ALUMINIUM

PRODUCTION OF ALUMINIUM
Aluminium is extracted by the Hall-Hroult process. The raw material for aluminium
manufacture is bauxite, which contains aluminium oxide, Al2O3, (alumina). The main impurities
are oxides, particularly iron (III) oxide and silicon dioxide, SiO2, (sand), so bauxite is first
purified. Aluminium oxide is amphoteric while iron (III) oxide is basic and silicon dioxide is
acidic. Powdered bauxite is dissolved in hot concentrated sodium hydroxide solution which the
aluminium oxide and the silicon dioxide.
Al2O3(s) + 2OH-(aq) + 3H2O(l) 2[Al(OH)4]-(aq) .
SiO2(s) + 2OH-(aq) SiO32-(aq) + H2O(l) .
The insoluble impurities (basic impurities) such as iron (III) oxide are filtered off. The residue,
highly alkaline and red-brown in colour due to the presence of the iron (III) oxide, is called red
mud.
The filtered solution is seeded with solid aluminium hydroxide or carbon dioxide is blown
through the solution to precipitate aluminium hydroxide. The silicate ions remain dissolved in
solution.
2[Al(OH)4]-(aq) + CO2(g) 2Al(OH)3(s) + CO32-(aq) + H2O(l) .
The aluminium hydroxide is filtered, washed and heated to form pure alumina, Al2O3.
2Al(OH)3(s) Al2O3(s) + 3H2O(g) .
Alumina is first dissolved in molten cryolite, Na3AlF6, and fluorspar, CaF2, and is then
electrolyzed. Electrolysis of pure alumina is too expensive since very high temperatures are
needed to melt it. Introducing the two fluorides allows a much lower temperature of about 950oC
to be used.

The overall reactions occurring at the electrodes are as follows:AT THE CATHODE:
AT THE ANODE:

Al3+(l) + 3e Al(l).
2O2-(l) O2(g) + 4e.

Aluminium formed is molten as the temperature of the cell is above the melting point of
aluminium. It sinks to the bottom of the cell and is run off and allowed to cool. The aluminium
obtained is exceptionally pure, being at least 99.9% aluminium.
At the high temperatures used the carbon anode burns away in the oxygen to form carbon
dioxide and carbon monoxide gases and must be replaced frequently. Apart from the replacement
of the anode, the process is continuous, alumina being added regularly to the cell and molten
aluminium being siphoned off.

USES OF ALUMINIUM
Aluminium is light, strong, has low density and is resistant to corrosion. It also has useful
thermal properties such as being a good thermal conductor which allows for it to be used to make
cooking utensils. It can also act as a thermal insulator as it is good at reflecting radiant heat and
light. This allows for its use in coating firefighters garments which reflect heat from the fire to

keep the firefighter cool. This insulating property is sometimes used in hospitals to keep newborn
babies warm. It is also used to make mirrors and reflecting telescope lens.
Aluminium is widely used in transport for making the body of aeroplanes, trains, buses, cars
engines and bodies. It is used to make double-glazed window frames and in overhead electrical
power lines.
It is used to make foil used to package food and cans for soft drink. Aluminium metal is very
reactive so when it is exposed to air a layer of aluminium oxide rapidly forms on the surface of
the metal. This layer prevents the rest of the metal from reacting which allows it to be safe for
use around food. Aluminium metal cans will not dissolve in the drinks they contain nor will
aeroplanes dissolve in water when they fly through a rain cloud.

IMPACT OF ALUMINIUM ON THE ENVIRONMENT

Approximately one tonne of red mud residue must be disposed for each tonne of aluminium
oxide is produced. The caustic residue can percolate into the underground water of local areas.
This can significantly increase the sodium concentration and pH of the water. Sodium is known
to be associated with higher cases of hypertension.
Fluoride gases are also produced from the electrolyte during the process. Although about 98% of
these gases are scrubbed out and recycled, the 2% that escape into the atmosphere slowly

accumulate in the environment and can cause damage to plants many kilometers away. Fluorides
can also enter the food chain as livestock graze on grass exposed to it. The symptoms of fluoride
damage in animals and humans include dental mottling, stiffness in knees and joints, anaemia
and respiratory distress.
The economical disposal of use of carbon cell linings remains a problem. The linings contain
highly alkaline bath, aluminium carbide, cyanides and other materials. A small part is ground and
added to cement kilns as a source of fluoride, but most still end up in landfills. Exposure to coal
tar pitch volatiles from the carbon electrodes and cryolite are associated with increased risk of
bladder and lung cancer.
Aluminium smelting requires an enormous amount of electricity since 3 moles of electrons are
needed to discharge 1 mole of aluminium. A modern smelter pot is typically 10 meters long, 4
meters wide and 1.5 meters high and take about 15 000 kilowatt hours of electricity to produce
about 1 tonne of aluminium per day. There are about 100 of these pots in a room, thus the cost of
electricity is central to the economics of the process. Smelting generally takes place in areas
where electricity is cheap and abundant. This is usually done in places where hydroelectric
power is available. Pollution caused by power generation depends on how the electricity is
generated.