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    Production of Aluminum - Energy

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    Thanos Paraschos
    Aluminum is produced commercially using Bayer process and Hell- Héroult process. Besides scrap recycling and reuse of aluminum hydroxide contribute to total production. Bauxite is crushed, digested, precipitated, and calcined resulting in alumina. The alumina is then reduced to aluminum by electrolysis. The worldwide Al production is 41.1 million tons in 2010. The global average in energy is consumption is about 15kWh/kg of Al. The production process is energy intensive and used about 3% of global electricity production in 2010.

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    Production of Aluminum - Energy

    Uploaded by

    Thanos Paraschos
    172 views12 pages
    Aluminum is produced commercially using Bayer process and Hell- Héroult process. Besides scrap recycling and reuse of aluminum hydroxide contribute to total production. Bauxite is crushed, digested, precipitated, and calcined resulting in alumina. The alumina is then reduced to aluminum by electrolysis. The worldwide Al production is 41.1 million tons in 2010. The global average in energy is consumption is about 15kWh/kg of Al. The production process is energy intensive and used about 3% of global electricity production in 2010.

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    Aluminum is produced commercially using Bayer process and Hell- Héroult process. Besides scrap recycling and reuse of aluminum hydroxide contribute to total production. Bauxite is crushed, digested, precipitated, and calcined resulting in alumina. The alumina is then reduced to aluminum by electrolysis. The worldwide Al production is 41.1 million tons in 2010. The global average in energy is consumption is about 15kWh/kg of Al. The production process is energy intensive and used about 3% of global electricity production in 2010.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    172 views12 pages

    Production of Aluminum - Energy

    Uploaded by

    Thanos Paraschos
    Aluminum is produced commercially using Bayer process and Hell- Héroult process. Besides scrap recycling and reuse of aluminum hydroxide contribute to total production. Bauxite is crushed, digested, precipitated, and calcined resulting in alumina. The alumina is then reduced to aluminum by electrolysis. The worldwide Al production is 41.1 million tons in 2010. The global average in energy is consumption is about 15kWh/kg of Al. The production process is energy intensive and used about 3% of global electricity production in 2010.

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    Material & energy requirements

    Technical University of Crete Mining Department of Mineral Resources Engineering Metalurgical Processes Prof. Komnitsas Athanasios Paraschos 2007020037

    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

    Worldwide Aluminum production in 2010

    Source http://www.alueurope.eu/?page_id=1509

    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

    Mostly aluminium is produced in two ways;


    Primarily Production Process

    Bayer process: Bauxite refining


    Hall-Hroult process : Reduction of Alumina to Aluminum

    Secondary Production Process


    Recycling of scraps containing Al Recyling aluminium hydroxide

    Bayer Process: Refining Bauxite

    The Hall-Hroult Process: Alumina to Aluminum

    2Al2O3 + 3C 4Al +3CO2

    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

    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

    On the basis of 1kg aluminum


    Bayer process

    Source: Wang et al.2012

    Al from recycled Al(OH)3,

    Scrap recycling

    Requires only 43% total energy of primary Al prod.

    If Scrap contains >20% Al (wt.)

    Source: Wang et al.2012

    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

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