How aluminum is made
Aluminum is the most abundant metal in the Earth's crust. It makes up about 8% by weight of the Earth's solid surface. The highest concentration of aluminum oxide is found in the ore bauxite. Pure aluminum is obtained by extracting alumina from the bauxite. Employing an electrolytic bath, 1 kg of pure aluminum is obtained out of 1,9 kg alumina.
Although aluminum is the most abundant metal on earth, it is rarely found in its basic, elemental state. It's found in many minerals, the most commonly used being bauxite. The major industrial process for extracting aluminum is the Hall-Héroult process, which includes an electrolytic bath. The process requires a lot of energy and therefore most companies are using recycled aluminum, which only requires about 5% of the energy required to make aluminum from scratch.