---
title: Our aluminium
date: 2023-01-17T15:55:00+11:00
author: Walker Designs
canonical_url: "https://bellbayaluminium.com.au/our-aluminium"
section: Site Content
---
![Our aluminium](https://bellbayaluminium.com.au/volumes/images/Banners/_3500x2000_crop_center-center_none/our-aluminium.jpg) 

 # Our aluminium

Starting as Bauxite in the earth to becoming the panels on an aircraft, discover how our aluminium is processed and where our metal goes.

 

 

 

 1. [ Home](https://bellbayaluminium.com.au/)
2. [About](https://bellbayaluminium.com.au/about)
3. Our aluminium
 
 

 

 

 ## Aluminium is one of the most sought-after metals in the world. It is light, strong, flexible, non-corrosive and infinitely recyclable.

In a world with evolving customer demand and a focus on sustainability and durability, aluminium is now - more than ever - the metal of the future. Australia is the world’s fifth largest producer of aluminium, known for global best practice for electricity efficiency and controlling greenhouse emissions during production.

### Bell Bay Aluminium produces ingot, T-bar and rolling block aluminium products.

 

 

 

### Exported around the world

More than 90% of our produce is exported, primarily to southeast Asia, east Asia and India.

### Trusted by our customers

We have relationships spanning decades with customers who trust in the quality of our aluminium.

### Multiple industry applications

Our metal is custom cast for use in the transport, construction, packaging and electrical industries.

 

 

 

 

 

 

 

 ## How Aluminium is made

 

 

 

 [ Download the Flyer ](https://bellbayaluminium.com.au/volumes/documents/Publications/How-Aluminium-is-made-DLFlyer.pdf) 

 

 

 

 

 

 

 

  ![How aluminium is made graphic2](https://bellbayaluminium.com.au/volumes/images/content/Our-Aluminium/_3500x979_fit_center-center_70_none_ffffff/33377/how-aluminium-is-made-graphic2.webp) 

 

 

 

 

 

 

 

 ## 1.

Aluminium begins its life as bauxite, the third most abundant element in the Earth’s crust. Mined in Weipa, North Queensland, ore-bauxite is shipped to  
Rio Tinto Yarwun and Queensland Alumina in Gladstone for refining into alumina (Al2O3).

 

  

## 2.

The fine white alumina powder (Al2O3) is shipped to Bell Bay Aluminium (BBA) every five weeks. It takes 4 tonnes of bauxite to produce 2 tonnes of alumina, which yields 1 tonne of aluminium.

 

  

## 3.

Alumina is transformed into aluminium through smelting - the electrical current flows in the reduction cell through carbon blocks called anodes to the cathodes at the bottom of the cell. Anodes are made on site from petroleum coke, liquid pitch and recycled carbon anodes, returned from the reduction process.

 

  

## 4.

The raw materials are mixed and formed into carbon anodes weighing about 545 kilograms. Anodes are baked at up to 1,200ºC for up to 14 days to improve the strength and conductivity.

 

  

## 5.

Baked anodes are attached to copper rods with molten cast iron transported via an overhead conveyor and delivered to the cells using an Anode Transport Vehicle (ATV).

 

  

## 6.

The smelter uses two Dry Scrubbers to remove over 99% of fluoride gases and dust from process emissions.

 

  

## 7.

Chemical reduction of alumina to aluminium takes place in individual cells or pots connected to an electrical circuit. The smelter has 558 cells or pots across three Potlines (Lines 2, 3 & 4) housed in buildings 600m long, using Kaiser P57 technology.

 

  

## 8.

Line 1 at Bell Bay closed on 26 August 1981.

 

  

## 9.

Electricity is supplied via two transmission lines supplying 355 megawatts. Rectiformers convert Alternating Current (AC) to Direct Current (DC) to power the Potlines up to 1020 volts. Each Potline operates at around 125,000 amps.   
Cells contains 20 anodes which are gradually consumed during the smelting process. The remaining anode butts are recycled back into the carbon plant.

 

  

## 10.

Crucibles suspended from overhead cranes siphon molten aluminium from the cells in the Potlines.

 

  

## 11.

Metal delivery vehicles transport the molten aluminium to furnaces in the Casthouse, where the metal is held in furnaces and alloyed prior to being cast.

 

  

## 12.

40% of aluminium is cast in moulds as 8, 12 or 22 kilogram ingots cooled in water troughs and bundled into 1 tonne stacks.

 

  

## 13.

55% is cast as rolling block or T-bar using vertical direct chill (VDC) technology. The metal is chilled instantly, first using air and then water. Block is cast up to 6 metres in length and weighs up to 14 tonnes. 5% of hot metal is transported on an internal road to Kymera International at Bell Bay.

 

  

## 14.

Aluminium is transported by train to Burnie from Bell Bay for shipping to Melbourne and overseas. Some products are shipped directly from Bell Bay via TasPorts. Most of BBA’s aluminium is exported to Asia, with around 10% used domestically Kymera International and Bluescope.