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
Reykjavík Energy owns the Hellisheidi geothermal power plant, a combined heat and power plant located about 20 km from Reykjavík in south-west Iceland. The area is one of Iceland’s most active high enthalpy areas. A new area, at Gráuhnúkar, is being investigated for steam and fluid extraction. The purpose of the plants is to meet increased demand for electricity for industrial and domestic use and for hot water for heating. The 303 MWe geothermal power plant in Hellisheiði, Iceland, was commissioned in 5 stages during the years 2006-2011. The first stage was completed in 2006 with two high pressure geothermal turbines of 45 MWe capacity each. The second stage was completed in 2007 with one low pressure geothermal turbine of 33 MWe capacity. The third stage was completed in 2008 with two additional high pressure geothermal turbines, 45 MWe each.
In 2010 a heating plant for hot water generation was added to the plant, intended for district heating. The heat output of the first stage is 133 MWth and two further 133 MWth stages are to follow later. At the same time the Hellisheiði hot water main was put into service. The main is a 19,5 km long pipeline, 0,9-1,0 m in diameter, that carries hot water to Reykjavík. In 2011 the 5th stage of the plant was finished, which includes two new 45 MWe high pressure geothermal turbines, similar to the former turbines, situated in a new power house in Sleggjubeinsdalur.
The plant utilizes 500 kg/s of 180°C geothermal steam for electrical generation. The hot fluid is extracted from 30 wells, 2.000 – 3.000 m deep, and is led through steam and mist separators before entering the turbines. The high pressure steam gathering system operates at 9 bara pressure. The low pressure steam is generated with flashing of brine water from the steam separators at a pressure of 2 bara. The generating units are of single flow, single flash type with axial exhaust. Cooling is achieved through wet cooling towers of the counter flow type.
The main components of the electrical system for each unit consist of a 50 MVA generator, 50 MVA step-up transformer to 220 kV transmission voltage, an 11/11 kV transformer for connection to the 11 kV station service system and two 11/0,4 kV transformers for station service. The generating units, as well as the 11 kV and 0,4 kV distribution boards, are monitored and controlled by the state of the art control- and protection equipment.
Our Solution
Reykjavík Energy owns the Hellisheidi geothermal power plant, a combined heat and power plant located about 20 km from Reykjavík in south-west Iceland. The area is one of Iceland’s most active high enthalpy areas. A new area, at Gráuhnúkar, is being investigated for steam and fluid extraction. The purpose of the plants is to meet increased demand for electricity for industrial and domestic use and for hot water for heating. The 303 MWe geothermal power plant in Hellisheiði, Iceland, was commissioned in 5 stages during the years 2006-2011. The first stage was completed in 2006 with two high pressure geothermal turbines of 45 MWe capacity each. The second stage was completed in 2007 with one low pressure geothermal turbine of 33 MWe capacity. The third stage was completed in 2008 with two additional high pressure geothermal turbines, 45 MWe each.
In 2010 a heating plant for hot water generation was added to the plant, intended for district heating. The heat output of the first stage is 133 MWth and two further 133 MWth stages are to follow later. At the same time the Hellisheiði hot water main was put into service. The main is a 19,5 km long pipeline, 0,9-1,0 m in diameter, that carries hot water to Reykjavík. In 2011 the 5th stage of the plant was finished, which includes two new 45 MWe high pressure geothermal turbines, similar to the former turbines, situated in a new power house in Sleggjubeinsdalur.
The plant utilizes 500 kg/s of 180°C geothermal steam for electrical generation. The hot fluid is extracted from 30 wells, 2.000 – 3.000 m deep, and is led through steam and mist separators before entering the turbines. The high pressure steam gathering system operates at 9 bara pressure. The low pressure steam is generated with flashing of brine water from the steam separators at a pressure of 2 bara. The generating units are of single flow, single flash type with axial exhaust. Cooling is achieved through wet cooling towers of the counter flow type.
The main components of the electrical system for each unit consist of a 50 MVA generator, 50 MVA step-up transformer to 220 kV transmission voltage, an 11/11 kV transformer for connection to the 11 kV station service system and two 11/0,4 kV transformers for station service. The generating units, as well as the 11 kV and 0,4 kV distribution boards, are monitored and controlled by the state of the art control- and protection equipment.
The Result
Reykjavík Energy owns the Hellisheidi geothermal power plant, a combined heat and power plant located about 20 km from Reykjavík in south-west Iceland. The area is one of Iceland’s most active high enthalpy areas. A new area, at Gráuhnúkar, is being investigated for steam and fluid extraction. The purpose of the plants is to meet increased demand for electricity for industrial and domestic use and for hot water for heating. The 303 MWe geothermal power plant in Hellisheiði, Iceland, was commissioned in 5 stages during the years 2006-2011. The first stage was completed in 2006 with two high pressure geothermal turbines of 45 MWe capacity each. The second stage was completed in 2007 with one low pressure geothermal turbine of 33 MWe capacity. The third stage was completed in 2008 with two additional high pressure geothermal turbines, 45 MWe each.
In 2010 a heating plant for hot water generation was added to the plant, intended for district heating. The heat output of the first stage is 133 MWth and two further 133 MWth stages are to follow later. At the same time the Hellisheiði hot water main was put into service. The main is a 19,5 km long pipeline, 0,9-1,0 m in diameter, that carries hot water to Reykjavík. In 2011 the 5th stage of the plant was finished, which includes two new 45 MWe high pressure geothermal turbines, similar to the former turbines, situated in a new power house in Sleggjubeinsdalur.
The plant utilizes 500 kg/s of 180°C geothermal steam for electrical generation. The hot fluid is extracted from 30 wells, 2.000 – 3.000 m deep, and is led through steam and mist separators before entering the turbines. The high pressure steam gathering system operates at 9 bara pressure. The low pressure steam is generated with flashing of brine water from the steam separators at a pressure of 2 bara. The generating units are of single flow, single flash type with axial exhaust. Cooling is achieved through wet cooling towers of the counter flow type.
The main components of the electrical system for each unit consist of a 50 MVA generator, 50 MVA step-up transformer to 220 kV transmission voltage, an 11/11 kV transformer for connection to the 11 kV station service system and two 11/0,4 kV transformers for station service. The generating units, as well as the 11 kV and 0,4 kV distribution boards, are monitored and controlled by the state of the art control- and protection equipment.
Icelandic
