Yarwun expansion project
Overview of Project
In July 2007, Rio Tinto approved a US$1.8 billion expansion of the Yarwun Alumina Refinery. The expansion, known as Yarwun 2, will more than double annual production, increasing alumina output by two million tonnes to 3.4 million tonnes by 2011.
Rio Tinto's long life resource at Weipa in northern Queensland will supply bauxite to the refinery. The Yarwun expansion will have the benefit of substantial scale efficiencies gained from the construction of the first stage of the refinery.
Yarwun 2 will focus on the construction of the five alumina process areas: tube digestion, precipitation, filtration, clarification and calcination. Major and minor facilities utilised in these process areas will be replicated. In some instances new facilities will feature improvements that will increase process and environmental efficiency. Major non-process facilities will be extended or expanded as part of the Yarwun 2 project.
One of the most important features of Yarwun 2 is the new equipment designed to reduce the refinery's air and greenhouse emissions. Flue Gas Desulphurisation equipment will be installed on Yarwun 2's coal fired boiler at a cost of $15 million. As a consequence the total site sulphur dioxide emissions will increase by only 10%, in spite of an overall increase of 140% in alumina production. In addition, a gas turbine with heat recovery steam generator has been included in the Yarwun 2 project scope. Known as a gas cogeneration plant, it will reduce Yarwun 2's greenhouse intensity by 36% relative to coal and will facilitate the refinery's ability to sell electricity back to the state grid.
Key Facts
| Yarwun 2 | |
| Capital cost | US$1.8 billion |
| Alumina capacity | 2 million tonnes per annum |
| Bauxite used | 4.5 million tonnes per annum |
|
Employment Construction Operations* |
2,200 at peak 270 |
*Figures include full-time equivalent contractors
Project Construction
Bechtel Australia has been engaged as the Engineering, Procurement and Construction Management (EPCM) contractor for Yarwun 2. A Rio Tinto Aluminium (RTA) Owner's team will manage overall project delivery including setting project objectives, approving the EPCM scope of work and finalising key commercial impacts of the project. Construction of the project is expected to commence in October 2007.
Key Milestones
| October 2007 | Bulk earthworks commence |
| February 2008 | First concrete work |
| June 2008 | First steel erected |
| June 2009 | Fisherman's Landing Wharf extension complete |
| September 2009 | Process area pre-op testing begins |
| March 2010 | First caustic transfer to refinery site |
| June 2010 | First bauxite to Digestion Unit 3 |
| August 2010 | First bauxite to Digestion Unit 4 |
| September 2010 | Project mechanically complete |
Employment
The recruitment of personnel for the construction of Yarwun 2 will be an ongoing process and will depend on the milestones to be achieved by set dates and the amount of work to be completed. The peak construction workforce will be approximately 2,200. At this stage, the construction of the project is expected to ramp up in earnest from June 2008 and the majority of construction personnel will need to be onsite from this time onwards.
The Yarwun 2 Employment and Mobilisation Centre has application forms and up-to-date information on project recruitment. To register for employment log onto: http://yarwun2.nga.net.au/ or call 07 4976 8500.
Contractor Opportunities
While the main contractors used in the refinery's construction have again been engaged for Yarwun 2, there will be opportunities for local fabricators, suppliers and contractors to be involved in the project. Interested parties should submit an Expression of Interest to Ralph Miles at Bechtel Australia, Level 10, 300 Ann Street, Brisbane 4000.
Accommodation
RTA is mindful that accommodation and housing availability in the Gladstone Region is an important community issue. RTA is working with local councils and developers to mitigate any impacts on the community from increased housing demand associated with accomodating non-local employees for the Yarwun 2 Project.
A Yarwun 2 Accommodation Plan has been developed. It includes a range of innovative and flexible options; the implementation of which will depend on project milestones, project manning requirements and developments in the local housing market.
At this stage people interested in renting homes or units to the project are advised to contact Robyn Hayes, Yarwun 2 Accommodation Officer on 4976 8510 or robyn.hayes@riotinto.com. Developers interested in working with RTA are advised to contact Paul Arnold on 07 3115 3522.
Further Information
A Yarwun 2 website is currently under construction. For more information about the RTA Yarwun Alumina Refinery or Yarwun 2 construction, please contact us directly on 1800 226 258 or via rtay.info@riotinto.com.