General Superintendent - Cell Design

Ega; Abu Dhabi; On-site; AED 360,000 - 600,000; Full time

Job summary

Emirates Global Aluminium seeks a Senior Modelling Engineer to lead advanced cell design studies and material/lining optimizations using CAE tools. You will drive energy efficiency and cost reductions through cross-functional collaboration across engineering, process control, and IT teams.

The role requires a strong foundation in metallurgy and mathematical modelling, with experience in COMSOL/ANSYS and 3D CAD.

Qualifications

• Bachelor’s degree in Metallurgy/Material Science/Mechanical Engineering or equivalent.
• Master’s degree in Metallurgy/Material Science/Mechanical Engineering preferred.
• 6 years’ experience in a similar capacity; 3 years in modelling engineering.
• Experienced user of CAE software (COMSOL, ANSYS).
• Proficient with 3D CAD tools (Space Claim or similar).
• Strong knowledge of physics and mathematics; MS Office skills.

Responsibilities

• Lead SME guidance for modelling and cell design initiatives.
• Develop and optimize cell designs to improve KPI performance using modelling tools.
• Collaborate with technical consultants, operations, and IT for modelling activities.
• Propose material/design changes to reduce energy use and costs.
• Ensure safety, quality and environmental compliance in modelling work.
• Prepare sectional statements and reports for management.

Skills

CAE modelling

COMSOL

ANSYS

3D CAD

SpaceClaim

MATLAB

Data analysis

Excel

Physics & maths

Communication

Education

Bachelor’s in Metallurgy/Materials/Mechanical Eng

Master’s in Metallurgy/Materials/Mechanical Eng

Tools

COMSOL

ANSYS

SpaceClaim

Job description

Emirates Global Aluminium is the world’s biggest ‘premium aluminium’ producer and the largest industrial company in the United Arab Emirates outside the oil and gas industry. EGA is an integrated aluminium producer, with operations on four continents from bauxite mining to the production of cast primary aluminium and recycling. EGA employs over 7,000 of these people including more than 1,200 UAE Nationals. EGA operates aluminium smelters in Jebel Ali and Al Taweelah in the United Arab Emirates, an alumina refinery in Al Taweelah, a bauxite mine and associated export facilities in the Republic of Guinea, a speciality foundry in high strength recycled aluminium in Germany, and a recycling plant in the United States.

1. JOB PURPOSE:

Provides specialist expertise and internal consultancy for the development of new cell design and lining material and support cell lining, pot room process control and operation with mathematical modelling to achieve the best possible KPIs with optimal costs within both EGA sites, ensuring alignment with the overall technical strategy.

2. KEY ACCOUNTABILITIES:

Team Guidance

• Ensures the provision of subject matter expertise for the assigned domain and provides counsel on all related areas to facilitate the achievement of technical strategy and functional objectives.
• Provides guidance and on the job training for junior colleagues and conducts knowledge sharing to facilitate achievement of team objectives and completion of tasks in an efficient manner which is consistent with operating procedures and policy.
• Promotes the organization’s values and ethics in all activities within the team to support the establishment of a value drive culture within the organization.

Budgeting and Financial Performance

• Monitors the financial performance of a given area of activity versus budgets and ensures all activities are carried out in line with the approved guidelines while promptly reporting on any variances to management.
• Provides inputs and implements policies, systems, and procedure for the assigned area so that all relevant procedural/legislative requirements, fulfilled while delivering a quality, cost-effective service.

Operational Management

• Optimizes existing reduction cell technologies, improving cell performance to achieve excellent KPI's by using modelling and analytical tools. This is done by using thermo-electric, thermo-mechanical, electro-magnetic, MHD and CFD models and validates the models.
• Evaluates different cell design performance through working closely with reduction and process control team and propose required lining material or structure changes to enhance.
• Leads/ interacts with Technical Consultants, Material Suppliers, Operations, Process Control, Process Development, Engineering, and IT departments for the various modelling activities.
• Develops modifications to EGA cell designs and control logics (D18, D18+, CD20, D20, D20+, DX, DX+) to reduce energy consumption and improve current efficiency, reduce operation and relining costs, increase cell service life.
• Provides technical input and collaborates with technology modelling team to identifies software, hardware resource requirement and develop in-house thermal, electrical, mechanical, CFD and magnetic modelling capabilities.
• Conducts measurement campaigns on existing cells improving the model’s accuracy.
• Maintains a close loop with technology development team to link of continuous development between in cell design, software, and models in which is reflected on lining material testing, enhance cell design and unit cost.

Safety, Quality & Environment

• Ensures compliance with all relevant safety, health and environmental management policies, procedures, and controls.
• Ensures employee safety, legislative compliance and a responsible environmental attitude and standard within legal limits.
• Provides subject matter expertise and supports in the identification of opportunities for continuous improvement and sustainability of systems, processes and practices considering global standards, productivity improvement and cost reduction.
• Develops and trains fresh National graduate trainee in the modelling field to strengthen the company’s technical base.
• Keeps abreast of technological developments by attending technical seminars, symposia, reading specialized technical literature, co-ordinating effectively with technical consultants, academics, universities, and suppliers so that company remains competitive by using best ideas / practices.

Reporting

• Prepares sectional statements and reports timely and accurately to meet EGA and department requirements, policies, and quality standards.

3. Authority/ Decision making:

• Choosing effective solutions for problem solving. Focusing on opportunities to introduce new technologies and innovations, to improve existing technologies
• Cascading improvements in cell design and materials selection to the new or existing technologies to make gains in productivity, specific energy, and cost-effectiveness
• Making conclusions about impact of changes in design, operational or technological parameters on cell performance
• Subject to managerial control and review of results

4. QUALIFICATIONS & SKILLS:

Minimum Qualifications:

• Bachelor’s degree in Metallurgy/Material Science/Mechanical Engineering or equivalent discipline from a recognized institution/ university

Desired Qualifications:

• Master’s degree in Metallurgy/Material Science/Mechanical Engineering or equivalent discipline from a recognized institution/ university
• 6 years’ overall experience in a similar capacity and 3 years relevant work experience as Modelling Engineer.
• Must be experienced user of at least one CAE (FEM or CFD) commercial software package (preferably COMSOL, ANSYS)
• Be able to work with 3D CAD geometry to do modifications required for modelling (3D CAD software, Space Claim or COMSOL geometry modeller or similar)
• Must have a good knowledge and understanding of physics and mathematics
• Skilled user of MS Excel Good skills in documentation, data analysis, data evaluation and validation methodologies
• High self-confidence, professional work ethics and be an open-minded, independent thinking with strong commercial acumen
• Team player with good communication skills
• Good technical, analytical, and problem-solving skills
• Experienced of MS Office tools such as MS Word and Power Point etc.
• Good report writing and presentation skills
• Knowledge of aluminium production process
• Be aware about different measurements technics and equipment
• Knowledge of MATLAB or similar math or statistics software