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Aluminium – Sustainability Information Aluminum Sustainability Information July 2020 Aluminium – Sustainability Information 2 AT A GLANCE cess ro ing mina fa P lu ct A o r ining 350 Mt y M A 304 Mt Run-of-mine ore Bauxite 525 Mt Mass movement lumi wertu A n r n u e g m V 127 Mt s 2 – 9 Mio. t Alumin m Alumina e l t industrial e 176 Mio. t raw r Red mud material ca. 40 Mt l-sup A p Tailings l 175 Mt 59 Mt y tailings primary alumi- and spoil 73 Mt nium CO cyclin 2 2 e g 40 – 50 km /a land use R Greenhouse gas emissions 1.080 Mt CO 2 14,4 Mt Secondary Fig. 1: : Calculated mass flows in aluminium production and principal effects on the environment, data from 2017 [1]. • Most of aluminium‘s added value comes from processing the bauxite ore and not from mining. The principal bauxite producers are Australia, China and Guinea; the largest primary aluminium producers are China, Russia, Canada and India. • Bauxitedepositsarethinandshallow.Miningthereforehasalargespecificlandrequirement.However, for the same reasons, the excavated land is relatively simple to recultivate. • Aluminium production is extremely expensive in terms of energy. The true primary energy consumption in the production chain, and therefore the CO2 emissions depend on the status of the adopted technology and, to a greater extent, on the available primary energy mix. • Due to the relatively low energy costs (only 5 % compared to primary aluminium) aluminium recycling plays an important role, but the majority of the aluminium used in vehicles and infrastructure is not yet available for recycling. • LanduseconflictsinongoingorplannedprojectshavebeenreportedfromGuinea,Brazil,India, Ghana and Vietnam. • In the Aluminium Stewardship Initiative (ASI), more than 100 companies in the added value chain have committed to adhere to sustainability standards and their review. CONTENT 1 Aluminium‘s Relevance p. 3 2 From Deposit to Metal p. 3 3 Recycling p. 7 4 Sustainability Aspects of Mining p. 7 5 Sustainability Aspects of Processing p. 10 Aluminium – Sustainability Information 3 1 RELEVANCE rock is weathered that the aluminium is enriched in concentrations that are worth mining. AT A GLANCE Aluminium is a silvery-white light metal which, due to its material properties – high electrical and Bauxiteisaresidualrockformedfromtheweathering thermal conductivity, low density, high resistance to ofavarietyofrocks,generallyigneous.Thesesource environmental influences, high strength-to-weight rocks were exposed to weathering over long periods ratio – is used in Germany in particular in construction (millions of years) under tropical, subtropical or very (15 %), automotive and aircraft engineering (48 %), in humid, temperate conditions. Today, 90% of known the mechanical engineering and electrical engineering global bauxite deposits are located in tropical or fields (14%), and as packaging material (10%) [1]. subtropical countries. With a consumption of 2.1 Mt worldwide, Germany is the third largest consumer of primary aluminium after The largest deposits of bauxite are located in Central China(33.3Mt)andtheUSA(4.6Mt)[2]. and South America, in West Africa, especially in Guinea, as well as in India, China, Vietnam and In the transport sector, the light metal aluminium Australia. Some occurrences are also known from reduces vehicle weights. The level of development of northern Russia, the Mediterranean region and today‘s aircraft industry and in aviation would otherwise Saudi Arabia. The currently estimated global bauxite beimpossibletoachieve.100kilogramslesscarweight, resource is more than 70 billion tonnes. The greatest so says the car designers‘ rule of thumb, reduces fuel concentration of deposits is in located Guinea, where consumptionfor100kmofdrivingbyuptohalfalitre there are proven resources of around 25 billion tonnes of fuel, which corresponds to an emission saving of [4].Thealuminiumcontentinthedepositsisdifferently approx. 11 g CO2 per km. In automotive engineering distributed regionally. The deposits in Indonesia and the transition from a steel body to an aluminium Australia have an average aluminium oxide content bodysavesaround150kginweight[3].Accordingto of approx. 40 %, in America and the Caribbean the one automobile manufacturer, the increased energy levels are approx. 48 % and the highest levels, at 53 %, consumptionrequiredtoproducealuminiumwouldbe are found in West Africa. Australia has extremely rich compensated for by the fuel savings after about 60 – 80 bauxite deposits in the north, which mainly produce thousandkm, but only if renewable or CO2-neutral bauxite for export. The deposits in the south of Australia, energy sources were used as primary energy sources in contrast, are regarded more as the „poor“ deposits in aluminium production. and are predominantly processed domestically. The global average content of metallurgical – i.e. used for The parent rock, bauxite, is not only exploited for aluminium production – bauxite is approximately 45 % aluminium production, but also for other purposes, aluminium oxide. in particular for Portland cement, proppants and the refractory industry, as well as for abrasives and mineral The aluminium content of the bauxite ore is a decisive wool. In 2015 approx. 12 Mt of bauxite were used factorfortheeffort(e.g.energyexpenditure)necessary globally for these purposes. for further processing the bauxite in an alumina plant in order to produce alumina from it. For this reason, mainly high-quality bauxite ores from Guinea, Liberia 2 FROM DEPOSIT TO METAL and Northern Australia are imported into Germany. In principle, the karst-bauxite districts are distinguished Aluminiumisextractedfrombauxiteore,whichisfirst from the laterite-bauxite districts (Fig. 2). Compared leached in order to produce the raw material aluminium to the lateritic deposits, the karst bauxite deposits oxide,alsoknownasalumina,usingtheBayerprocess. are usually smaller, but due to their higher aluminium The alumina is then converted into pure aluminium in a oxide content they have a more favourable – because primaryaluminiumsmelterusingmeltfluxelectrolysis, reduced – bauxite-to-alumina ratio. In the long term, the inwhatisknownastheHall-Héroultprocess. proportion of bauxite production from karst deposits, which in 1996 was approx. 20 % of total production has been reduced to a few percent today. 2.1 Geology Althoughaluminiumisthethirdmostfrequentelement 2.2 Mining involved in the structure of the earth‘s crust, it is not sufficientlyenrichedinprimaryrockstobeeconomically Many bauxite deposits are shallow and horizontal, extracted from them. It is only when the primary with only 0.5 to 1 m cover. Typical bauxite deposit Aluminium – Sustainability Information 4 CENTRAL URAL Timann (Rusal), Rank 10 ARABIA Sangaredi (Gov. of Guinea, CENTRAL Guinea), Rank 3 CHINA CARIBBEAN Pingguo (Chinalco), Rank 7 MRN (Vale), Weipa (Rio Tinto), Al Ba´itha Rank 4 Rank 2 (SA Mining Co.), Paragominas Rank 9 Juruti (Alcoa), (Norsk Hydro), Rank 8 Rank 5 Gove (Rio Tinto), Rank 6 SOUTH Darling Range (Alcoa), AMERICA Rank 1 WEST AND CENTRAL AFRIKA SOUTH ASIA AND OCEANIA Laterite bauxite Distrikt Karst bauxite Distrikt Fig. 2: The 10 largest bauxite producers and locations of the bauxite provinces and districts, (modified after [17] and [19]). thicknesses are between 2m and 10m. Due to the In 2018 Australia (96.5 Mt) was the world‘s largest stratigraphic relationships, bauxite is almost exclusively bauxite producer, followed by China (79 Mt) and Guinea extracted in open-cast mining. (59.5Mt)[2].ThelargestaluminaproducersareChina (69Mt),Australia(20Mt)andBrazil(11Mt).Together, The bauxite from many deposits can be processed these 3 countries produced three quarters of the directly as raw ore in alumina plants, also called alumina produced worldwide in 2017. In the same year, refineries, without further treatment. In some cases, China (32 Mt) was also the largest primary aluminium however, the bauxite ore must be upgraded in a washing producer with almost half of global production, followed plant where the aluminium oxide content of the raw ore is by Russia (4Mt), Canada (3Mt) and India (2Mt) [4]. increased by removing accompanying clays and silicate Although the demand for aluminium is increasing nodules. Typical bauxites consist of approximately 45 % rapidly, the known bauxite reserves are sufficient to aluminium oxides. In addition, bauxite also contains meet global demand for aluminium for many centuries. iron, silicon and other minerals. The mineralogical composition of the bauxite is important because it Aluminium is mainly produced by vertically integrated, influences process engineering and the metallurgical internationally positioned, specialised raw material results in the production of alumina. groups. „Vertically integrated“ means that both bauxite mining and its processing (alumina and aluminium In 2018, 342.5 Mt of bauxite were mined worldwide production) are under the control of a single company. and were processed into 130.5 Mt of aluminium oxide In the case of Rio Tinto, South32 and Vale, they may (Al2O3). From this, 62.6 Mt of primary aluminium were also be more broadly based conglomerates that mine extracted. The global ratio of bauxite to alumina to avarietyofrawmaterials.Themarketleaderalongside primary aluminium calculated from this is 5.2 t of bauxite Rio Tinto is the Alcoa group, which specialises in : 2.2 t alumina : 1 t primary aluminium. Deviations producingandmarketingaluminiumonly.Itcanbeseen from these averages can be explained by variations that a relatively large number of the major aluminium in the
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