Bauxite: The Ore Underpinning the Aluminum (Aluminium) Economy

In 2019, TAKRAF delivered various equipment for CBG’s bauxite expansion project. This equipment, delivered on an Engineering, Procurement & Construction (EPC) basis, consisted of a greenfield wagon unloading (wagon tippler or railcar dumper) and primary crushing station as well as a secondary crushing station and a complex brownfield conveyor system within existing facilities.

Following the success of Phase 1, TAKRAF was later awarded an important conveyor system contract that was brought forward from the planned Phase 2 of CBG’s bauxite expansion project. The contract, which also includes civil works, includes the replacement of two existing conveyors to cater for the upcoming and planned Phase 2 expansion, which aims to increase bauxite production capacity to 5,400 t/h, as opposed to the Phase 1 capacity of 3,600 t/h. Both conveyors, with capacities of 7,000 t/h and 3,600 t/h respectively, are being supplied by TAKRAF as complete new installations.

• Technical Challenges: Bauxite deposits vary greatly in grade, depth, and mineral composition. Producing bauxite is highly infrastructure-dependent, with mines often located in remote regions where infrastructure needs to be built to move millions of tons of ore efficiently. Energy use is another key requirement - while mining itself is not as energy-intensive as refining, it still demands attention. Reliable power supply and cost-effective material handling are critical to maintaining competitiveness in global markets and this is where TAKRAF’s integrated material handling systems and efficient and reliable machines can play an important role in a project’s success.

• Sustainable Production: Bauxite miners face increasing expectations for sustainability, transparency, and low-carbon operations. Certification frameworks such as the Aluminum Stewardship Initiative (ASI) promote responsible mining practices, from biodiversity protection to community welfare. As such a bauxite operation’s future success will depend on integrating Environmental, Social & Governance (ESG) principles into every stage of production - ensuring that bauxite remains a vital resource for the global aluminum industry without compromising ecological or social integrity. As such, as a key global supplier helping customers decarbonize, TAKRAF Group’s is well-positioned, especially with our advanced and efficient conveying and material handling solutions to assist our clients across all facets of ESG.

Bauxite is essential to the modern economy: aluminum produced from bauxite is lightweight, corrosion-resistant and infinitely recyclable. These qualities make it a cornerstone material especially in a low-carbon future. 

Interestingly, the most abundant metal element in the earth’s crust is aluminum. Although the metal itself does not occur naturally in pure metallic form due to its high reactivity, its mainly found in the form of aluminum-bearing minerals such as feldspars, micas and bauxite.

• Chemical symbol: Bauxite does not have a single chemical symbol because it is an ore composed of a mixture of minerals, not a pure compound.
• World bauxite mine production (2024p): 421.5
• Bauxite mine production, top 3 countries: Australia, Guinea and China

Value in million tons; p = preliminary.

Source: U.S. Geological Survey (USGS).

• Aluminum production: Around 90% of bauxite is processed into alumina (Al₂O₃) via the Bayer process*, then smelted into aluminum metal.
   
• Other Uses: The remaining share is used in abrasives, cement, refractories, water treatment, and chemicals.

* The Bayer process: This is the primary method for producing alumina from bauxite ore, which is then used to create aluminum. 

Interestingly, aluminum can act as a substitute for copper in some applications, especially in power transmission, heat exchange and construction, but not a full replacement. Aluminum has about 60% of the electrical conductivity of copper and as such is not suited to high-performance electrical and electronic systems. The two metals are increasingly viewed as complementary in building a modern, electrified and low-carbon economy.

Aluminum recycling is one of the most efficient and sustainable processes in the metals industry. Unlike many materials, aluminum can be recycled indefinitely without losing quality or strength. Recycling aluminum requires significantly less energy than producing it from raw bauxite ore. Such a material reduction in energy use means that there is are substantial reductions in Greenhouse Gas (GHG) emissions and resource use. Common sources include used beverage cans, automotive parts and building materials, all of which can be melted down and reused within weeks. This closed-loop process makes aluminum a cornerstone of the circular economy.

Bauxite mining is the foundation of the global aluminum industry, supplying the raw material needed to produce alumina and ultimately aluminum metal. With rising demand for aluminum in clean energy and infrastructure, the future of bauxite mining is positive; however, as with all mining operations, such mining needs to be conducted in a sustainable manner across all ESG factors to ensure long-term viability.

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