The Project

Rio Tinto’s BC Works Operation, near Kitimat, British Columbia, comprises a newly modernized aluminium smelter and the Kemano Powerhouse, a hydropower facility supplied by the Nechako Reservoir. From Canada’s west coast, Rio Tinto transports the products from the BC Works operations by ship and rail, primarily to customers in Japan, South Korea and the United States. BC Works is certified by the Aluminium Stewardship Initiative (ASI) for producing aluminium to the highest internationally recognized standard for responsible environmental, social and governance practices. 

Services Provided

The smelter experienced a major shutdown and restart, which led to reduced operations. Giffen (subcontractor of AtkinsRéalis) was engaged by Rio Tinto for the Modernization Project, which was a comprehensive modernization program to ramp up the smelter’s production and return the smelter to full capacity.

Giffen played major role in the upgrades of the Kitimat Smelter at the BC Works operation. A team of four Project Managers were seconded to support Rio Tinto’s Capital Projects Team on a variety of projects.

Our involvement included planning, implementing, and overseeing the sustaining capital projects to maintain and upgrade the aging infrastructure of the smelter. This involved following Rio Tinto’s project framework from evaluation to implementation which included:

  • Establishing business case
  • Risk assessment and design review
  • Developing procurement/construction packages
  • CAPEX estimate
  • Schedule
  • Risk identification and mitigation
  • Procurement support, including technical and commercial bid evaluations
  • Managing EPC consultant and construction contractors
  • Financial planning
  • Field inspections

Project Management

The Giffen team successfully established positive relations with the core teams of Rio Tinto along with the other consultants onsite. Example projects managed by the Giffen team:

  • Pallet Storage Building Remediation
  • ABF Maintenance Shop Crane Addition
  • ABF Stacking Crane Power Rail Access Platform
  • ARS Hydraulic Power Unit Upgrades
  • 9 Silos Drainage
  • GTC Vibrating Screens

A Successful Restart

In October 2023, Rio Tinto’s Kitimat aluminium smelter reached full capacity for the first time since 2018, following a 17-month strike. Production has fully returned to its annual rate of 432,000 tonnes. This was a milestone for the community and its 1,100-member workforce. The restart boosts Rio Tinto’s aluminium output and strengthens the local economy. The operation has contributed over C$517.6 million to the British Columbia economy in 2023, and are one of the single largest contributors to the province’s manufacturing GDP. At the same time as the restart, a C$135 million upgrade is replacing the plant’s 1.1 km alumina conveyor to improve efficiency, cut dust and spills, and extend service life by about 50 years. Together, the recovery and investment underscore Rio Tinto’s long-term commitment to modernizing BC Works and supporting sustainable, low-carbon aluminium production in northwest British Columbia.

Full article on the smelter restart can be found here.