ALUMINIUM

Extraction and uses

BACKGROUND

Aluminium is the most common metal in the Earths crust.

It comprises approximately 7.5% of the crust by mass.

Aluminium is very reactive and is found in a range of oxide,

hydroxide and silicate minerals.

THE REACTIVITY SERIES

Aluminium is higher than carbon in the reactivity series so

cannot be extracted by carbon reduction, unlike less reactive
metals such as zinc, iron and lead.

For those metals above carbon, electrolysis is used.

 ELECTROLYSIS

Electricity Lyse/lysis
meaning to move

For electrolysis we need a system we can pass a current

through.
What is current?

A strict definition would say that current is a flow of electrical

charge through a conductor. The important point for electrolysis
is that this charge may be as electrons or as charged ions.
 What systems can undergo electrolysis?

1. Aqueous solutions of ions

Aluminium compounds found in ores that are very

insoluble as we shall see later. This means that
dissolving isnt an option.

2. Melting the ore to produce a molten liquid

Molten liquids can produce ions that may be

separated. This is used for aluminium.
 The process of aluminium electrolysis is not new:

The present industrial method of production was

discovered simultaneously and independently in 1886
by Paul-Louis Hroult in France and Charles Hall of the
United States. Their method is the basis for the world
aluminium industry today

Before we look at the ores, we should look at

the main features of processing plants ..
 LYNEMOUTH, just north of Newcastle, is one of two primary
Aluminium production plants in the UK. There is another on
Anglesey in N. Wales.

Electrolysis plant and

rolling mills

Waste residues, largely Coal-fired power

iron oxides station dedicated
to the plant

Can you identify the three main features marked?

There are a number of secondary aluminium plants in the UK
where waste aluminium is separated, smelted and recovered.
This plant is near Fort William in Scotland.

Water from reservoir below

Hydroelectric power Ben Nevis
station
Smelting and
electrolysis plant
with rolling mills

Again, can you see the two main features not waste this time!
 Aluminium Ore

BAUXITE
Bauxite is not a single composition, more a range
of hydrated aluminium oxides and hydroxides.

It is found as a weathering
product in soils in hot
sub-tropical and tropical
climates.

Main resources are in N. Africa,

S. America, SE Asia and N.
Australia
Typical mining operations for bauxite
 The chemistry of bauxite processing

The complex mixture that makes up bauxite is first processed

to produce pure aluminium oxide, alumina (Al2O3)
(For GCSE you do not need to know how, however this
Is a requirement for AS/A2)

So we need molten alumina to do electrolysis .

..however, this would require a temperature over 2072oC,

the melting point of alumina. This is far too high for an
economic process.

Alumina is melted in another chemical, cryolite (Na 3AlF6),

which lowers the melting point to around 1000oC.
 The electrolysis process for aluminium

Draw this, noting the bubbles. We will discuss the chemistry of these
later. Note the tap hole for molten aluminium. This is a CONTINUOUS proc
 Keeping the electrolysis cell molten

The energy to keep the alumina and cryolite molten comes

from a 100000A current flowing through the 6V electrolysis cell.
The energy to provide the initial melting is enormous so these
run continuously for many years before finally being taken out
of service.
 Aluminium Electrolysis Chemistry

The negative cathode, around the edges of the cell, attracts the
positively charged aluminium ions. These gain electrons and
aluminium which fall to the base of the tank as molten metal

Al3+(l) + 3e- => Al(l)

The positively charged anode, as blocks in the surface of the cell,
Attracts the negatively charged oxide ions..

2O2-(l) => O2(g) + 4e-

Oxygen is not evolved though. This process is at 1000oC with a carbon
anode. This anode burns away producing carbon dioxide. This is the gas
given off from the process. The carbon anodes need regular
replacement to keep the cells operational.
 Watch the TV/Video

Link your knowledge of the process

to what it looks like in real life!
 ANODISING ALUMINIUM

Aluminium is very unreactive for a metal so high up the

reactivity series. This is due to the ease with which it forms a
protective oxide layer. Anodising makes this oxide layer even
stronger.

Step 1. The original oxide layer is removed with sodium

hydroxide.

Step 2. The aluminium is made into the anode in dilute

sulphuric acid. Any metal can make the cathode but
usually this is made of aluminium as well.

Step 3. Oxygen, evolved at the anode, reacts with the

aluminium to form a 0.02mm oxide film. Much thicker than
before anodising.

Step 4. At this stage, the oxide is porous and dyes can be added.
Further treatment makes the oxide solid and resistant.
 Examples of anodised aluminium.

Benefits of anodised aluminium

1. Increased corrosion resistance.

2. Dyed products available
 Uses of aluminium

Aluminium is low density, strong, a good conductor of heat and

good conductor of electricity.

1. Electricity cables along overhead pylons.

2. Aircraft industry

3. Vehicles particularly where weight is an issue eg. Trams,

trains etc.

4. Cooking pans this includes the appearance of the metal as

a factor in choice, to complement the low density, strength and
heat conducting aspects.

Examples of anodised aluminium are now also seen in many

applications.