Aldel Aluminium

The Opportunity

As part of a new investment scheme in aluminum smelting at the Aldel site, the client and investors decided to upgrade and reinstate Potline 1 to operate in parallel with the currently active Potline 2, significantly increasing aluminum output. Potline 1 had been mothballed for many years due to the reduced competitiveness of the site. Therefore, the work required to bring a section of 120 cells in Potline 1 back into operational status represented a significant challenge for all involved.

Aldel awarded Power System Services the contract to install and overhaul dense phase feed systems and the structures that regulate flow into the pots. This work included the following key elements, fundamental to an automated smelting operation, consisting of both free-issue and manufactured parts:

• Manufacture and installation of new pipe inserts for dense-phase flow.

• Manufacture and installation of a combination of new and existing asset pipework.

• Repair and resealing of all joints.

• Overhaul and modification of turbo bin alumina feeds (two per cell).

• Removal, inspection, overhaul, and reinstallation of feed bins.

• Overhaul of crust breakers.

• Overhaul of gearboxes and motors.

• Manufacture of start-up conductors from aluminum.

• Installation of pneumatic control pipework.

The in-house expertise at Power System Services, strong references from previous contracts with certain engineers at Aldel, and familiarity with aluminum smelting facilities were key factors in the client’s decision to award us the contract. Naturally, the competitiveness of our offer also played a significant role.