Have you ever wondered how aluminium is made?

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Aluminium is at the heart of modern life, from the smartphone in your hand, to the plane you fly in, to the buildings where you live and work. As economies grow and living standards rise, industry experts expect that demand for aluminium will increase.

Step 1: Bauxite Mining
The production process for aluminium starts with the mining of bauxite ore. Layers of bauxite are generally found near the surface so it is extracted through open cast mining. Around 90% of the world's resources are in tropical & sub-tropical regions

Step 2: Alumina Refining
Bauxite is refined into alumina using the Bayer process. Two or three tonnes of bauxite are required to produice one tonne of alumina. In the digestion stage, hot caustic acid is added to the bauxite to dissolve the aluminium bearing minerals in the bauxite. Clarification separates bauxite solids from the pregnant liquor via sedimentation. In the precipitation stage, alumina crystals are recovered from the liquor via crystallization. Calcination is a roasting process to remove the remaining water.

Step 3: Aluminium Smelting
Alumina is smelted into aluminum using the Hall-Heroult process. It takes two tonnes of alumina to produce one tonne of aluminium. Alumina is poured into special reduction cells called pots with an electrolytic bath of molten salt called cryolite at temperatures around 960 degrees Celsius. An electrical current is then projected into the mixture at 400KA or above. This current then breaks the bonds between aluminium and oxygen atoms in alumina, resulting in liquid aluminum settling at the bottom of the reduction cell.

Step 4: Casting
Aluminium is then transferred to the cast house, where it is made into products using several different methods. Alloys are added into many of our products, according to customer specifications, before the solidification stage. In re-melt casting aluminum, at a temperature of 700 degree Celsius, is poured into moulds. The moulds are cooled and the aluminium solidified before being packed and shipped to the customer. EGA also supplies nearby customers in Khalifa Industrial Zone Abu Dhabi. Receiving aluminum as molten metal eliminates the need to use high energy to re-melt it before use. We transfer molten metal by truck in preheated 14.5 tonne crucibles which can keep the metal liquid for 18 hours at temperatures of around 780 degrees Celsius.
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Awesome animation .Helped a lot in learning about ALuminium Smelting Class 10

moreshravan
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Beautiful animation, thoroughly presented.
Thank you,
EGA.

adnanghoniya
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This was a very well done video with appropriate animations that informed without distracting. Impressed!

Raptorman
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Just wow ...knowing extraction of aluminium from its makers itself....
Thanks a lot....

justtelescopic
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excellent. There's a similar presentation from the 1950's that is very entertaining (HOW IT'S MADE: Aluminum) and gives some personality to the process. This is great, though, thanks!

Psycandy
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At about 5.00 the ingot caster is shown. At my plant we had electromagnetic casting molds which were fascinating to study. We also had older direct chill molds. I was told that the use of EMC eliminated the need to use a scarfing saw to prep the ingot sides prior to hot rolling. DCC would cause unwanted surface defects that the saw would remove. Nice animation.

gregkocher
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Even though done 2 years ago I helps a lot in understanding the concepts thankyou for this very well done animation.

cyril
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very user-friendly narration. thank you

manjunathgkallur
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That was the besst vide, i have ever seen. Thnak you so much, you helped me a lot and saved my project!

brk.
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Excellent animation, easy to understand, great EGA 👍

raisnizamuddin
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The visualization is awesome!, thanks a lot anyway

indahkusumawardani
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You make it look like some paradise where you mine.

ymj
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Amazingly explained...perfect work..great industry..awsome people..just loved it..wish to be a part of this amazing industry..

fwbproductions
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most informative video i have watched, this will definitely help many people

Arceus
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no words its an exellent video ..great clarity thankyou

navyaprajapat
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Best animation video....just loved it..Well done guys

avisheksunani
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It's a great apresentation. Thanks for the share.

befontes
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Thanks for the info. Using this as quest inspiration for my DF tabletop game. Just need to find out what happens if the process fails during the acid treatment or if the alumina isn't allowed to be in electrolysis long enough now.

roetemeteor
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Truly beautiful animation and indeed informative too!

srajanamin
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Awesome Animation and shared a brilliant information

titocleetus