Bauxite Mining
Bauxite is the primary ore from which aluminium metal is extracted.
Australia has the second largest reserves of bauxite in the world and is currently the world’s largest producer (100 Mt in 2022).
Once the bauxite is mined from the surface, the land is rehabilitated.
Alumina Refining
Alumina refineries process bauxite ore to produce alumina, which is then used to extract aluminium metal.
Australia is the second largest producer of alumina in the world (20.3 Mt in 2022).
Aluminium Smelting
Aluminium smelters use an electrolytic process to extract aluminium metal from alumina.
Australia is currently the sixth largest producer of primary aluminium (1.51 Mt in 2022).
Semi Fabrication and Products
Aluminium can be formed into a variety of products by extruding, rolling or casting. Australian operators provide products to key sectors of the market, including the construction, automotive and packaging sectors. Production of aluminium products by A.A.C. members was 72,215 tonnes in 2022.
Recycling
Aluminium is infinitely recyclable without any loss of its unique properties. Aluminium scrap is of high value, which is a key incentive for recycling and is why nearly 75 per cent of aluminium ever produced is still in use today. Globally, aluminium recycling rates tend to be high in transport and construction, and around 70 per cent for beverage cans.
Bauxite Mining
Bauxite in Australia is almost always found near the surface and is generally extracted using open cast (surface) mining. The processes involved include land clearing, removal of overburden where required, transport, and crushing. Inputs generally include energy in the form of transport fuels, electricity for crushers and conveyors, and water (for those mines which use beneficiation).
Alumina Refining
All Australian alumina refineries use the Bayer Process to extract alumina from bauxite. Inputs typically include caustic soda, energy in the form of gas or coal (to produce the required heat and steam for the process), flocculants (to assist the sedimentation process), and water (to recover the caustic soda for reuse).
Aluminium Smelting
Inputs into the primary aluminium smelting process include: alumina, cryolite (or bath – in which the alumina is dissolved at high temperature), coke and pitch (to form the anodes), refractory materials, graphitic cathodes, and electricity.
Semi Fabrication and Products
Downstream products and semi-fabrication use aluminium metal, energy and fuels.
Recycling Aluminium
Recycling uses both old and new scrap, as well as energy, although recycling uses only 5% of the energy it takes to produce primary aluminium.
Bauxite Mining
About two thirds of the bauxite mined in Australia is used locally to produce alumina. In 2020 approximately 37 Mt of Australia’s bauxite production was exported – valued at around $1.3 Billion.
Total production in 2020 was estimated to be 102 Mt.
Alumina Refining
Around 85 per cent of the alumina produced in Australia annually is exported to smelters around the world. In 2020, 18 Mt of alumina with a value of approximately $6.3 billion was exported.
Total production in 2020 was 21.2 Mt.
Aluminium Smelting
More than 90 per cent of Australia’s primary aluminium metal production is also exported. In 2020, 1.43 Mt of aluminium was exported valued at approximately $3.6 billion.
Total production in 2020 was 1.59 Mt.
Semi Fabrication and Products
No data
Recycling Aluminium
In 2020, 0.3 Mt of aluminium scrap was exported, valued at approximately $495 million.
