Hydro places an order with Danieli for the supply, installation, and commissioning of a state-of-the-art wire rod casting and rolling line as part of the NOK 15 billion expansion project at its Karmøy aluminum smelter in Norway. The project is in response to growing demand for aluminum wire rod.
An aluminum conductor with the same electrical conductivity as a copper conductor weighs approximately 50% less, or half the weight, of a copper conductor. Aluminum is, therefore, a key component in the European energy transition. With a new wire rod casthouse, Hydro can produce more aluminum wire for a rapidly growing market.
“Europe’s energy transition is about one thing, more renewable power production, and the power produced must be transported over long distances. Aluminum is crucial for transporting electricity to where it is needed. By expanding the capacity to deliver low-carbon aluminum from Norway to the EU, we help ensure that the infrastructure, the very backbone of the future energy system, supports both Europe’s security and climate policy goals,” said Eivind Kallevik, president and CEO of Hydro, when the project was announced in 2025. “Our ambition is for Hydro to play a key role as a stable, reliable supplier of the aluminium solutions Europe needs to succeed.”
Karmøy is one of Europe’s largest aluminum smelters, with a total production of around 270, 000 tonnes of primary aluminum. The new wire rod casthouse will provide a capacity of 110,000 tonnes per year of aluminum wire rod in compact coils from 2 to 3.6 tons, with diameters of 9.5, 12, 19, and 25 mm.
Integrated within the existing Karmøy facilities, the Danieli wire rod casting and rolling line will feature melting furnaces, a high-performance wire rod casting and rolling line (15 tons per hour), an automated handling and storage system, and a fully automated packing line. This includes metal treatment systems (degasser and filters), a casting wheel with ingot transport, 13 two-roll mill stands, a water-cooling line, and two coilers.
Engineered with a strong focus on safety and future-ready production, the plant is designed with a high level of automation, ensuring optimal efficiency and reliability. Automation is integrated across all critical processes, from material handling to production and quality control.
The start-up of the new plant is scheduled for the beginning of 2028.