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Bauxite Processing An employee at the Alcoa San Ciprian, Spain, plant examines a conveyor belt full of bauxite, the ore from which alumina is refined. Alumina is then transported to a smelter where it is processed to yield aluminum.
The Deschambault Smelter An old anode is removed from a pot line furnace.
Bauxite Mining Alcoa signed an agreement with the Government of Guinea that sets forth the framework for developing a jointly owned, 1.5-million-mtpy alumina refinery in the country.
Alumina Refinery Pinjarra is one of the most successful and cost efficient alumina refineries in the world and currently produces about 7 per cent of the world’s alumina.
Bauxite Processing The Maranhão Aluminum Consortium (Consórcio de Alumínio do Maranhão, also known as Alumar) is one of the world’s largest aluminum and alumina production complexes. Alcoa holds a stake in the two main businesses of the undertaking: the Reduction Plant and the Refinery. The Refinery produces alumina from bauxite. At the Reduction Plant, alumina is electrolytically processed into primary aluminum.
Bauxite Mining Bauxite mining and reforestation in Western Australia.
Alumina Delivery The Pine Arrow docked March 2007 in Reydarfjordur, Iceland with the first alumina shipment for the Alcoa Fjardaál smelter.
Alumina Delivery Vessel loaded with alumina about to head for the world market.
Smelter Potroom Potline in the São Luis smelter, Alumar, in Brazil.
Bauxite Mining One of two bauxite mines in Western Australia, the Huntly mine, established in the early 1970's to supply the Pinjarra refinery, now also supplies the ore for Kwinana. This expanded capacity makes Huntly the biggest bauxite mine in the world.
Bauxite Processing Pinjarra is one of the most successful and cost efficient alumina refineries in the world and currently produces about 7 per cent of the world’s alumina.
Smelter Potroom The Point Henry Smelter near Geelong, Australia, has a capacity of 185,000 tonnes of aluminium a year. Nearly half of this aluminium is sold to the neighboring Alcoa Australia Rolled Products plant, where aluminium is rolled into sheet for can manufacture.
Alumina Refinery Jamalco mines bauxite in the hills of Manchester with a mining contractor, refines it into alumina at the refinery in Clarendon, and ships the alumina from the port facility at Rocky Point. The alumina is shipped primarily to Alcoa’s Canadian operations and, to a lesser extent, other North American facilities within the company.
Smelter Situated on 6,500 acres in Berkeley County, Alcoa Mt. Holly produces 235,000 tons of primary aluminum annually. Built in 1977, Mt. Holly is the most advanced plant of its kind in the United States, a pacesetter in production efficiency, energy utilization and environmental protection.
Aluminum Smelter The upgrade to the Aviles smelting plant in Spain was completed successfully and safely (2008). The upgrade allows the plant to meet European environmental standards for lower emissions.
Smelter Potroom Alcoa Mt. Holly has an annual capacity of 245,000 tons of aluminum.
Bauxite Processing The Willowdale mine in Australia supplies bauxite ore to the Wagerup Refinery. The mine produces about 9 million tonnes of bauxite a year. Bauxite is off loaded into the crusher where it is crushed ready for travelling via the conveyor to Wagerup for processing.
Alumina Delivery Bulk alumina loading facility in Kwinana, Western Australia.
Alumina Refinery Precipitation starts when the alumina-laden liquor is pumped into tanks that are more than five stories high and 24 feet in diameter. Each tank can hold nearly 200,000 gallons. During the Precipitation process the liquid is cooled and seed crystals are added causing the alumina to crystallize or “grow.” As the crystals grow they gradually settle out of the solution.During the last step of the refining process, the crystals, now called “hydrate,” are filtered, washed and heated at temperatures up to 2,000 degrees Fahrenheit to remove the water. What remains is alumina, the white powder that is half aluminum and half oxygen.
Bauxite Processing The crusher area of the Juruti mine project. (2009)
Bauxite Processing Improvements to the Alumar bauxite transportation system enable the conveyor system to increase the amount of bauxite moved from the port to the refinery’s bauxite storage yard. (2009)
Alumina Refinery Production flow is enhanced with the completion of the capacity expansion at the Alumar port. Cargo handling capacity will increase from 5 million to 13 million tons a year. (2009)
Alumina Refinery Progress continues on the Alumar refinery expansion. The upgrade and expansion project will increase the output of the refinery from approximately 1.5 million mt to a total production capacity of 3.5 million mt per year for the Alumar consortium. (2009)
Bauxite Mining Halco Mining, Guinea.
Bauxite Processing Jamalco uses a new, sustainable method to transport bauxite from its mine in South Manchester to the rail station, where it is loaded for shipping to the Clarendon alumina refinery. The cable conveyor system uses gravity to move bauxite through mountainous terrain; it is quiet, dust-free, and uses less land than road transport.
Alumina Refinery The upgrade of the Pinjarra alumina refinery included updating equipment with best-practice technology and installation of new emissions control technology, making it one of the most efficient alumina refineries in the world.
Smelter Alcoa invested Au$89 million to enhance sustainability at it's Point Henry smelter in Victoria, Australia. The project significantly improved the carbon bake scrubber's environmental performance while decreasing downtime, enhancing its draft capacity, and reducing the frequency of cleaning, enabling Alcoa to maintain production.
Smelter Alcoa aluminum smelter in Wenatchee, Washington (USA).
Smelter Potroom Alcoa Inespal S.A., La Coruna, Spain. This plant produces primary aluminium via electrolysis in a variety of alloys and formats, such as slabs for rolling, billets for extrusion and rod for both the Spanish and European markets.
Alumina Refinery The ship unloader for the Alumar refinery —a hulking 65 meters high and 27 meters wide—was transported fully erected from Buenos Aires, Argentina to São Luís, Brazil in July 2009.
Alumina Refinery The 1,640 ton unloader arrives at the pier in São Luís, Brazil. The new ship unloader, along with the upgrades at the Alumar port, will increase the annual raw material handling capacity from 4.9 to 13 million tons per year by providing better flow for the ships coming in and out of the port.
Alumina Refinery It took three days to skid the unloader from the ship. The Alumar Port handles bauxite, coal, caustic soda, coke, pitch and alumina.
Alumina Refinery Final testing of the electrical and control systems for Alumar’s new ship unloader is underway–one of the final steps to making expansion of the São Luís, Brazil refinery fully operational.
Smelter Potroom Point Henry Smelter located near Geelong, Victoria, Australia.
Smelter Potroom Bath transfer in one of the two potrooms at the Alcoa Fjardaál smelter as part of the startup on January 9, 2008.
Casthouse In the Massena West Casthouse, molten metal from the smelter is being poured into molds called “sow” or “pigs” from a transportation vessel called a cruce or crucible. The molds will harden and that metal is sold to downstream customers for use in a variety of products.
Bauxite Stockpiling Bauxite stockpiling operation at Alcoa Juruti Mine in Brazil.
Transporting Bauxite Alcoa locomotive carrying Juruti bauxite through Alcoa Railroad to port.
Bauxite Shipment On May 17 2011, Alcoa's Juruti Mine (Brazil) completed its 100th shipment by loading the Castillo de Guadalupe vessel with a volume of 44,000 tons of bauxite to supply Alumar Refinery in São Luís (Brazil).