Aluminum: Abundance, Extraction from Bauxite, and the Properties That Make It a Highly Valuable Industrial Metal
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| Aluminum |
Aluminum is the third most abundant element in the
Earth's crust after oxygen and silicon. While abundant, it is never found in
its pure form in nature due to its high affinity for oxygen and chlorine.
Instead, it is always found combined with other elements such as oxygen,
silicon, and fluorine. The two most common minerals are bauxite and cryolite.
Bauxite consists primarily of aluminum hydroxides and oxides along with
silicates and iron oxides. It is the primary ore used for commercial
production.
Extraction from Bauxite
To extract it from bauxite, the Bayer process is employed. In this process,
bauxite is digested using a hot sodium hydroxide solution under high pressure.
This results in the formation of its hydrate along with small amounts of
impurities. The hydrate is then separated by filtration before being calcined
to produce its oxide. Finally, the oxide goes through an electrolytic process
known as the Hall-Héroult process where it is smelted using an electrolytic
reduction to produce metallic aluminum. This electrolytic process requires
enormous amounts of electricity making it an energy-intensive metal to produce.
Properties Making It Highly Valuable
There are several properties of it that make it a highly valuable metal with
many industrial uses. Firstly, despite being so widely available, it is
lightweight with a density of only about one-third that of steel. This makes it
useful for applications where weight is an important consideration like
aircraft construction. Additionally, it is highly ductile and malleable
allowing it to be cast or worked into various shapes. It is also resistant to
corrosion due to the thin oxide layer that forms on its surface. It does not
rust the way iron does. It is non-toxic and recyclable without losing its
properties.
Major Applications
Transportation
With its high strength to weight ratio, it finds widespread use in
transportation. Airplanes use its alloys for their lightweight frames that
allow for increased fuel efficiency. Automobiles are also utilizing more Aluminum
in bodies, chassis and engine components to reduce weight and increase fuel
economy.
Packaging
Thin aluminum foil and composite packaging materials are extensively used
for food packaging, pharmaceuticals, beverages and other consumer products due
to its barrier properties and recyclability. It cans are popular as they are
lightweight and allow lever-top opening for drinks on the go.
Construction
Its extrusions and panels go into construction of buildings where
non-corrosive and durable cladding properties are required. Its alloy window
and door frames provide strength and energy efficiency. It is also utilized in
prefabricated structures, roofing and curtain wall applications.
Electrical
As a good conductor of electricity, it sees wide utilization in power
transmission lines, cables and welding electrodes. Its resistance to corrosion
makes it suitable for use even in marine environments. Its alloy busbars help
distribute high amperage loads in industrial equipment.
Other Applications
It is useful in heat exchangers (due to conductivity), lithographic plates
(due to anodizing), foils (due to malleability), pipes and tubing. Common
household products contain aluminum in cooking utensils, ladders and lawn
furniture for their combination of strength, workability and resistance to
corrosion.
Future Growth Prospects of the Industry
With increasing global focus on sustainability and reduction of carbon
footprint, its usage is expected to grow in the future. Lightweighting of
vehicles using it will improve fuel efficiency supporting emission reduction
targets. It is infinitely recyclable and recycling it consumes only 5% of the
energy used to produce primary aluminum, benefitting the circular economy. Many
nations have set recycling targets for beverage cans which will drive further
demand. Expanding use of green building materials will uplift its shares in the
construction sector. Investments in renewable energy infrastructure will boost
demand from the power industry. Overall the outlook for it remains positive
underpinned by its versatile properties and sustainability edge over competing
materials. Emerging innovations around its ion batteries also holds promise for
new growth prospects.
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