2023-07-26
Two-step process to convert alumina to aluminum
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1. Extraction of alumina from bauxite
Almost all of the world's alumina supply is produced using the Bayer process. Austrian chemist Carl Josef Bayer developed this technique in the late 19th century.
It involves crushing bauxite into a fine powder, mixing it with water and heating the mixture with caustic soda. Caustic soda dissolves the alumina and passes it through the filter.
Producers add aluminum hydroxide crystals to an alumina solution, which is then heated and dried to produce alumina.
2. Smelting alumina to produce aluminum metal
To smelt aluminum, refineries dissolve alumina in a fluorinated bath and use an electric current to break it down into metallic aluminum and oxygen through a process called electrolysis. They then collect the aluminum and take it to a furnace, where they combine it with the recycled aluminum material and heat it until it is melted.
It is then poured into a mold or mechanically extruded in various forms. The most common are plates, billets, bars, tubes, plates, bars and wires. They are then cut into different shapes and sizes and shipped to another company or manufacturer who will process them into countless products.
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