Expertise
Aluminium
SNC-Lavalin has been a global leader in the aluminium sector for over 25 years. Many of its feasibility studies for leading primary aluminium producers, including Alcan, Alcoa, BHP-Billiton, Hydro Aluminium and Aluminium Pechiney, have led to its involvement in the construction or expansion of world-class smelters.
Among these are the Alusaf Hillside Aluminium Smelter in South Africa, the largest ever built as a singlestage greenfield project, and Mozal I, a greenfield smelter in Mozambique which garnered a “Project of the Year Award” from the Project Management Institute (PMI).
Locally in Australia, SNC-Lavalin's flagship aluminium project is the Boyne Smelter project. SNC-Lavalin is also active in alumina refining on a global scale, from the Aughinish greenfield refinery in Ireland, to many brownfield refinery projects around the world. SNC-Lavalin’s prominence in the international aluminum industry is a result of its long-time involvement in Canada’s aluminum sector.
Since 1980, nine new projects totalling over 1.7 million tonnes of modern smelter capacity have been completed in the province of Quebec. Such experience means that its personnel are always up to date and in demand. From conceptual studies, to the execution of billion dollar projects, SNC-Lavalin supplies the world’s most qualified project teams to match its clients' highest expectations.
At SNC-Lavalin, a commitment to protecting the health and safety of all personnel, a real concern for the environment, a close attention to quality and a respect for the communities in which it works are all key values.
Alhouette Aluminium Smelter - Canada
SNC-Lavalin was the leader of a joint venture to provide EPCM services for the expansion of the Aluminerie Alouette aluminium smelter at Sept-Iles, Quebec. This smelter is the largest in the Americas with a capacity of 550,000 tpa.
Alhouette Aluminium Smelter - Canada
SNC-Lavalin provided the EPCM services for the original Alouette smelter completed in 1992. The Phase II expansion increased capacity to 550,000 tpa, the largest in the Americas. SNC-Lavalin was the leader of a joint venture to provide EPCM services for the Phase II multi-billion dollar expansion which was completed in 2005. This expansion increased production of primary aluminium by 305,000 tonnes per year.
The project involved a new potline having 312 pots, and the addition of 18 pots to the existing potline, all using modified Pechiney AP-30 electrolysis technology. The new potline included transformers/rectifiers and exhaust gas treatment centres.
To increase the anode production capacity, the expansion included an increase in liquid pitch storage capacity, a new Pechiney bake furnace complete with a fume treatment centre, as well as modifications to the paste plant and the other sections of the carbon plant.
A new casthouse equipped with three sow casting machines provides the required additional casting capacity. At the port, two new alumina silos and a new coke silo were added, complete with a new transfer conveyor and other extensive modifications to the material handling systems.
Boyne Smelter - Australia
SNC-Lavalin in joint venture undertook the feasibility study which was followed by the award of an EPCM contract for project delivery for an upgrade of Australia’s largest smelter on Boyne island near Gladstone.
Boyne Smelter - Australia
SNC-Lavalin in joint venture undertook the feasibility study which was followed by the award of an EPCM contract for project delivery for an upgrade of Australia’s largest smelter on Boyne island near Gladstone.
Rio Tinto Alcan’s Boyne Smelter produces some 550,000 tpa of aluminium and this upgrade project consists of the replacement of Carbon Baking Furnaces 1 & 2 as well as replacement of cranes and associated runways on Reduction lines 1 & 2. Approximately 50% is in Brownfield conditions.
The Brownfield component involves the installation of new Cell Tending Assemblies, together with a new alumina distribution system and runway upgrade.
To improve working conditions for the crane runway upgrade, an existing crane has been modified into a mobile work platform, part of an innovative solution to enable personnel to safely complete repairs to column heads and crane clip replacement above the cells.
Mozal II Project - Mozambique
In June 2001 Mozal S.A.R.L. awarded SNC-Lavalin, in joint venture the engineering, project management, procurement and construction management of this expansion project to double the capacity of the Mozal aluminium smelter in Mozambique.
Mozal II Project - Mozambique
Following the successful completion of the Mozal I aluminium smelter project by SNC-Lavalin in joint venture, the decision was made to proceed with a 253,000 tpa expansion of the project by adding a second potline. The go ahead was given in June 2001 and the project was scheduled for completion in August 2003, 7 months ahead of schedule. A capacity of 271,000 tpa aluminium was achieved during commissioning and the project was delivered under the approved budget. The new potline comprises 288 electrolytic cells, and utilises Pechiney AP-30 technology as in Mozal I.
In addition to the new potline the project included construction of a new gas treatment centre, expansion of the main substation, a new anode baking furnace, a furnace tending assembly, a new paste plant, a fume treatment centre, new holding furnaces in the casthouse, new horizontal direct chilled casting machines, a water cooling facility, a new alumina silo at Matola port, a new ship unloader, an export yard, and a liquid pitch facility.