This document discusses the material and energy requirements for aluminum production. It notes that in 2010, global aluminum production was 41.4 million tons, requiring 621 billion kWh of electricity, which accounted for 3% of total global electricity production. Aluminum is primarily produced through the Bayer process to refine bauxite into alumina, followed by the Hall-Héroult process to reduce alumina into aluminum. Secondary aluminum production involves recycling aluminum scrap and hydroxide. Producing 1kg of aluminum requires mining 5,900kg of earth, 5.1kg of bauxite, 1.93kg of alumina, and 0.45kg of carbon anode. Recycling aluminum hydroxide

1. Material & energy requirements
Technical University of Crete Mining
Department of Mineral Resources Engineering
Metalurgical Processes – Prof. Komnitsas
Athanasios Paraschos 2007020037

2. 
Aluminum is a light metal with density of
2.7g/cm3 (three times less than of steel) .

It is one of those elements which are excessive
on earth. It is an excellent heat and electrical
conductor with very good reflectivity, resistance
to corrosion and ductility.

Aluminum is used extensively in electronics
infrastructure, packaging and transportation

3. Worldwide Aluminum production in 2010
Source http://www.alueurope.eu/?page_id=1509

4. 
In 2010, global Al production is 41,4million tons

Global average energy consumption is 15kWh/kg Aluminum

Thus,

Electricity consumption is 621 billion kilowatt hours of electricity

Global electricity production is 20261 billion kilowatt hours

Therefore,
 Three percent of the total electrical supply goes to aluminum extraction

5. 
Mostly aluminium is produced in two ways;

Primarily Production Process



Bayer process: Bauxite refining
Hall-Héroult process : Reduction of Alumina to Aluminum
Secondary Production Process

Recycling of scraps containing Al

Recyling aluminium hydroxide

6. 
Bayer Process: Refining Bauxite

7. 

8. 
Scrap recycling
 The scrap is cleaned and sorted
 If the scrap contains more than 20% Al by wt.

Aluminum hydroxide
 It is a waste from Al production and can be
assumed as free of impurities
 It is then Calcined directly

9. 
To produce 1kg of aluminum,





5,900kg earth has to mined
5.1kg Bauxite,
1.93kg alumina and
0.45kg carbon anode
This means that for 2010 annual world
production of 41.1 million tons aluminum,
 210 million tons of bauxite,
 80 million tons of alumina and
 21 million tons of carbon anode

10. 
On the basis of 1kg aluminum
Bayer process
Source: Wang et al.2012

11. 
Al from recycled Al(OH)3,
Requires only 43% total energy
of primary Al prod.
Scrap recycling
If Scrap contains >20% Al (wt.)
Source: Wang et al.2012

12. 
Wang H., Leung D.Y.C, Leung M.K.H, 2012, Energy analysis of hydrogen and
electricity production from aluminum-based processes, Applied energy 90, 100105

U.S. Department of energy, U.S. Energy requirement for aluminum production:
historical perspective, theoretical limits and current practices, February 2007

Totten G.E, Mackenzi D.S., 2003, Handbook of Aluminum, Vol 1,Physical
Metallurgy and processes, Marcel Dekker, Inc, USA