General planning for the new construction of the world's largest aluminum recycling plant at Novelis Europe / Novelis USA

Overview

Location: Nachterstedt, Saxony-Anhalt, Germany
Project duration: 2012-2015 + follow-up orders
Production area: approx. 60.000 sqm
Investment sum: over €200 million

HÖRMANN Rawema Engineering & Consulting GmbH successfully implemented the general planning for the new construction of the world's largest aluminum recycling plant for Novelis Europe / Novelis USA. The aim of the project was to plan processes, plants and infrastructure holistically on a greenfield site, to ensure performance through simulation and to accompany the realization including commissioning on schedule.

Project content

General planning on a greenfield site

Integrated planning of production plants, ancillary processes, buildings and technical infrastructure. Early interface clarification for smooth plant construction.

Front End Engineering Design (FEED)

Concept planning Data acquisition and analysis as the basis for the basic engineering of production equipment, ancillary processes and buildings. Derivation of reliable design parameters and functional concepts.

Engineering (Procurement) Construction Management - E(P)CM

Detailed planning, tendering and supplier selection for production equipment. Logistics planning and simulation as well as detailed layout development in 2D/3D to ensure performance.

Implementation and construction coordination

Construction supervision and coordination with clear milestones and quality checks. Close control of execution to minimize risks and rework.

Supplier and start-up management

Coordination of suppliers across all trades. Structured start-up planning for media, systems and processes up to the stable start of operations.

Commissioning support

Tests and acceptances Support during commissioning with test and acceptance plans. Proof of the required performance and quality parameters for a reliable production start.

Advantages of our solution

• Comprehensive general planning: Integration of systems, logistics, buildings and technical infrastructure reduces interface risks.
• Planning reliability: FEED and E(P)CM with 2D/3D layouts and simulations create a reliable basis for design and decisions.
• On-time implementation: Structured construction coordination, supplier control and milestone management ensure that the project runs smoothly.
• Scalability and performance: Simulation-supported logistics and layout concepts enable high throughput and future expansions.
• Clear investment: Transparent tendering and selection processes increase cost control and quality within the scope of over €200 million.
   

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