Aluminium:

a unique metal

driving the green transition

Aluminium production begins with bauxite, a reddish rock that is the primary “aluminium ore”. Most bauxite is mined in tropical or subtropical regions but also in Europe to a certain extent. Through the Aluminium Stewardship Initiative and corporate programs, the aluminium industry takes a proactive stake in contributing to responsible mining that minimises social and environmental impacts during operation and post-closure of the mine.

To produce primary aluminium, you need alumina. Alumina is extracted from bauxite via a process called refining. The refining process has two steps: first, the bauxite is dissolved with caustic soda to remove residues and obtain aluminium hydroxide; then, it is heated to remove the water contained in this hydroxide. After the refining process, alumina looks like a white powder similar to table salt.

Molten aluminium is extracted from alumina through a process called smelting. This process is fully electrified and uses a powerful electric current to extract pure aluminium from alumina. After this electrolysis, molten aluminium can be collected from the bottom of the pot. This liquid metal is transferred to the casthouse, where it is purified, alloyed to specification, and then cast into ingots or billets ready for semi-fabrication.

Aluminium ingots can be rolled into sheets for use in aluminium beverage cans, foil and car bodies, for example. Through extrusion, aluminium billets can be shaped in their required form and deliver almost unlimited possibilities in product design for furniture, building components, or cars.

Once aluminium scrap is collected and sorted, it is placed into a melting furnace and turned into molten aluminum, which can be cast into new ingots or billets. Depending on customer requirements, alloying elements may be added to produce the desired product specifications. Aluminium can be recycled endlessly without losing its original properties, making it a key contributor to a more resource-efficient society. Furthermore, recycling aluminium only requires about 5% of the energy used to produce primary aluminium, providing huge CO₂-saving benefits.