Aluminium Production through Electrolytic Reduction

This report provides an exhaustive cost evaluation of Aluminium production process through electrolytic reduction. In this process, bauxites are mined from the ground and further processed to make alumina or aluminum oxide using Bayer’s process. In Bayer’s process, the crystallized aluminum hydrate found in the bauxite is dissolved in the concentrated caustic soda at higher temperatures.

When the temperature is decreased, and the concentration of the solution is increased again, the aluminum hydrate crystallizes, leaving behind the other elements undissolved, which are then removed. The thus obtained crystallized aluminum hydrate particles are dried and calcined, i.e., heated till the water is removed to obtain alumina.

The alumina is mixed with cryolite which provides a conducive environment and is sent to the reduction cells for the electrolytic reduction of alumina into aluminum. The molten aluminum is then sent to the cast house, where the aluminum is remelted to remove the other impurities. The resultant pure aluminum is stored in molds where it solidifies.

The project economic analysis provided in the report discusses a Germany-based plant:

• Manufacturing Process
  • Process Flow
  • Material Flow
  • Material Balance
• Raw Material and Product's Specifications
  • Raw Material Consumption
  • Product and Co-Product Generation
  • Capital Investment
• Land and Site Cost
  • Offsites/Civil Works
  • Equipment Cost
  • Auxiliary Equipment Cost
  • Contingency
  • Engineering and Consulting Charges
  • Working Capital
• Variable Cost
  • Raw Material
  • Utilities
• Fixed Cost
  • Labor Requirement & Wages
  • Overhead Expenses
  • Maintenance Charges
• Financing Costs
  • Interest on Working Capital
  • Interest on Loans
• Depreciation Charges
• General Sales and Admin Costs
• Production Cost Summary