The Alouette Aluminum smelter was expanded from 248,000 tonnes per annum to 555,000 tonnes per annum. A new potline housing 312 pots was constructed as well as 18 pots added to the end of the Phase 1 potline.
Two new gas treatment centre were incorporated for the new potline.
In the process, two new anode baking furnaces and a fume treatment centre were constructed along with a major expansion to the paste plant. A new casthouse was added. Port facilities were expanded as well by the addition of 2 x 50,000 t alumina silos and 1 x 20,000 t coke silo. The substation portion included five new 89-kA, 1340-V rectifiers.
Hatch provided detail engineering, procurement, construction and management services through to commissioning and startup.
- Completed below budget and three months ahead of schedule resulting in an additional 55,000 t of production establishing new benchmarks in aluminum smelter construction and startup
- No lost production during multiple tie-ins and complex upgrades to existing anode-manufacturing facilities
- Extensive and novel usage of pre-cast concrete elements in pot room and anode bake furnace
- First industrial application of hot bath cooling
- Novel cast house using air cooling for sow casting
- Plant-wide automation and programmation performed by Hatch saving months during commissioning and startup
- Innovative pot room pilot plant (test facility) integrated in expansion
- Established new safety records in Québec industry
- Awarded the Grand Prix 2006 for construction projects by the Québec Council of Consulting Engineers
- Awarded the Mercuriade 2005 Award for Best Project in Québec by the Québec Chamber of Commerce
