Norðurál – aluminum smelter

Work on the Norðurál aluminum smelter began in 1996. Phase I with 60 ktpy capacity was completed in 1999. Phase II with 30 ktpy capacity was completed in 2001. Phases III and IV with a combined capacity of 130 ktpy, was completed in 2006. Phase V was completed in 2007, bringing the total capacity up to 260 ktpy. HRV Engineering is supplying Engineering, Procurment and Construction Management (EPCM) and was involved in all phases of the Norðurál Aluminum smelter project. HRV’s involvement in the project evolved from being a subcontractor in phase I to becoming the only EPCM service provider in an integrated team with the owner during the later phases. Verkís is a leading partner in HRV Engineering.

Aluminum production takes place in two 600 m potrooms, each with 90 reduction pots, and two 900 m long potrooms, each with 130 reduction pots. The potrooms cover more than 50.000 m² in total. The two potlines include overhead pot tending machines, alumina conveying system, pot-gas extraction ducts, compressed air pipes, and a pot control system.

In addition to the potlines, the plant includes the following: Alumina unloading, handling and storage facilities at the harbor, including vacuum ship unloader and harbor silos. Alumina conveying system from the harbor silos to the gas treatment centers and pots. Gas treatment centers (dry) and associated ducting. Rectifier transformers with harmonic filters. Switchgear substation and main distribution system. Anode rodding and storage facilities, including butt crushing and bath processing. Casthouse to produce re-melt ingots and sows. Potline service facilities, including pot tending machine maintenance shop, and cathode de-lining and relining facilities. Compressor stations and associated piping. Warehouse and workshops. Administration and personnel facilities.

During the systems design of the plant, quality control of electricity was made and magnetic field measurements. Verkís made a model of maintenance system and updated the safety equipment used in maintenance work. Along with CE markings.

Verkís services was participation in the project as leading partner in HRV Engineering, project management, cost estimation, civil/structural engineering, mechanical engineering, construction management and site supervision, procurement management, tender documents and bid review, contractor and vendor technical control, quality control, operation and maintenance documentation review.

The Challenge

The Norðurál Aluminium Smelter was developed through multiple expansion phases to meet growing production demand while maintaining high standards of operational efficiency, reliability and environmental performance. The project required the design, construction and continuous expansion of a complex industrial facility integrating advanced aluminium production processes with extensive supporting infrastructure.

Our Solution

As a leading partner in HRV Engineering, Verkís provided EPCM services across all phases of the project, including project management, cost estimation, multidisciplinary engineering, procurement, tendering, construction management and site supervision. Our team also carried out power quality analyses, magnetic field assessments, maintenance system development, CE compliance, quality control and technical reviews, supporting the successful delivery and long-term operation of the plant.

The phased expansion increased the smelter’s production capacity to 260,000 tonnes of aluminium per year, creating one of Iceland’s largest and most advanced industrial facilities. Through integrated engineering, construction management and asset management expertise, Verkís helped deliver a highly efficient, reliable and scalable aluminium production plant capable of supporting long-term industrial growth.