ALUMINIUM

 Aluminium occurs in abundance in the surface of the earth. It is available

in various forms such as oxides, sulphates, silicates, phosphates, etc. but
is commercially produced mainly from bauxite.
 In nature, Aluminium is found only in chemical compounds with other
elements such as sulphur, silicon and oxygen.
 Pure, metallic aluminium can be economically produced only form
aluminium oxide ore.
 Occurs in all types of clay.

MANUFACTURING PROCESS OF ALUMINIUM

 The production of 1 kg aluminium requires about 2 kg of alumina
 The production of 1 kg of alumina requires 2 kg of bauxite.
 Therefore, to obtain a kg of aluminium, 4kg of bauxite is required
 There are two main processes in the manufacture of aluminium
1. Bayer’s Process – for converting aluminium ore to alumina
2. Hall-Heroult’s Process – for converting alumina into pure
aluminium
Bayer’s Process

 First, the bauxite ore is mechanically crushed. Then, the crushed ore is
mixed with caustic soda and processed in a grinding mill to produce a
slurry (a watery suspension) containing very fine particles of ore.
 The slurry is pumped into a digester, a tank that functions like a pressure
cooker. The slurry is heated to 230-520°F (110-270°C) under high
pressure. These conditions are maintained for a time ranging from half
an hour to several hours.
 The hot slurry, which is now a sodium aluminate solution, passes
through a series of flash tanks that reduce the pressure and recover
heat.
 The slurry is pumped into a settling tank. As the slurry rests in this tank,
impurities that will not dissolve in the caustic soda settle to the bottom
of the vessel.
 This process can be compared to fine sand settling to the bottom of a
glass of sugar water; the sugar does not settle out because it is dissolved
in the water, just as the aluminium in the settling tank remains dissolved
in the caustic soda.
  The filtered liquid is pumped through a series of six-story-tall
precipitation tanks. Seed crystals of alumina hydrate (alumina bonded to
water molecules) are added through the top of each tank.
 The crystals precipitate (settle to the bottom of the tank) and are
removed. After washing, they are transferred to a kiln for calcinating.
 A temperature of 2,000° F (1,100° C) drives off the water molecules,
leaving anhydrous (waterless) alumina crystals.

Hall- Heroult’s Process

 Conversion of alumina into metallic aluminium takes place in a reduction
pot.
 The bottom is lined with carbon which acts as one electrode, and the
opposite electrodes are a set of carbon rods suspended above the pot.
 The molten aluminium when separated due to the reaction settles at the
bottom of the pot and is extracted through the plug.
 A typical smelting plant consists of two or more potlines.

 Manufactured aluminium id obtained in many forms such as Smelted

grade, Calcined, Low soda, Reactive, Tabular, etc.

CONVERSION OF ALUMINIUM INTO MARKET FORMS

Aluminium is generally casted into usable and available market forms after its
manufactured and obtained in its pure form.
 Casting is the original and most widely used method of forming
aluminium into products. 
  Molten aluminium is poured into a mold to duplicate a desired pattern.
 The three most important methods are die casting, permanent mold casting
and sand casting.
1. Die casting
 The die casting process forces molten aluminium into a steel die
(mold) under pressure. 
 This manufacturing technique is normally used for high-volume
production. Precisely formed aluminium parts requiring a minimum
of machining and finishing can be produced through this casting
method.

2. Permanent mold casting

 Permanent mold casting involves molds and cores of steel or
other metal.
 Molten aluminium is usually poured into the mold, although a
vacuum is sometimes applied. 
 Permanent mold castings can be made stronger than either die or
sand castings.
 3. Sand casting
 The most versatile method for producing aluminium products is
sand casting. The process starts with a pattern that is a replica of
the finished casting.

ALUMINIUM MANUFACTURING COMPANIES IN INDIA

 Bharat Aluminium Company Limited (BACL): ...
 Madras Aluminium Company: ...
 Indian Aluminium Company Limited (IACL)
 HINDALCO: ...
 STERLITE: ...
 NALCO