Aluminum is an example of a material that has seen rapid growth in demand in recent years, and that demand has been met by expanded primary production. Aluminum has a density of 2.7 kg/dm3 at room temperature, which is about one-third of the density of iron and steel. With proper alloying and microstructure, as, a high strength-to-weight aluminum ratio can be achieved — along with great flexibility for efficient formability — into complex shapes using contemporary design features.
Aluminum occurs in nature in the form of chemically very stable compounds, in particular oxides. The raw material for its production, alumina , is refined from bauxite, which is an ore mined from strip mines. The production process also requires carbon anode production, electrolysis, casting, and secondary metal treatment.
The Green Aluminum Smelter project, led by Century Aluminum Company, plans to build the first new US primary aluminum smelter in 45 years. Upon completion, the smelter would double the size of the current US industry while avoiding an estimated 75% of emissions from a traditional smelter due to its state-of-the-art, energy efficient design and use of carbon free energy.