Aluminium Smelter

Fjarðaál aluminium smelter

Reyðarfjörður - Iceland

Verkís services was participation in the project as leading partner in HRV Engineering, teaming up with Bechtel Corp. as Bechtel-HRV, feasibility study, engineering in various fields, cost estimation, execution planning, preparation of bid documentation and review of bids, site execution management, site supervision and quality control.

 Sizes: 345 tpy
 Project time:  2003 - 2008

Project overview:
Following an international competition in the spring of 2003, the contractor, Bechtel Corporation, and HRV Engineering were chosen by Alcoa to design and build a new aluminium smelter in Reyðarfjörður, Iceland. Verkís is a leading partner in HRV Engineering. Design work started in the autumn of 2003 and earthworks in the summer of 2004.

The smelter was designed using AP36 technology from Aluminium Pechiney, with a total of 334 reduction pots and a total production capacity of 345 ktpy. In addition to the two potlines with associated overhead pot tending machines, alumina conveying system, pot-gas extraction ducts, compressed air pipes and pot control system, the following main ancillary facilities were included:

Alumina unloading, storage and handling facilities, including vacuum ship unloader, alumina and aluminium fluoride silos and alumina conveying system from the silos to the gas treatment centers. Gas treatment centers (dry) and associated ducting. 220 kV gas insulated switchgear substation, main distribution system and rectifier transformers with harmonic filters. Anode rodding and storage facilities, including butt crushing and bath processing. Casthouse with rod caster and mill, and sow and ingot casting. Potline service facilities, including pot tending machine maintenance shop, and potline equipment maintenance shop. Compressor station and associated piping. Warehouse and workshops. Administration and personnel facilities and external road and utilities. The power to the smelter is produced at the Kárahnjúkar hydropower plant, which has an installed capacity of 690 MW.

Verkís handled the development of the property tree, reliability analysis equipment, planning of preventive maintenance and condition analysis, as well as general maintenance advice and overhaul of CE marking.