[China Aluminum Network] The primary aluminum production process today is mainly based on the Hall-Héroult electrolysis method, a technology developed independently by Charles Martin Hall in the United States and Paul Héroult in France in 1886. This process uses alumina as the raw material and cryolite (Na₃AlF₆) as the electrolyte. At temperatures between 950°C and 970°C, the aluminum oxide in the molten electrolyte is decomposed through electrolysis. Molten aluminum is deposited at the carbon cathode, while oxygen reacts with the carbon anode to form carbon dioxide gas. For every ton of primary aluminum produced, approximately 1.5 tons of CO₂ are emitted, and the overall energy consumption reaches around 15,000 kWh.
Industrial aluminum electrolytic cells can be broadly categorized into three types: side-bottom anode self-baking cells, top-bottom anode self-baking cells, and pre-baked anode cells. However, due to the high energy consumption and environmental impact associated with self-baking cell technology, it has gradually been phased out. Today, global primary aluminum production stands at about 28 million tons annually, with China being the largest producer, accounting for roughly 7 million tons each year.
If further purification is required, the aluminum obtained from electrolysis can undergo refining processes to achieve higher purity levels. In terms of aluminum alloy production, the most common method involves melting and casting. Due to its excellent machinability, aluminum and its alloys can be shaped through various techniques such as forging, casting, rolling, stamping, and extrusion, resulting in a wide range of products like sheets, foils, tubes, wires, and other profiles. These materials are widely used across industries, from construction to aerospace and consumer goods.
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