03 · Aluminium
Aluminium is a metal of paradoxes. It is the most abundant metal in the Earth's crust, yet also a high-tech material; producing it from ore is among the most energy-intensive processes in industry, yet once made it can circulate in the economy indefinitely, using only a fraction of the original energy when recycled. It is precisely these tensions — between lightness and energy intensity, between the heavy footprint of primary production and near-perfect circularity — that make aluminium one of the most important and fascinating metals of the 21st century.
Properties
Aluminium combines features rarely found together in one metal. Its density (approx. 2.7 g/cm³) is about one-third that of steel, yet aluminium alloys achieve high strength. A thin, self-forming oxide layer provides corrosion resistance; the metal is non-magnetic, reflects light and heat well, is non-toxic, and its electrical conductivity (approx. 61% IACS) exceeds copper on a per-mass basis — which is why aluminium is used in overhead transmission lines. Its low melting point (660 °C) makes casting and recycling easier.
The value chain: bauxite → alumina → aluminium
The road from rock to metal is two-stage and energy-intensive. First the Bayer process converts bauxite into alumina, and then the Hall-Héroult process (developed in 1886) extracts pure aluminium by electrolysis of molten alumina. The proportions are telling: roughly 4–5 tonnes of bauxite yield 2 tonnes of alumina and 1 tonne of aluminium.
Bauxite→
AluminaBayer→
AluminiumHall-Héroult→
Recycling
The geography of the chain is heavily concentrated. Guinea holds the largest bauxite reserves (about 7.4 billion t), alongside Australia and China as leading producers; China dominates both alumina refining and smelting. This concentration — of raw material, energy and processing capacity — is today one of the main risk factors for European industry.
Alloy families — from the 1xxx to the 8xxx series
Pure aluminium is soft; its usefulness is determined by alloys. The international designation system divides wrought alloys into the 1xxx to 8xxx series, according to the principal alloying element. The choice of additions makes it possible to "engineer" the metal for a specific application — from soft foil to aerospace alloys with the strength of steel.
| Series | Principal alloying element | Typical applications |
| 1xxx | Pure aluminium (≥99%) | Electrical, foil, chemical industry |
| 2xxx | Copper (Cu) | Aerospace (duralumin), high strength |
| 3xxx | Manganese (Mn) | Cans, heat exchangers, roofing |
| 4xxx | Silicon (Si) | Welding wire, pistons |
| 5xxx | Magnesium (Mg) | Marine, automotive, tanks |
| 6xxx | Magnesium + silicon (Mg-Si) | Extruded profiles, construction, automotive |
| 7xxx | Zinc (Zn) | Aerospace, high-strength structures |
| 8xxx | Other (lithium, iron) | Foil, Al-Li alloys (aerospace) |
Source: International aluminium alloy designation system (Aluminum Association).
Market and production — China's dominance and prices
Aluminium is — after steel — the world's second most produced metal. World primary production in 2024 was about 72.7 million tonnes, and production is led overwhelmingly by China (about 59%), which has at the same time introduced a capacity cap of 45 million t by 2030.
| Country | Output 2024 (Mt) | Share | Notes |
| China | ~43 | ~59% | Dominant; 45 Mt capacity cap by 2030 |
| India | ~4.2 | ~6% | Rapidly growing output |
| Russia | ~3.8 | ~5% | Major exporter |
| Canada | ~3.3 | ~5% | Hydropower — low-carbon aluminium |
| UAE | ~2.7 | ~4% | Gas-powered; major exporter |
| World (rounded) | ~72.7 | 100% | Strong Chinese dominance |
Source: International Aluminium Institute; U.S. Geological Survey (2024 data, rounded; shares estimated).
The LME aluminium price in 2024 held around USD 2,400–2,600/t. Crucially, the profitability of smelting is determined above all by the cost of electricity — which is why smelters are sited where power is cheap, and increasingly where it is low-carbon.
Applications and the energy transition
Aluminium's application profile is defined by its two largest sectors — transport and construction — followed by packaging, electrical equipment and machinery. In transport, lightness counts: a lighter car, train or aircraft uses less energy throughout its life, which is why aluminium is a pillar of transport decarbonisation and electromobility. In renewable energy it forms the frames of photovoltaic modules and overhead transmission conductors; in construction — façades, joinery and roofing; in packaging — cans and foils with the highest recycling rates. The greener and more electrified the economy, the greater its appetite for aluminium.
Energy intensity and decarbonisation
The price of aluminium's properties is the energy intensity of primary production — about 186 GJ per tonne (in Europe about 140 GJ/t). The global average carbon footprint is about 14.8 t CO₂ per tonne of metal, but this figure hides a huge spread depending on the power source: from about 2–4 t with hydropower to about 16–20 t with coal. In the age of carbon pricing, the carbon footprint thus becomes a key competitive variable.
| Smelter power source | Carbon footprint (t CO₂/t Al) | Example |
| Recycling (secondary aluminium) | ~0.5 | Scrap — ~5% of primary energy |
| Hydropower | ~2–4 | Canada (Quebec), Norway |
| Natural gas | ~6–10 | Persian Gulf |
| Global average | ~14.8 | IAI (2023) |
| Coal | ~16–20 | Part of China's capacity |
Source: International Aluminium Institute; producer data / CarbonChain (indicative figures).
Decarbonisation is advancing on two fronts. The first is "green" power in smelters (hydro, renewables). The second, a breakthrough, is the inert anode: in the ELYSIS technology (a Rio Tinto–Alcoa joint venture) the anode does not burn but releases oxygen instead of CO₂, eliminating direct process emissions from smelting. In 2025 an industrial-scale 450 kA cell was commissioned, and the first customer for this "carbon-free" aluminium is Apple. It is potentially the most important change in smelting technology since Hall-Héroult.
Recycling and the circular economy
Here aluminium reveals its second, almost ideal nature. Remelting scrap uses only about 5% of the energy needed for primary production (a saving of about 95%), and the metal loses none of its properties across successive cycles — it is sometimes called a "permanent material". The scale effect is spectacular: about 75% of all aluminium ever produced (out of about 1.5 billion tonnes) remains in use, and more than 30 million tonnes of scrap is recycled each year. The recycling input rate reaches about 32%, recovery from end-of-life vehicles about 90%, and from beverage cans about 75% (2023). This makes aluminium recycling one of the pillars of the European circular economy and a key area of activity for the Chamber's members.
CBAM and Europe's raw-material security
Energy intensity and exposure to "carbon leakage" have placed aluminium at the centre of EU climate-and-industrial policy. The CBAM mechanism (Regulation (EU) 2023/956) entered its definitive phase on 1 January 2026, under which importers of aluminium (among other goods) bear a real cost for the emissions embedded in the product — so as to equalise it with the carbon price paid in the EU under the ETS. Over the past two decades Europe has lost about two-thirds of its primary aluminium capacity, becoming a net importer. In parallel, the Critical Raw Materials Act (CRMA) classified aluminium as a critical and strategic EU raw material, setting 2030 targets (10% extraction, 40% processing, 25% recycling, ≤65% dependence on any single supplier).
Aluminium and the human being
Unlike copper or zinc, aluminium is not an essential element for the body, and its inorganic forms have low toxicity at normal exposure — which is why they are safely used in food packaging, foil and cookware. In everyday surroundings aluminium is ubiquitous: cans and foil in the kitchen, window joinery and façades, electronics casings, wheels and body parts, bicycle frames, and power conductors.
~72.7 Mtprimary production 2024
~95%energy saving in recycling
~75%of all Al still in use
~14.8 tcarbon footprint per t (CO₂)
660 °Cmelting point
1 Jan 2026definitive CBAM phase starts
The Polish context and the role of the Chamber
Poland does not today smelt primary aluminium at scale — energy intensity and electricity costs are decisive. It is, however, a significant European processor and recycler: in the extrusion of profiles, rolling, and the recovery of aluminium from scrap. It is precisely in these links — processing and recycling — that Poland's advantage in the value chain lies. Under CBAM and the CRMA, the importance of this potential is growing: low-carbon recycling is becoming a strategic asset, and Polish importers of aluminium products are subject to new obligations. The Chamber represents the industry at the national and European level.
Light in use, heavy in smelting, almost eternal in circulation — aluminium is a test of whether we can reconcile industry with the climate.