US production of aluminum, 1940–2014. Data from USGS
The aluminum industry in the United States in 2023 produced 860 thousand metric tons of aluminum from refined metal ore (primary production), at six smelters. In addition, US industry recycled 3.4 million tons of aluminum (so-called secondary production aluminum).[1] Total annual imports of metal and alloy for use in secondary production stood at 2.6 million metric tons in the year to August 2023, with the previous decade seeing a fundamental shift toward recycled production.[2]
Primary production
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In 2014, primary aluminum, which is produced from bauxite, was produced by three companies at nine smelters. Primary aluminum is preferred for high-quality uses such as aircraft. The leader in US production was Alcoa. Also operating multiple primary plants was Century Aluminum.
Primary Aluminum Smelters in the US
Secondary production
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Secondary production is the recycling of metallic aluminum derived from scrap. Secondary production can be from either new scrap (from aluminum manufacturing), or from old scrap (post-consumer scrap such as recycled aluminum cans).
Raw materials
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Proportion of US aluminum production from various raw materials. Data from USGS.The principal raw materials for aluminum production are bauxite (for primary production) and scrap (for secondary production).
Primary aluminum production consumes a great deal of electricity, which makes up about a third of the cost. Making a ton of primary aluminum consumes at least 12,500 kW-hr, and most plants consume 14,500 to 15,000 kW-hr per ton of primary aluminum.[13]
Secondary production of a given unit of aluminum requires about 10% of the electricity of primary production.
The United States mined production of bauxite for primary aluminum production is insignificant. In 2013, the US mined only 1.3 percent of the bauxite it used, US mined production being less than 0.1 percent of world production.
International trade
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The US imported nearly all the bauxite (the only commercial aluminum ore) used in producing primary aluminum. For years, the US has produced less than 1% of the bauxite used to make aluminum.
The US also imported 33 percent of the aluminum metal that was used in 2014. Of the imported aluminum, 63% came from Canada.[1][14]
History of US aluminum production
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The US used to be a much more important factor in the world primary aluminum market. As recently as 1981, the US produced 30% of the world's primary aluminum, and for many years up through 2000, the US was the world's largest producer of primary aluminum. In 2014, by contrast, the US ranked sixth in primary aluminum production, and provided only 3.5% of world production.
US production of primary aluminum peaked in 1980 at 4.64 million metric tons. Since then, US primary aluminum production has fallen by more than half, but secondary production has increased, making up much of the difference. In the 1950s and 1960s, primary production made up about 80% of the aluminum output. In 2014, primary production made up 32%, while secondary from new scrap made up 36% and secondary from old scrap made up 32% of US aluminum production.[1]
Climate impact and market competitiveness
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The development of tools which calculate upfront carbon emissions is expected to bring changes to the relative competitiveness for US-produced aluminum products, and result in states with cleaner electric grids gaining a competitive advantage both for sourcing aluminum construction materials, and for siting of new aluminum industry facilities.[16]
See also
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References
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Aluminium foil is the most preferred choice of raw material in the packaging industry because it acts as a total barrier to light and oxygen, odours and flavours, and moistness and germs. Hence, there is an estimate for robust growth of the global aluminium foil market in ten years, from US$26.3 billion in 2022 to US$42.3 billion in 2032, at a compound annual growth rate (CAGR) of 5%. To this significant growth contributes the United States and Europe, with a market value of USD 8.69 billion in 2022, which is also likely to grow at a CAGR of 5% till 2030.
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The United States accounts for a symbolic consumption of aluminium foil globally and also considered a prominent producer. AL Circle, in one of its articles in 2017, posted that Amcor, Novelis, ACM Carcano, Reynolds Group Holdings, Aleris, and All Foils, Inc. were some of the then leading producers of aluminium foil. After more than five years, we have come back with another article to find out if those companies continue to be the primary producers or the market witnesses some new leaders.
Novelis: The US-headquartered world leader in producing aluminium flat rolled products supplies premium aluminium foil and sheet to transportation, packaging, construction, industrial and consumer electronics sectors. Novelis’ aluminium converter foil is a part of the light- or thin-gauge product group, ideally between 5 and 70 μm. Due to the versatility and flexibility of the product, it offers the perfect solution to food and pharmaceutical packaging. The product also find a technical application in the building and construction sector, where it is used for creating specific roofing solutions using combinations of aluminum with PET and other materials.
In FY2023 ended March 31, Novelis’ net income was recorded at $658 million against net sales of $18.50 billion. The company’s total shipments through the year stood at 3,790 tonnes.
Amcor in North America: Amcor in North America offers a wide portfolio of aluminium packaging solutions. The company is known for developing and producing flexible, recyclable packaging for the past 150 years. Amcor in North America serves food and beverage packaging sector with its ultra-thin aluminium foil. For baby & toddler food to pet care and juice, sports and energy drinks to ready meals and components, Amcor has a solution for all kinds of packaging. The company also serves Industrial & Building materials, personal care, and home care sectors with its rolled products.
For FY2023 ended June 30, Amcor posted global sales of US$15 billion, of which North America accounted for 48 per cent. Net income stood at US$805 million and EBITDA at US$ 2,117 million.
Reynolds Consumer Products: Belong to Reynolds Group Holdings, Reynolds Consumer Products is a leading provider of aluminium foil under the iconic brand Reynolds Wrap®. The company offers a wide range of foil products fit for various needs. The portfolio includes Everyday Foil, Foil Sheets, Grill Bags, Grill Foil, Heavy Duty Foil, Nonstick Foil, Pitmaster’s Choice Foil, and Recycled Foil.
In 2022, Reynold Consumer Products concluded another year with record revenue of US$3.8 billion, growing 7% from the previous year. Net income stood at $258 million and Adjusted EBITDA at $546.
All Foils, Inc.: All Foils is a foil converter and distributor of light gauged metals, with an extensive inventory of 2 million pounds, containing aluminium foil products. With the highest quality products, All Foils serve industries like food service, medical & pharmaceutical, cryogenics, and automotive repair & manufacture. The company’s average revenue stands at US$15 million per year.
Alufoil Products Co., Inc.: Headquartered in Hauppauge, New York, Alufoil Products Co., Inc is a manufacturer of standard and custom packaging supplies including laminated aluminum foil in roll and sheet forms. Their foils are available in 0.00045 to 0.025 in. thickness, suitable for printing, packaging, and food service industries. The company’s product categories include aluminium foil & aluminium sheet, confectioners foil, food service foil, artists & craft foil, highlighting foil, foil paper & board, pharmaceutical and heat seal foil and so on and so forth.