---
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.

 

 

 

 

 

 

 

 ## Aluminium is the third most abundant element in the Earth’s crust, but it doesn’t occur as a metal naturally.

#### Bell Bay Aluminium works in smelting: the final step of aluminium’s journey from bauxite to a final product.  

 

 

 

 

 

 

 

  ![Add Bath & Alumina](https://bellbayaluminium.com.au/volumes/images/content/Our-Aluminium/bauxite.png)### 1. Bauxite mining  

The first step in producing aluminium is mining its ore – bauxite. Mined land is rehabilitated once the  
bauxite is extracted from the surface.

 

  

 ![Add Bath & Alumina](https://bellbayaluminium.com.au/volumes/images/content/Our-Aluminium/alumina.png)### 2. Alumina refining  

Alumina is a white granular material – also called aluminium oxide. Approximately two tonnes of alumina are required for every tonne of aluminium produced.

 

  

 ![Add Bath & Alumina](https://bellbayaluminium.com.au/volumes/images/content/Our-Aluminium/ingot.png)### 3. Aluminium smelting

Smelting is where aluminium is extracted from alumina and cast into products. Like most smelters, Bell Bay Aluminium uses the **Hall-Héroult process**.

 

 

 

 

 ## The smelting process

 

 

 

 

 

 

 

  ![Add Bath & Alumina](https://bellbayaluminium.com.au/volumes/images/content/Our-Aluminium/smelting-add-bath.gif)### Add Bath & Alumina

In a large rectangular cell, known as a “pot”, alumina is dissolved in a bath of molten cryolite and other materials.

 

  

 ![Add Bath & Alumina](https://bellbayaluminium.com.au/volumes/images/content/Our-Aluminium/smelting-anode.gif)### Anode

Carbon blocks, called anodes, are suspended to conduct electricity through the row of pots, called the “potline”.

 

  

 ![Add Bath & Alumina](https://bellbayaluminium.com.au/volumes/images/content/Our-Aluminium/smelting-electrolysis.gif)### Electrolysis 

An electric current flows through the potline, with temperatures of 950°C splitting the alumina into aluminium and oxygen.

 

  

 ![Add Bath & Alumina](https://bellbayaluminium.com.au/volumes/images/content/Our-Aluminium/smelting-tapping.gif)### Tapping

At regular intervals, molten aluminium is tapped from the pots and transported to the casthouse.

 

  

 ![Add Bath & Alumina](https://bellbayaluminium.com.au/volumes/images/content/Our-Aluminium/smelting-casting.gif)### Casting

Aluminium is cast into its final form: at Bell Bay Aluminium, that’s ingot, T-bar and rolling block products.