Fjarðaál – aluminum smelter

Design work started in the autumn of 2003 and earthworks in the summer of 2004.

The Fjarðaál smelter was designed using AP36 technology from Aluminum 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 aluminum 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.

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.

The Challenge

The Fjarðaál Aluminium Smelter was developed as one of Iceland’s largest industrial projects, requiring the design and construction of a world-class aluminium production facility powered entirely by renewable hydropower. The project demanded the coordination of complex industrial systems, advanced process technology and large-scale infrastructure within a fast-track international EPC project.

Our Solution

As a leading partner in HRV Engineering, working alongside Bechtel, Verkís provided multidisciplinary engineering and project delivery services throughout the project lifecycle. Our work included feasibility studies, engineering design, cost estimation, execution planning, procurement support, site management, construction supervision and quality control. Verkís also developed the plant’s asset structure, maintenance strategy, reliability analyses, preventive maintenance plans and CE compliance documentation to support safe and efficient long-term operation.

The completed Fjarðaál smelter has an annual production capacity of 345,000 tonnes of aluminium, powered by renewable electricity from the 690 MW Kárahnjúkar Hydropower Plant. Through integrated engineering, project management and asset management expertise, Verkís helped deliver one of Iceland’s largest industrial developments, creating a modern, highly efficient aluminium production facility designed for reliable, long-term operation.