustic Soda from its joint venture SAMAPCO. The SAMAPCO plant, located in Jubail Industrial City, also produces Ethylene DiChloride as a by-product of its caustic soda output. It produces 250,000 tonnes per year of concentrated Caustic Soda and 300,000 tonnes per year of Ethylene DiChloride.