Aluminum compounds are found in all types of clay, but bauxite is the most useful ore for producing pure aluminium. Bauxite is composed of 45-60% aluminium oxide and other impurities such as sand, iron, and other metals. Although some bauxite deposits are hard rock, the majority are relatively soft dirt that can be easily extracted from open-pit mines. Australia produces more than one-third of the world's bauxite supply. 1 lb (0.5 kg) of aluminium metal requires approximately 4 lb (2 kg) of bauxite.
To separate the aluminium compounds found in bauxite from the impurities, caustic soda (sodium hydroxide) is used to dissolve them. Small amounts of other chemicals may be used in the extraction depending on the composition of the bauxite ore.
Aluminum is produced in two stages: the Bayer process, which involves refining bauxite ore to produce aluminium oxide, and the Hall-Heroult process, which involves smelting the aluminium oxide to produce pure aluminium.
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made of aluminium Some examples include starch, lime, and sodium sulphide.
The electrolyte (current-conducting medium) in the smelting process is cryolite, a chemical compound composed of sodium, aluminium, and fluorine. Cryolite was once mined naturally in Greenland, but the compound is now synthesised for use in the production of aluminium. To lower the melting point of the electrolyte solution, aluminium fluoride is added.
Carbon is another important component in the smelting process. Carbon electrodes conduct electricity through the electrolyte. Some of the carbon is consumed during the smelting process as it combines with oxygen to form carbon dioxide. In fact, for every pound (2.2 kg) of aluminium produced, approximately half a pound (0.2 kg) of carbon is used. Some of the carbon used in aluminium smelting comes from oil refining, while the rest comes from coal.
Aluminum smelting necessitates a large amount of electrical energy because it involves passing an electric current through a molten electrolyte. On average, it takes 15 kilowatt-hours (kWh) to produce 2 lb (1 kg) of aluminium. Electricity costs roughly one-third of the cost of smelting aluminium.
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