ALUMINUM—2002 5.1 1 A reference that includes a section mark (§) is found in the Internet
Reference Cited section. 

# ALUMINUM

By Patricia A. Plunkert

Domestic survey data and tables were prepared by Lauri Watson, statistical assistant, and the world production table was prepared by Linder Roberts, international data coordinator.

In 2002, 7 domestic companies operated 16 primary aluminum reduction plants in 13 States and produced more than 2.7 million metric tons (Mt) of metal. Smelters east of the Mississippi River accounted for 75% of the production. The value of production was estimated to be $3.9 billion. Three additional companies had plants that were idle during the year. The 10 domestic producers had a total of 7 smelters that were either temporarily or permanently idled in 2002. At yearend, about 1.5 million metric tons per year (Mt/yr) of domestic primary aluminum smelting capacity, equivalent to 35% of total capacity, was closed.

Aluminum recovered from purchased scrap decreased slightly to 2.93 Mt. Of this recovered metal, 60% came from new (manufacturing) scrap, and 40% came from old (discarded aluminum products) scrap. Aluminum used beverage cans (UBCs) accounted for more than one-half of the reported old scrap consumption in 2002. According to the Aluminum Association Inc. (2003a), the recycling rate for aluminum UBCs was 53.4%.

The transportation and the container and packaging industries remained the largest markets for aluminum products in Canada and the United States in 2002. The transportation industry accounted for 35% of consumption; containers and packaging, 23%; building and construction, 16%; consumer durables, 8%; electrical, 7%; and other uses, 11%.

U.S. imports for consumption increased in 2002 compared with those of 2001. Canada remained the largest shipper of aluminum materials to the United States, followed by Russia. Total exports from the United States in 2002 were at the same
level as those in 2001.

The price of primary ingot on the domestic and the international markets fluctuated during the year. The 2002 annual average domestic price decreased by almost 4 cents per pound compared with that of the previous year.

At the end of 2002, world inventories of aluminum, as reported by the International Aluminium Institute (IAI), decreased compared with those of 2001. Inventories of primary metal held by the London Metal Exchange Ltd. (LME), however, increased.

Primary aluminum was produced in 43 countries in 2002. China and Russia surpassed the United States as the world’s largest producers. China produced 17% of the world total, followed by Russia with 13%. The United States and Canada each accounted for about 10% of the total world production. World primary metal production increased by 7% compared
with that of 2001.

Production

Primary.—Domestic primary aluminum production, which totaled a reported 2,706,582 metric tons (t), increased by 3% compared with that of 2001. Production data were obtained from the 11 domestic producers, all of which responded to the U.S. Geological Survey (USGS) request for production data.

Despite the slight increase in production, most of the domestic primary smelting capacity that had been closed during the previous few years remained closed. At yearend, about 1.5 Mt/ yr of U.S. primary aluminum smelting capacity was closed. Of this total, 270,000 metric tons per year (t/yr) was permanently closed and the remainder was classified as temporarily idled. The bulk of the idled capacity was in the Pacific Northwest. Most of the smelters outside this region continued to operate at or near their engineered capacities.

In July, Alcoa Inc. announced a series of primary aluminum smelter closures. Alcoa announced the temporary closure of its 120,000-t/yr primary aluminum smelter in Badin, NC, which had been operating at 90,000 t/yr since September 2000. Metal production at the smelter ceased in mid-August. Alcoa also announced the permanent closure of its 121,000-t/yr Troutdale, OR, facility and a 76,000-t/yr potline at its 320,000- t/yr Rockdale, TX, smelter. Both the Troutdale smelter and the potline at Rockdale, which had been idled previously, were dismantled (Alcoa Inc., 2002g).

Alcoa announced that the company would delay indefinitely the planned restart of Line 1 at its 310,000-t/yr Warrick County, IN, primary aluminum smelter. That line has a capacity of 41,000 t/yr. The smelter had been gradually restarting capacity since a power outage interrupted production in December 2001 (Alcoa Inc., 2002b).

Kaiser Aluminum & Chemical Corp. agreed to sell the property, plant, and equipment at its Tacoma, WA, primary aluminum smelter to the Port of Tacoma. The plant is adjacent to the Blair Waterway, which the Port is redeveloping for use as a container terminal. Under the agreement, the Port of Tacoma would assume responsibility for any necessary demolition
and environmental remediation at the site. Production at the 73,000-t/yr facility had been curtailed since mid-2000 (Kaiser Aluminum & Chemical Corp., 2002c).

Glencore International AG purchased Vanalco Inc.’s bankrupt, Vancouver, WA, primary aluminum smelter for $24 million. The 116,000-t/yr smelter had been idled since August 2000 (Mining Journal, 2002c).

In May, Alcoa began the gradual restart of two potlines (95,000 t/yr) at its Intalco smelter in Ferndale, WA. The 278,000-t/yr smelter had been closed since May 2001 (Alcoa Inc., 2002b).

By June, Columbia Falls Aluminum Co. had reopened three
of the five potlines at its 168,000-t/yr smelter in Columbia Falls, MT. The smelter had been closed since January 2001 (Reese, 2002§ 1 

## ).5.2 U.S. GEOLOGICAL SURVEY MINERALS YEARBOOK—2002 

## In September, Golden Aluminum Co. announced the restart of one potline at its 168,000-t/yr primary aluminum smelter in Goldendale, WA. The restart increased operating capacity to 50,000 t/yr from 12,000 t/yr (Platts Metals Week, 2002e).

Kaiser filed voluntary petitions for bankruptcy reorganization under Chapter 11 of the Federal Bankruptcy Code in the U.S. Bankruptcy Court for the District of Delaware. Although the filing included certain U.S. subsidiaries through which the company held an interest in foreign operations, it did not include Kaiser’s interest in the following offshore facilities: alumina refineries in Jamaica and Australia; the Jamaica Bauxite Company; smelters in Ghana and Wales; and an extrusion plant in Ontario, Canada (Kaiser Aluminum & Chemical Corp., 2002a).

Noranda Inc. and members of the United Steelworkers of America (USWA) at its 250,000-t/yr New Madrid, MO, smelter signed a new 5-year labor agreement. The new contract, which took effect on September 1, allowed for wage increases each year during the course of the contract, improved pension benefits, and instituted some changes in health care benefits (Noranda Inc., 2002).

Century Aluminum Co. and members of the USWA ratified a 3-year extension to a labor agreement that was set to expire on May 31, 2003. The new agreement, which runs through May 31, 2006, covered workers at Century’s Ravenswood, WV, primary aluminum smelter. Terms of the agreement were not disclosed (Century Aluminum Co., 2002).

Alcan Inc. announced plans to close one of two cold mills at its Fairmont, WV, plant. The plant produced light gauge aluminum sheet and foil used in the transportation, packaging, and industrial markets. Alcan anticipated that the mill would be closed in 2003 (Alcan Inc., 2002b).

Kaiser announced the sale of the coating line at its Trentwood, WA, rolling mill to Alcoa (American Metal Market, 2002d). With the sale, Kaiser ceased production of aluminum lid and tab stock for the beverage can industry. In 2000, Kaiser exited the can body stock market at Trentwood. Kaiser anticipated that
the Trentwood mill would continue to concentrate on its heattreat business for the aerospace and general engineering markets (Guerriere, 2002b).

Pechiney purchased the equipment of McCook Metals L.L.C. (Pechiney, 2002c). McCook filed for Chapter 11 bankruptcy protection in August 2001. At yearend, the plate manufacturing and rolling equipment of the Chicago plant was still being held in a warehouse (Brooks, 2002).

Norsk Hydro ASA announced the closure of its Moultrie, GA, aluminum extrusion plant. The plant had 2 extrusion presses and employed 121 workers (Guerriere, 2002a).

Strategic Minerals Corp. (Stratcor), Danbury, CT, closed the aluminum-vanadium master alloy line at the Niagara Falls, NY, plant operated by its subsidiary, U.S. Vanadium Corp. Production will shift to a new facility being built in New Castle, PA, by Stratcor’s partner, International Specialty Alloys (American Metal Market, 2002j).

Secondary.—Metal recovered from new and old scrap decreased slightly to 2.93 Mt in 2002 (table 3), according to data derived by the USGS from its “Aluminum Scrap” survey. Of the 69 companies and/or plants to which monthly or annual survey requests were sent, 39 responded; they represented 92% of the total scrap consumed, as listed in table 4. According to figures released by the Aluminum Association Inc., the Can Manufacturers Institute, and the Institute of Scrap Recycling Industries, 53.8 billion aluminum UBCs were recycled in the United States in 2002, for a beverage can recycling rate of 53.4%. For 21 of the past 22 years, the rate has exceeded 50% (Aluminum Association Inc., 2003a).

TST Inc. announced the opening of a secondary smelter in Sweetwater, TX. The smelter was expected to produce aluminum die cast alloys 380, 319, and 356 (Schaffer, 2002b).

Superior Aluminum Alloys announced plans to add a fourth furnace at its secondary aluminum smelter in New Haven, IN.The 2,270-metric-ton-per-month (t/mo) (5-million-pound-permonth) furnace would increase capacity at the plant to about 90,700 t/yr (200 million pounds per year). Under normal operating conditions, the smelter planned to operate three furnaces at capacity and use the fourth furnace as a backup (Platts Metals Week, 2002j).

Production at the new Norsk Hydro remelt facility in Commerce, TX, began on November 15. The plant will have the capacity to produce 90,000 t/yr of aluminum from scrap. Norsk Hydro has a total U.S. remelt capacity of more than 400,000 t/yr with additional plants in Henderson, KY; Monet, MO; Ellenville, NY; Phoenix, AZ; and St. Augustine, FL (Norsk Hydro ASA, 2002b).

Allied Metal Co. purchased the assets of Ares Corp., a closed secondary aluminum smelter in Scottsboro, AL. The plant, which had been shuttered for 18 months, contained a 91-t (200,000-pound) reverberatory furnace. No decision had been made by yearend on the types of alloys to be produced by the new company, Allied Scottsboro LLC (Schaffer, 2002a).

In support of its announced strategy to shift production to locations that would provide improved service for its major customers, Wabash Alloys LLC reported the closure of two of its secondary aluminum smelters and the purchase of another. In June, Wabash closed its Syracuse, NY, smelter. The former Roth Brothers facility had been capable of producing 6,350 t/mo (14 million pounds per month) of specification alloy ingot (Platts Metals Week, 2002k). In November, Wabash announced plans to close its Benton, AR, smelter by yearend. The plant had a reported capacity of 3,630 t/mo (8 million pounds per month) of alloy production. Since 2000, Wabash has also closed facilities in Marietta, PA; Checotah, OK; Russellville, AL; Bellwood, VA; and Milwaukee, WI. Wabash has eight operating facilities located in Cleveland, OH; Wabash, IN; Tipton, IN; Dickson, TN; Steele, AL; Montclova, Mexico; and Mississauga and Guelph, Ontario, Canada (Platts Metals Week, 2002l). Wabash purchased the Steele, AL, facility in September of this year. The former Culp Aluminum Alloys facility had a reported production capacity of 54,400 t/yr (120 million pounds per year) of aluminum alloy (Schaffer, 2002c).

Zemex Corp., the Toronto, Ontario, Canada-based owner of dross processor Alumitech, announced the purchase of Resource Recovery Industries Inc. The Friendly, WV, facility used tilting rotary furnaces to convert dross, residues, and other forms of aluminum scrap into sows. The facility also included a cold processing line that converted mixed residues, such as black dross and saltcake, into concentrates of 85% to 90% metal content (Schaffer, 2002d).ALUMINUM—2002 5.3 

## Consumption

The end-use shipment data reported by the Aluminum Association have been revised to include aluminum product shipments in both the United States and Canada. In 2002, the combined United States and Canadian shipments of aluminum products to the transportation industry totaled 3.4 Mt (table 6). Shipments to the container and packaging industry, which was the second largest end-use market, was 2.26 Mt. Total shipments, excluding exports, of aluminum products in 2002 increased about 3% compared with those of 2001.

The weight of the average North American-built family motor vehicle increased by 14 kilograms (kg) (30 pounds) to 1,515 kg (3,340 pounds) in 2002 compared with 1,501 kg (3,310 pounds) in 2001. To hold the weight increases of many newmodels to a minimum, automakers increased the use of lighterweight grades and forms of steel, a variety of aluminum alloys, powder metals, and magnesium die-casting alloys in the bodies, structural components, powertrains, suspension systems, and other subassemblies. The average aluminum content of the 2002 family vehicle was 122 kg (268 pounds) compared with 116 kg (255 pounds) in 2001 (Wrigley, 2002).

According to a recent study by Ducker Research Co., the average aluminum content of automobiles was expected to grow to 130 kg (287 pounds) per vehicle across the three major automotive markets of the world by 2010. This included a North American average aluminum content of 144 kg (318 pounds) per vehicle by 2010, a European average of 122 kg (268 pounds) per vehicle, and a Japanese average of 119 kg (263 pounds) per vehicle. Castings have dominated aluminum automotive applications throughout the industry’s history, representing nearly 80% of all shipments in the three major world markets. However, during the balance of this decade, other product forms are expected to increase their share, particularly aluminum sheet (Light Metal Age, 2002).

Jaguar Cars Ltd.’s all new XJ sedan, unveiled at the 2002 Paris Auto Show, reportedly is the first volume production vehicle with an aluminum unibody structure. Alcan’s Aluminum Vehicle Technology was used to design a stamped sheet structure that is about 40% lighter than an equivalent steel body. All of the car’s “hang-on” body parts—hoods, doors, fenders, and trunk lids—are also produced of aluminum, further contributing to weight reduction and improved performance (Alcan Inc., 2002k).

Norsk Hydro announced the development of an all-aluminum engine block for a new high performance diesel engine. Blocks for high performance diesel engines must sustain high temperatures and up to three times the pressure of traditional gasoline engines. Norsk Hydro also approved a major investment for a new production line for aluminum blocks at Dillingen, Germany. Upon completion, the new facility would be capable of producing 350,000 engine blocks per year (Norsk Hydro ASA, 2002d).

Harley Davidson Inc.’s 2003 VRSCA V-Rod is reportedly the first motorcycle produced by a major U.S. manufacturer using aluminum body panels. The 100th Anniversary V-Rod uses anodized aluminum in the cycle’s body panels, front and rear fenders, chain guard, louvered front side covers, radiator shroud, airbox cover, and swing arm (Journal of Metals, 2002). Alcoa received antitrust clearance from the European Union to complete the acquisition of Fairchild Fasteners from The Fairchild Corporation. Fairchild Fasteners was a leading producer of precision fastening systems and components used in the construction and maintenance of commercial and military aircraft (Alcoa Inc., 2002f).

Ball Corporation completed its acquisition of SchmalbachLubeca AG, Europe’s second largest manufacturer of beverage cans. Schmalbach operated 12 beverage can and can-end manufacturing facilities: four each in Germany and the United Kingdom, two in France, and one each in the Netherlands and Poland. The facilities, which will be operated under the name Ball Packaging Europe, reportedly had a combined capacity to produce more than 12 billion cans and ends per year (Platts Metals Week, 2002b).

Alcoa introduced a new nonstick aluminum foil, Reynolds Wrap Release. The foil, which is coated with a special proprietary food-safe, nonstick surface, can be used both as a cooking/baking item as well as a wrap for storage. Reynolds Wrap Release will compete in the $1.7 billion U.S. food wrap and bag industry (Alcoa Inc., 2002h).

Stocks

Domestic inventories of aluminum ingot, mill products, and scrap held by U.S. producers increased to 1.32 Mt at yearend 2002 from 1.30 Mt at yearend 2001 (Aluminum Association Inc., 2003b). The LME, however, reported that primary aluminum metal ingot at its U.S. warehouses decreased dramatically to 650 t at yearend 2002 from 28,500 t at yearend 2001 and that its U.S. warehouses still did not hold any stocks of aluminum alloy ingot (London Metal Exchange Ltd., 2002).

On March 4, the LME launched a new aluminum alloy contract, the North American Special Aluminium Alloy Contract (NASAAC). It is a modified version of the LME alloy contract with a tighter A380.1 specification (Pinkham, 2002). Delivery points were limited to four U.S. warehouses—Baltimore, MD; Chicago, IL; Detroit, MI; and St. Louis, MO (Platts Metals Week, 2002h). At yearend 2002, these warehouses held 44,200 t of NASAAC ingot (London Metal Exchange Ltd., 2002).

Prices

The monthly average U.S. market price of primary aluminum metal, as reported by Platts Metals Week, fluctuated throughout the year. The monthly average price began the year at 64.6 cents per pound, reached a low for the year of 62.6 cents per pound in August, and, by December, had risen to 66.1 cents per pound. The average price for the year decreased to 64.9 cents per pound in 2002 from 68.8 cents per pound in 2001.

The LME average monthly cash price for high-grade primary aluminum ingot and the average monthly spot settlement price for primary aluminum ingot on the COMEX division of the New York Commodity Exchange, Inc. followed the same general trend as the U.S. market price. The 2002 average annual LME cash price was 61.2 cents per pound. The COMEX monthly average spot settlement price declined slightly from 65.1 cents per pound in January to 64.7 cents per pound in December.

Purchase prices for aluminum scrap, as quoted by American Metal Market, also fluctuated but closed at higher levels than5.4 U.S. GEOLOGICAL SURVEY MINERALS YEARBOOK—2002 

## those at the beginning of the year. The yearend price ranges forselected types of aluminum scrap were as follows: mixed lowcopper-content aluminum clips, 51 to 52 cents per pound; old sheet and cast aluminum, 48 to 49 cents per pound; and clean, dry aluminum turnings, 48 to 49 cents per pound.

Aluminum producers’ buying price range for processed and delivered UBCs, as quoted by American Metal Market, also closed higher at yearend. The price range began the year at 44 to 45 cents per pound and closed the year at 49 to 51 cents per pound. Resource Recycling published a monthly transaction price for aluminum UBCs in its Container Recycling Report. During the year, the monthly average fluctuated but closed higher at yearend. The January average was 47.3 cents per pound, and the December average was 52.4 cents per pound. The annual average transaction price for aluminum UBCs, however, decreased to 49.1 cents per pound in 2002 from 50.2 cents per pound in 2001.

The yearend indicator prices for selected secondary aluminum ingots, as published in American Metal Market, also increased compared with those at the beginning of the year. The closing prices for 2002 were as follows: alloy A380 (3% zinc content), 76.2 cents per pound; alloy B380 (1% zinc content), 77.6 cents per pound; alloy A360 (0.6% copper content), 80.5 cents per pound; alloy A413 (0.6% copper content), 80.5 cents per pound; and alloy 319, 79.1 cents per pound. Platts Metals Week published an annual average U.S. price of 70.2 cents per pound for A380 alloy (3% zinc content). The average annual LME cash price for a similar A380 alloy was 56 cents per pound.

In June, the LME started cash trading for the NASAAC. The annual average NASAAC cash price for 2002, based on 6 months of trading, was 65.4 cents per pound.

Trade

Total exports of aluminum materials from the United States in 2002 were at the same level as those of 2001 (table 8). The decrease in exports of semifabricated material was compensated for by increases in exports of crude metal and alloys and aluminum scrap (table 9). About two-thirds of total U.S. exports in 2002 was shipped to Canada and Mexico. Shipments of aluminum scrap to China accounted for an additional 13% of total exports.

Imports for consumption increased compared with those of the previous year (table 10), reversing a 2-year downward trend. Canada remained the major source country, supplying more than one-half of the total imports in 2002 (table 11). Russia continued to be the second largest supplier of aluminum
materials to the United States.

World Review

World production of primary aluminum metal increased 7% in 2002 compared with that of 2001 (table 12). Most of the production increase was from new or expanded facilities in China. The estimated Chinese primary production has almost doubled over the past 5 years.

Unwrought aluminum inventories held by members of the IAI decreased to 1.66 Mt at yearend 2002 from 1.74 Mt at yearend 2001. Unwrought aluminum is defined by the IAI as aluminum in its basic form made from primary metal or from scrap that is unworked in the metallurgical sense. IAI total aluminum inventories decreased to 2.93 Mt at yearend 2002 from 3.02 Mt at yearend 2001. Total aluminium is unwrought aluminum plus unprocessed scrap, metal in process, and finished semifabricated (mill) products (International Aluminium Institute, 2003).

Yearend 2002 inventories of primary aluminum metal held by the LME increased to 1.24 Mt from 821,000 t at yearend 2001. Aluminum alloy inventories decreased dramatically to 34,700 t at yearend 2002 from 121,000 t at yearend 2001. At yearend 2002, LME warehouses also held 44,200 t of NASAAC ingot (London Metal Exchange Ltd., 2002).

Industry Mergers.— Norsk Hydro of Norway purchased VAW Aluminium AG from E.ON AG, the German utility group. The new company will be called Hydro Aluminium AS (Norsk Hydro ASA, 2003, p. 20). VAW’s primary aluminum assets included the 210,000-t/yr Norf and 68,000-t/yr Stade smelters in Europe, the 150,000-t/yr Kurri Kurri smelter in New South Wales, and a 12.4% interest in the 460,000-t/yr Tomago smelter, also in New South Wales. VAW also had downstream aluminum assets, most notably a 50% interest in Aluminium Norf GmbH, which owns a 1.2-Mt/yr rolling mill that produced aluminum can sheet (Mining Journal, 2002b). VAW was particularly strong in the area of rolled and cast products, which would complement Norsk Hydro’s substantial market position in extruded products and profiles (Norsk Hydro ASA, 2002g). The acquisition made Norsk Hydro the third largest integrated aluminum company in the world, ranking behind Alcoa and Alcan (Platts Metals Week, 2002g).

Corus Group plc, which was formed by the merger of Kononkliijke Hoogovens Aluminium and British Steel in 1999, announced plans to sell its aluminum assets—Corus Primary Aluminium, Corus Aluminium Rolled Products, and Corus Aluminium Extrusions (Metal Bulletin, 1999). Corus Primary operated two smelters, the 100,000-t/yr Delfzijl smelter in the Netherlands and the 86,000-t/yr Voerde smelter in Germany.
Corus also held a 20% interest in the Alouette smelter in Canada. (More information can be found under the Canada section.) Corus Rolled Products operated rolling mills in Koblenz, Germany, and Duffel, Belgium, and had a 60% interest in the Cap de la Madeleine mill in Canada. Corus Extrusions had plants in Belgium, China, and Germany (Corus Group plc, 2002a). On October 23, Corus Group agreed in principle to sell its rolled products and extrusions businesses to Pechiney pending approval of shareholders and appropriate regulatory authorities (Corus Group plc, 2002b). On March 11, 2003, however, Corus Group announced that the proposed sale to Pechiney had been rejected by the supervisory board of Corus Nederland BV (a wholly owned subsidiary of Corus Group) (Corus Group plc, 2003a). A subsequent court appeal was also rejected. As a result, Corus Group informed Pechiney that it had no further redress and would not proceed with the proposed sale (Corus Group plc, 2003b).

Armenia.—The Armenian Government approved the sale of its 26% of the Armenian-Russian joint-venture foil mill, Armenal, to Russian Aluminum (RusAl) making RusAl the sole owner of the plant. RusAl reportedly agreed to pay $500,000 for the share package and to invest $34 million in the company during the next 10 years (Interfax Mining & Metals Report,ALUMINUM—2002 5.5 

## 2002). Following completion of the latest upgrade to the mill in April 2002, capacity increased to approximately 23,000 t/yr of foil (Henry, 2002).

Australia.—Comalco Limited (a wholly owned subsidiary of Rio Tinto plc.) purchased Kobe Steel Ltd.’s interest in the 490,000-t/yr Boyne Island primary aluminum smelter in Gladstone. Comalco’s ownership share in the smelter increased
from 54.19% to 59.39%. The remainder of the smelter is held by other Japanese interests (Rio Tinto plc., 2002). Expansion plans to increase capacity at the smelter to 700,000-t/yr, announced in 2001, have been deferred and will be reevaluated as aluminum market conditions improve (Platts Metals Week, 2002c).

Norsk Hydro announced plans to install new technology on two potlines of the Kurri Kurri aluminum smelter in Hunter Valley, New South Wales. The upgrade would increase capacity at the primary smelter by 10% to 165,000 t/yr and improve the plant’s environmental performance. The project was expected to be completed in about 3 years (Norsk Hydro ASA, 2002h).

The joint-venture partners in the 460,000-t/yr Tomago primary aluminum smelter near Newcastle, New South Wales, have agreed to expand production capacity by 70,000 t/yr by increasing the current intensity of the smelter’s pots to 225,000 amps. Participants in the smelter are Pechiney (51.55%), Gove Aluminium Finance Ltd. (36.05%), and Norsk Hydro (12.4%). The first incremental increase in production was expected to occur in 2004, and the targeted capacity of 530,000 t/yr should be reached in 2006 (Pechiney, 2002d).

Bahrain.— Aluminium Bahrain (Alba) signed an agreement with Pechiney to use Pechiney AP30 technology on its Line 5 aluminum expansion project. The new 307,000-t/yr potline would have 336 cells and, upon completion, would increase capacity at the 520,000-t/yr smelter to more than 800,000 t/yr. Alba was also evaluating technical bids for the construction of a 650 megawatt (MW) power station to power the $1.7 billion Line 5 project. Meanwhile, Alba was preparing a report for its board of directors on a possible alliance with Alcoa and the construction of a 307,000-t/yr sixth potline that would increase capacity at the smelter to more than 1 Mt/yr (Platts Metals Week, 2002a).

Brazil.—Energy restrictions in the northern regions of Brazil that began in June 2001 were lifted in January. As a result, the Alumar and the Alumínio Brasileiro S.A. (Albrás) smelters returned to full production. The Albrás smelter restarted 160 pots that were taken offline during the period of energy rationing. In addition, the company started up 45,000 t/yr of new capacity that was completed in December 2001 but could not be put into production until the energy rationing was lifted. Upon completion of the startup, the smelter was operating at its full production capacity of 406,000 t/yr. Alcoa and BHP Billiton restarted the 92,500 t/yr of production capacity that had been taken offline at its 370,000-t/yr Alumar smelter (Metal Bulletin, 2002a).

Energy restrictions in other areas of the country were lifted at the end of February. As a result, Alcan resumed full production at its Ouro Preto and Aratu smelters, which had been operating at reduced levels since June 2001 (Kinch, 2002).

Alcan opened its first South American composites production facility in Camaçari, Bahia State. At capacity, the facility was expected to produce 100,000 square meters per month of aluminum composite material, made with two sheets of aluminum bonded to a thermoplastic core. It is used primarily as exterior cladding on commercial buildings (Alcan Inc., 2002i).

IMCO Recycling Inc. acquired an aluminum recycling plant in the city of Pindamonhangaba, Sao Paulo State, from Reciclagem de Materiais Industria e Comercio Ltda. (Recipar). The facility will be used to meet the terms of a long-term tolling agreement with Alcan, whose can sheet rolling mill is located nearby. The plant has shredding and delacquering equipment and two furnaces with a rated annual processing capacity of 45,400 t (100 million pounds) of scrap (IMCO Recycling Inc., 2002a).

Canada.— Alcan officially inaugurated its primary smelter and casting complex at Alma, Quebec. Construction on the Alma smelter began in March 1998, and the first metal was produced in October 2000. The smelter reached its engineered capacity of 400,000 t/yr in 2002 (Alcan Inc., 2002e).

Alcan purchased a 40% interest in the Aluminerie Alouette consortium that operates a 243,000-t/yr smelter in Sept-Îles, Quebec. In April, Alcan completed the purchase of the 20% interest held by Société Générale de Financement (SGF) (Alcan Inc., 2002c). In September, Alcan completed the acquisition of Corus Group’s 20% interest in the smelter (Alcan Inc., 2002h). In July, SGF purchased Kobe Steel Ltd.’s 13.33% interest in Alouette (McCulloch, 2002). Norsk Hydro, which acquired a 20% interest in Alouette through its acquisition of VAW, joined the other members of the consortium (Alcan, 40%; Austria Metall AG, 20%; SGF, 13.33%; and Marubeni Corp, 6.67%) in a planned 307,000-t/yr expansion of the smelter, which upon completion would bring total capacity to 550,000 t/yr. Construction began in September and the first production of metal was scheduled for February 2005 (Norsk Hydro ASA, 2002e). The technology selected for the smelter expansion was Pechiney’s AP30 technology, the same as that used in the existing smelter. The choice of technology will allow synergy benefits by combining the operation of the smelter’s existing 264 electrolytic cells with the 300 additional cells planned for the expansion (Pechiney, 2002a).

Alcoa announced plans for the modernization of its primary aluminum smelter in Baie Comeau, Quebec. The 8-year project will involve the replacement of the plant’s Soderberg production technology with a modern prebake technology. Alcoa also plans to maximize operations in the two units that are already using prebake technology. Upon completion of the project in 2010, production capacity at the plant is expected to increase from 437,000 t/yr to 547,000 t/yr (Alcoa Inc., 2002j).

Alcan announced the restart of 60,000-t/yr of capacity at its Kitimat, British Columbia, smelter. The company had reduced its operating capacity from 277,000 t/yr to 180,000 t/yr in June 2001 in response to a critical water shortage in the Nechako Reservoir, which supplied water to Alcan’s power generating station near Kemano, British Columbia (Alcan, 2002l).

Alcoa and the Government of Newfoundland and Labrador agreed to terminate discussions begun last year for new hydroelectric plants in the province, which would have supplied power for future aluminum processing facilities. The project is deemed to be uneconomic at this time (Keith, 2002).5.6 U.S. GEOLOGICAL SURVEY MINERALS YEARBOOK—2002 

## Alcan sold its dross processing facility in Quebec to Scepter Aluminum Company, a privately held recycling business based in the United States. Under the terms of the transaction, the Guillaume-Tremblay Works will continue to process the dross produced by Alcan’s Quebec smelters (Alcan Inc., 2002d).

China.— Alcan announced an agreement in principle to form a joint venture with Qingtongxia Aluminum Company (QTX). Under the proposed joint venture, Alcan would acquire a 50% ownership position in the recently completed 130,000-t/yr primary aluminum smelter in the Ningxia Autonomous Region. In addition, Alcan would have the option to secure a 50% interest in the planned and approved 150,000-t/yr expansion of this smelter (Alcan Inc., 2002a).

Lanzhou Aluminium Co., Ltd. and Pechiney announced an agreement in principle to develop a technical joint venture aimed at constructing a new 260,000-t/yr smelter in Gansu Province. After signing the letter of intent, the companies will begin a detailed prefeasibility study in 2003. If the project proves to be clearly profitable, then the companies would create a joint venture in 2004, subject to the formal approval by the relevant Chinese authorities (Pechiney, 2002b).

Meanwhile, Alcoa and Aluminium Corporation of China Limited (Chalco) announced that the formalization of its joint venture at Pingguo would be delayed until 2003 giving both parties more time to complete the necessary commercial terms and to obtain the necessary government approvals. Under the previously announced agreement, the companies would form a 50/50 joint venture at Chalco’s Pingguo alumina and aluminum production facilities. The companies have also committed to significant expansions of refining and smelting capacities during the next few years (Alcoa Inc., 2002i).

Emeishan Aluminium Industry Consortium announced the completion of the first phase of its new 300,000-t/yr smelter
in Sichuan Province. The first stage capacity was 73,000 t/yr. Subsequent phases were expected to increase capacity to 223,000 t/yr in 2003 and full capacity in 2005. The smelter uses prebake anode technology (American Metal Market, 2002e).

Chalco began trial runs at its new 55,000-t/yr Haixing smelter in Qinghai Province. The plant was expected to reach full production by yearend (American Metal Market, 2002a).

Henan Wanji Aluminium, formerly Xinan Aluminium Plant, reportedly completed a new smelter that increased capacity at its facility from 60,000 t/yr to 180,000 t/yr (American Metal Market, 2002b).

Guangdong Fenglu Aluminium Co. commissioned a new extrusion plant at its facility in Nanhai, Guangdong Province. The new facility, which was in the final stages of trial runs, would add 130,000 t/yr of capacity and increase the combined capacity of the plant’s two extrusion lines to 160,000 t/yr (Metal Bulletin, 2002c).

Czech Republic.— Nemak SA, headquartered in Monterrey, Mexico, began construction of its first European aluminum casting plant for automotive parts. The new facility, being built in Most, was expected to begin producing parts by late 2003 or early 2004. The size and capacity of the plant were not disclosed but the first castings were expected to be aluminum cylinder heads for Jaguar Cars Ltd. (American Metal Market, 2002f).

Sumitomo Light Metal Industries announced plans to build its first European production facility, also in the Czech Republic. The plant, which will produce extruded aluminum tubes for automotive air-conditioning systems, will be situated near Prague. Production at Sumikei Czech could begin as early as January 2004 (Metal Bulletin, 2002f).

Egypt.— Aluminium Company of Egypt announced a 50,000-t/yr expansion at its 190,000-t/yr smelter. The expansion, scheduled for completion in April 2004, included the construction of a new 92-pot potline and the refurbishment of an existing potline (Metal Bulletin, 2002b).

Germany.—IMCO exercised its preemptive rights to VAW’s50%-interest in VAW-Imco Guss und Recycling GmbH. VAWImco was formed in 1996 and operates two aluminum recycling and foundry alloy plants in Grevenbroich and Toging. The plants supply aluminum alloys to European automakers (IMCO Recycling Inc., 2002b).

Alcan announced that it had signed a definitive agreement with Norsk Hydro to purchase VAW Packaging (FlexPac) (Alcan Inc., 2002f). FlexPac, which included 14 plants in 8 countries, produced flexible packaging products for the food, dairy, and pharmaceutical industries. At the conclusion of the definitive share-purchase agreement, Alcan would waive its preemptive rights with respect to the Alunorf rolling mill in Germany and would terminate the related litigation (Alcan Inc., 2002g).

Ghana.—Drought conditions reduced the operating level of the Akosombo Dam hydroelectric plant and forced the Volta River Authority to reduce power allocations to the Volta Aluminum Company Limited (Valco) smelter. As a result, Kaiser, which owns 90% of the 200,000-t/yr smelter, curtailed production in March at a second of the smelter’s five potlines. Each of the smelter’s potlines has a capacity of about 40,000 t/yr. Kaiser operated four potlines in 2000 and 2001 (Kaiser Aluminum & Chemical Corp., 2002b).

Iceland.— Alcoa announced that it signed a memorandum of understanding (MOU) with the Government of Iceland and Landsvirkjun, Iceland’s national power company, formalizing its cooperation on a 295,000-t/yr primary aluminum smelter to be built in eastern Iceland. Under the MOU, Landsvirkjun would begin development of a 500 MW hydropower facility in eastern Iceland, and Alcoa would complete environmental and engineering studies of the smelter near Reydarfjordur. The MOU also included construction of a harbor facility at Mjoeyri as well as related infrastructure improvements in the area (Alcoa Inc., 2002d).

India.—Indian Aluminium Co. Ltd. (Indal) increased capacity at its Hirakud smelter by transporting potlines from the company’s mothballed Belgaum facility to Hirakud. The smelter’s capacity increased to 57,000 t/yr from 30,000 t/yr (Mining Journal, 2002a).

Italy. —Alcan announced the sale of its rolled product circles production unit in Pieve Emanuele to Aliberico Group of Madrid, Spain. The circles, manufactured from sheet aluminum, are largely for the kitchenware market (Alcan Inc., 2002j).

Japan.— Allis Sanyo (a subsidiary of Honda Trading) commissioned new facilities that would increase its capacity for secondary aluminum alloy production to 3,000 t/mo. Molten metal from Allis Sanyo will be delivered to Honda’s motorbike and engine plant in Ozu, Kumamoto (Metal Bulletin, 2002d).ALUMINUM—2002 5.7 

## Showa Denko shut five aluminum extrusion presses to bring active capacity closer to actual production levels. Sluggish demand for aluminum sashes, windows, and doors led the company to close down the presses at its Oyama and Sakai plants (Metal Bulletin, 2002e).

Tokai Aluminium Foil commissioned a new foil plant that initially will produce foil for the dairy industry. Throughput at the plant will be about 20 t/mo of primary ingot. Tokai Aluminium is Japan’s third largest aluminum foil maker (Metal Bulletin, 2002g).

In March, Alcoa purchased an additional 20.3% interest in Shibazaki Seisakusho Ltd., a manufacturer of plastic and aluminum closures and caps for the beverage and pharmaceutical industries, from The Furukawa Electric Co., Ltd. The acquisition increased Alcoa’s holding to 70.8% from its original 50.5% investment, which it had held since 1979. Alcoa then began a tender offer for the remaining shares of Shibazaka (Alcoa Inc., 2002e). Upon acquiring additional shares in the company, Alcoa’s ownership stake increased to 95.9% (Alcoa Inc., 2002c).

Malaysia.— A group of investors from Dubai and Bahrain, Gulf International Investment Group, signed an agreement for the development of a new 500,000-t/yr aluminum smelter in Sarawak. The smelter would be constructed in two stages of 250,000 t/yr each. BHP Billiton reportedly expressed interest in joining the consortium. The viability of the plan, however, hinged on the construction of the 2,400-MW Bakun Dam hydroelectric powerplant (CRU Aluminium Monitor, 2002).

Mexico.—IMCO announced that its joint venture in Monterrey (IMCO Reciclaje de Nuevo Leon S. de R.L. de C.V.) was awarded a long-term contract to recycle aluminum drosses and scrap for Nemak, S.A., a producer of aluminum cylinder heads and engine blocks. To meet the terms of the contract, a new 45,400-t/yr (100-million-pound-per-year) facility was built to upgrade and eventually replace the current operation of equivalent size (IMCO Recycling Inc., 2002c). Note that the annual capacity of the original facility quoted in the aluminum chapter of the 2001 USGS Minerals Yearbook is incorrect.

Norway.—In February, Alcoa increased its share of Elkem ASA to 40.2% (Alcoa Inc., 2002a). By November, Alcoa held 46.5% of Elkem’s shares (Alcoa Inc., 2002k).

Hydro Aluminium AS (a subsidiary of Norsk Hydro) commissioned the first cells in the new potroom of the Sunndal aluminum smelter. The new potroom is the first phase of the smelter’s expansion and modernization project that began in June 2001. Section 1, which consists of 108 cells with a total annual capacity of approximately 76,000 t, was expected to be fully operational early in 2003. Concurrently, the old Soderberg cells, with an annual capacity of 66,000 t, were to be gradually phased out. Section 2 was scheduled for completion in the summer of 2003. A total of 340 cells using Norsk Hydro’s proprietary process technology, HAL250, are to be installed. Upon completion of the project in 2004, capacity at the Sunndal smelter would increase to about 330,000 t/yr (Norsk Hydro ASA, 2002a, c).

In response to shortages in Norway’s electricity supply, Hydro Aluminium cut aluminum production at its Karmoy smelter by 3,500 t. The reduction coincided with the seasonal slowdown in demand for extrusion ingot expected early in 2003. The unused power was sold back to the Norwegian electricity grid. Rising electricity prices also forced Hydro Aluminium to close redundant Soderberg capacity at its Sunndal smelter sooner than originally planned, cutting production by 1,400 t (American Metal Market, 2002c).

In an effort to ease the country’s escalating power crisis, Norsk Hydro agreed to purchase 300 MW of electricity from Russian energy producer Unified Energy System.
Reduced autumn rainfall led to diminished reservoir levels at hydroelectric plants. The additional power, to be delivered in January 2003 through Finland to the joint Nordic electricity grid, will be sold by Norsk Hydro’s energy arm to the domestic market to improve the power balance in the region (American Metal Market, 2002g).

Qatar.— United Development Co. (UDC), a private investment company in Qatar, announced plans to build a 500,000-t/yr primary aluminum smelter in the Ras Laffan industrial area. The smelter could be expanded in stages to a capacity of up to 1 Mt/yr. UDC is developing the smelter under contract from the Qatari Government (Cooper, 2002).

Romania.— A consortium formed by U.S.-based trader Marco International, its Romanian subsidiary Conef SA, and Marco Acquisitions purchased a 10% interest in the 175,000-t/yr ALRO SA (Slatina) primary aluminum smelter. The purchase gave Marco controlling interest (roughly 54%) of the company’s outstanding shares (American Metal Market, 2002i; Guerriere, 2002c).

Later in the year, Marco purchased a controlling interest (69.9%) in the Aprom SA aluminum rolling mill from the Romanian Government for $4 million and pledged to invest an additional $9.9 million in mill improvements. The mill reportedly produces bars, pipes, and plates (American Metal Market, 2002h).

Russia.— Norsk Hydro and RusAl entered into a long-term agreement for the production and sourcing of high-grade aluminum extrusion ingots. Norsk Hydro will participate in a two-stage upgrade of the Sayanogorsk smelter cast house. Norsk Hydro will provide its own proprietary casting equipment, which RusAl will use to supply extrusion ingots back to Norsk Hydro. The first stage, scheduled for completion by yearend 2003, would add 80,000 t/yr of extrusion ingot casting capacity. The second stage, to follow a few years later, would bring casting capacity up to 160,000 t/yr (Norsk Hydro ASA, 2002f).

South Africa.—BHP Billiton approved the Hillside aluminum smelter expansion project Hillside 3. The $449 million project will add 132,000 t/yr of capacity to the 515,000-t/yr smelter at Richards Bay, which was completed in 1996. Construction began in April, commissioning was scheduled for April 2004, and full production was expected in mid-2004. Hillside 3 will include a third potline (half the size of the existing two potlines), an anode-baking furnace, additional casting facilities, and all necessary related infrastructure. The expansion, like the existing smelter, will use Pechiney AP30 technology (BHP Billiton, 2002).

Spain.— Norsk Hydro opened its new aluminum remelt and recycling plant at Azuqueca de Henares, near Madrid. The plant has the capacity to produce 60,000 t/yr of extrusion ingot from aluminum scrap (Platts Metals Week, 2002f).5.8 U.S. GEOLOGICAL SURVEY MINERALS YEARBOOK—2002 

## Sweden.—Elkem ASA’s wholly owned subsidiary (Elkem Sweden AB) increased its share in the Swedish aluminum semifabricator, Sapa AB, from 36% to 71.4% (Elkem ASA, 2002).

Stena Aluminium AS completed the installation of two new rotary furnaces at its secondary smelter in Älmhult. Each new furnace has the capacity to melt 25,000 t/yr of aluminum scrap. The project has increased the plant’s melt capacity from 30,000 t/yr (Conway, 2002).

Ukraine.— Ukrainskiy Aluminiy (UkrAl) (a subsidiary of RusAl) reportedly began construction on a 120,000-t/yr primary aluminum smelter in the city of Pervomaysk. The $300 million project was part of an investment commitment made by RusAl in March 2000 when it purchased a 30% interest in Ukraine’s Nikolayev Alumina Plant (Platts Metals Week, 2002i).
United Arab Emirates.—Dubai Aluminium Company Ltd. (Dubal) received approval for a refurbishment project, the Kestrel project, which would increase capacity at the 536,000- t/yr smelter to more than 700,000 t/yr. The project involves the upgrading and extension of Dubal’s initial three potlines and the extension of its more recent fourth potline. Work was expected to be completed by 2006 (Platts Metals Week, 2002d).

Outlook

World aluminum supply probably will continue to outstrip demand. Although many industry observers believe that there could be significant growth in aluminum demand during the next few years, supply expansions, especially in China, were expected to more than meet the increase in demand.

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American Metal Market, v. 110, no. 81, August 12, p. 4.



## Internet Reference Cited

Reese, Dave, 2002 (December 8), Columbia Falls Aluminum Company

operating smoothly since reopening, accessed June 18, 2003, via URL http://www.dailyinterlake.com.



## GENERAL SOURCES OF INFORMATION

U.S. Geological Survey Publications

Aluminum. Ch. in Mineral Commodity Summaries, annual. Aluminum. Mineral Industry Surveys, monthly. Aluminum and Bauxite. Ch. in United States Mineral Resources, Professional Paper 820, 1973. Bauxite and Alumina. Ch. in Mineral Commodity

Summaries, annual. Primary Aluminum Plants Worldwide, 1998. U.S. Trade in Bauxite and Alumina. Mineral Industry

Surveys, quarterly. World Bauxite Resources. Professional Paper 1076-B, 1986.

Other

Alumina Plants Worldwide. U.S. Bureau of Mines, 1993. Aluminum. Ch. in Mineral Facts and Problems, U.S. Bureau

of Mines Bulletin 675, 1985.

1998 1999 2000 2001 2002
United States:

Primary production:

Quantity thousand metric tons 3,713 3,779 3,668 2,637 2,707
Value millions $5,360 $5,470 $6,030 $4,000 $3,870 Price, average, U.S. market, spot cents per pound 65.5 65.7 74.6 68.8 64.9 Inventories (December 31):

Aluminum industr y2 thousand metric tons 1,930 1,870 1,550 1,300 1,320

LME stocks in U.S. warehouses 3 do. 13 14 (4) 28 45

Secondar yrecover y : 5 3,440 3,700 3,450 2,970 r 2,930 New scrap do. 1,950 2,120 2,080 1,760 r 1,750 Old scrap do. 1,500 1,570 1,370 1,210 r 1,170 Exports, crude and semicrude do. 1,590 1,650 1,760 1,590 1,590 Imports for consumption, crude and semicrude do. 3,550 4,000 3,910 3,740 4,060

Su

pp ly, a pp arent 6 do. 9,040 9,890 9,610 7,990 r 8,060

Consumption

, a pp arent 7 do. 7,090 7,770 7,530 6,230 6,310 World, production do. 22,600 23,600 24,400 24,300 r 25,900 e

4 Less than 1/2 unit. 3 Includes aluminum alloyed material. Commerce, U.S. Census Bureau; 1999 through 2002 data from the Aluminum Association Inc.

7Apparent supply less recovery from purchased new scrap. and industry stock changes. 6 Defined as domestic primary metal production plus secondary rec overy plus imports minus exports plus adjustments for Government 5 Metallic recovery from purchased, tolled, or imported new and o ld scrap expanded for full industry coverage. 2 Includes ingot, semifabricated material, and scrap. 1998 datafrom Current Industrial Reports, Series M33-D, U.S. Department o f 1 Data are rounded to no more than three significant digits, except "Primary production." eEstimated. rRevised. TABLE 1

SALIENT ALUMINUM STATISTICS 1ALUMINUM—2002 5.11 Company 2001 2002 2002 ownership Alcan Aluminum Corp., Sebree, KY 196 196 Alcan Inc., 100%.
Alcoa Inc.:

Alcoa, TN 210 210 Alcoa Inc., 100%. Badin, NC 120 120 Do. Evansville, IN (Warrick) 309 309 Do. Ferndale, WA (Intalco) 278 278 Alcoa Inc., 61%; Mitsui & Co. Ltd., 32%; YKK Corp., 7%. Frederick, MD (Eastalco) 192 192 Do. Massena, NY (St. Lawrence) 125 125 Alcoa Inc., 100%. Massena, NY 130 130 Do. Mount Holly, SC 212 212 Alcoa Inc., 50.3%; Century Aluminum Co., 49.7%. Rockdale, TX 340 264 Alcoa Inc., 100%. Troutdale, OR 121 -- Do. Wenatchee, WA 227 227 Do.

Total 2,260 2,070 Century Aluminum Co.:

Hawesville, KY 237 237 Century Aluminum Co., 80%; Glencore International AG, 20%. Ravenswood, WV 170 170 Century Aluminum Co., 100%.

Total 407 407 Columbia Falls Aluminum Co., Columbia Falls, MT 168 168 Glencore International AG, 100%. Goldendale Aluminum Co., Goldendale, WA 168 168 Private interest, 60%; employees, 40%. Kaiser Aluminum & Chemical Corp.:

Mead, WA (Spokane) 200 200 MAXXAM Inc., 100%.

Tacoma

, WA 2 73 -- Do.
Total 273 200 Longview Aluminum, L.L.C., Longview, WA 204 204 Michigan Avenue Partners, 100%. Noranda Aluminum Inc., New Madrid, MO 230 250 Noranda Mines Ltd., 100%. Northwest Aluminum Corp., The Dalles, OR 82 82 Private interest, 100%. Ormet Primary Aluminum Corp., Hannibal, OH 257 257 Ormet Corp., 100%. Vanalco Inc., Vancouver, WA 116 116 Glencore International AG, 100%.

Grand total 4,370 4,120 TABLE 2

PRIMARY ANNUAL ALUMINUM PRODUCTION CAPACITY IN THE UNITED STATE S, BY COMPANY 1

Yearend capacity (thousand metric tons)

2 Sold to Tacoma Port Authority December 2002; scheduled for permanent closure. 1 Data are rounded to no more than three significant digits; may not add to totals shown. -- Zero.

Class Consumption Aluminum Metallic

2001:

Secondary smelters 1,630,000 r 1,130,000 r 1,220,000 r Integrated aluminum companies 946,000 772,000 823,000 Independent mill fabricators 695,000 601,000 642,000
Foundries 89,000 74,800 80,000
Other consumers 12,100 12,100 12,100

Total 3,370,000 r 2,590,000 r 2,770,000 r Estimated full industry coverage 3,610,000 r 2,770,000 r 2,970,000 r

2002:

Secondary smelters 1,680,000 1,130,000 1,220,000 Integrated aluminum companies 869,000 707,000 752,000 Independent mill fabricators 698,000 607,000 648,000
Foundries 112,000 95,300 102,000
Other consumers 8,320 8,250 8,250

Total 3,370,000 2,550,000 2,730,000 Estimated full industry coverage 3,620,000 2,730,000 2,930,000 TABLE 3

U.S. CONSUMPTION OF AND RECOVERY FROM PURCHASED NEW AND OLD ALUMINUM SCRAP, BY CLASS 1, 2

(Metric tons)

1 Excludes recovery from other than aluminum-base scrap. rRevised.

2 Data are rounded to no more than three significant digits; may not add to totals shown. Calculated recovery5.12 U.S. GEOLOGICAL SURVEY MINERALS YEARBOOK—2002 Stocks, Net Stocks, Class of consumer and type of scrap January 1 receipts 3 Consumption December 31 Secondary smelters:

New scrap:

Solids 19,300 r 250,000 258,000 11,600 Borings and turnings 4,370 r 230,000 229,000 4,930 Dross and skimmings 3,090 r 502,000 500,000 5,020

Other4 1,060 r 178,000 178,000 616

Total 27,900 r 1,160,000 1,170,000 22,100 Old scrap:

Castings, sheet, clippings 6,090 r 301,000 298,000 8,870 Aluminum-copper radiators 1,710 r 17,900 18,000 1,550

Aluminum cans 5 1,390 93,100 93,600 838

Other6 5,670 r 92,400 96,800 1,310

Total 14,900 r 504,000 506,000 12,600 Sweated pig 151 r 9,370 8,950 567

Total secondary smelters 42,900 r 1,670,000 1,680,000 35,300 Integrated aluminum companies, foundries, independent mill

fabricators, other consumers: New scrap:

Solids 9,160 r 709,000 700,000 18,000 Borings and turnings 352 19,600 19,500 465 Dross and skimmings 148 5,340 5,320 163

Other4 7,770 176,000 177,000 6,150

Total 17,400 r 909,000 902,000 24,800 Old scrap:

Castings, sheet, clippings 4,210 131,000 131,000 4,880 Aluminum-copper radiators 324 4,820 4,780 361

Aluminum cans 5 31,500 616,000 619,000 27,900

Other6 22 29,800 29,800 22

Total 36,000 782,000 785,000 33,100 Sweated pig 33 1,130 1,140 22

Total integrated aluminum companies, etc. 53,500 r 1,690,000 1,690,000 57,900 All scrap consumed:

New scrap:

Solids 28,500 r 959,000 958,000 29,500 Borings and turnings 4,720 r 250,000 249,000 5,400 Dross and skimmings 3,240 r 507,000 505,000 5,180

Other4 8,840 r 353,000 355,000 6,760

Total 45,300 r 2,070,000 2,070,000 46,900 Old scrap:

Castings, sheet, clippings 10,300 r 432,000 429,000 13,700 Aluminum-copper radiators 2,030 r 22,700 22,800 1,910
Aluminum cans 32,900 709,000 713,000 28,700

Other6 5,690 r 122,000 127,000 1,330

Total 50,900 r 1,290,000 1,290,000 45,700 Sweated pig 184 r 10,500 10,100 589

Total of all scrap consumed 96,300 r 3,370,000 3,370,000 93,200 TABLE 4 U.S. STOCKS, RECEIPTS, AND CONSUMPTION OF PURCHASED NEW AND OLDALUMINUM SCRAP

(Metric tons) AND SWEATED PIG IN 2002 1, 2

6 Includes municipal wastes (including litter) and fragmentized s crap (auto shredder). 5 Used beverage cans toll treated for primary producers are included in secondary smelter tabulation. 4 Includes data on foil, can stock clippings, and other miscellaneous. 3 Includes inventory adjustment. 2 Data are rounded to no more than three significant digits; may not add to totals shown. metric tons, was received on toll arrangements. 1 Includes imported scrap. According to reporting companies, 8. 08% of total receipts of aluminum-base scrap, or 278,000 rRevised.ALUMINUM—2002 5.13 Net Net
Production shipments 2 Production shipments 2 Diecast alloys:

13% Si, 360, etc. (0.6% Cu, maximum) 21,000 r 22,200 r 24,300 25,200
380 and variations 385,000 r 388,000 r 384,000 379,000 Sand and permanent mold:

95/5 Al-Si, 356, etc. (0.6% Cu, maximum) 57,200 r 58,100 r 49,100 61,800
No. 319 and variations 116,000 r 121,000 r 128,000 134,000 F-132 alloy and variations 24,300 25,000 27,700 27,300 Al-Mg alloys 639 639 1,190 1,180 Al-Zn alloys 1,780 1,940 2,080 3,020 Al-Si alloys (0.6% to 2.0% Cu) 2,020 2,020 634 614 Al-Cu alloys (1.5% Si, maximum) 2,290 2,290 3,460 3,590 Al-Si-Cu-Ni alloys 949 950 45 38
Other 1,340 1,320 r 938 975 Wrought alloys, extrusion billets 209,000 r 206,000 r 240,000 240,000
Miscellaneous:

Steel deoxidation W W W W Pure (97.0% Al) W W W W
Aluminum-base hardeners 3,470 3,470 3,380 3,380

Other3 104,000 r 106,000 r 88,000 87,800

Total 929,000 r 939,000 r 954,000 968,000 Less consumption of materials other than scrap:

Primary aluminum 70,900 XX 97,700 XX Primary silicon 42,100 r XX 43,400 XX
Other 7,630 r XX 9,040 XX Net metallic recovery from aluminum scrap and sweated pig consumed in

production of secondar yaluminum ing ot4 808,000 r XX 804,000 XX TABLE 5

PRODUCTION AND SHIPMENTS OF SECONDARY ALUMINUM ALLOYS BY INDEPENDENT SMELTERS

(Metric tons) IN THE UNITED STATES 1

2001 2002

4No allowance made for melt-loss of primary aluminum and alloying ingredients. 3 Includes other die-cast alloys. 2 Includes inventory adjustment. 1 Data are rounded to no more than three significant digits; may not add to totals shown. rRevised. W Withheld to avoid disclosing company proprietary data; included with "Miscellaneous, other." XX Not applicable.

Quantity Quantity (thousand Percentage (thousand Percentage Industry metric tons) of grand total metric tons) of grand total Containers and packaging 2,250 22.0 2,260 21.1 Building and construction 1,500 14.6 1,560 14.6 Transportation 3,190 31.2 3,410 31.8
Electrical 686 6.7 677 6.3
Consumer durables 681 6.7 722 6.8 Machinery and equipment 641 6.3 616 5.8
Other markets 367 3.6 390 3.6

Total to domestic users 9,310 91.2 9,640 90.0

Exp orts e 902 8.8 1,070 10.0

Grand total 10,200 100.0 10,700 100.0 TABLE 6

DISTRIBUTION OF END-USE SHIPMENTS OF ALUMINUM PRODUCTS
IN THE UNITED STATES AND CANADA, BY INDUSTRY 1, 2

2001 2002

Source: The Aluminum Association Inc. 2 Data series revised to include shipments in both the United States and Canada. 1 Data are rounded to no more than three significant digits; may not add to totals shown. eEstimated.5.14 U.S. GEOLOGICAL SURVEY MINERALS YEARBOOK—2002 2000 2001 2002 Wrought products:

Sheet, plate, foil 4,840 4,380 r 4,510 Pipe, tube, extruded shapes 1,640 1,460 r 1,450 Rod, bar, wire, cable 592 r 354 r 369 Forgings (including impacts) 106 87 r 89 Powder, flake, paste 59 56 56

Total 7,240 r 6,330 r 6,470 Castings:

Sand 152 r 124 NA Permanent and semipermanent mold 549 r 489 NA
Die 991 r 871 NA
Other 156 r 167 NA

Total 1,850 r 1,650 NA
Grand total 9,080 r 7,980 NA TABLE 7 U.S. NET SHIPMENTS OF ALUMINUM WROUGHT AND CAST PRODUCTS,

(Thousand metric tons) BY PRODUCERS 1, 2

Sources: The Aluminum Association Inc. and U.S. Department of Commerce. 2 Data are rounded to no more than three significant digits; may not add to totals shown. shape from the domestic industry's gross shipments of that shap e. 1 Net shipments derived by subtracting the sum of producers' dome stic receipts of each mill rRevised. NA Not available.ALUMINUM—2002 5.15 Quantity Value Quantity Value Quantity Value Quantity Value Country or territory (metric tons) (thousands) (metric tons) (thousands) (metric tons) (thousands) (metric tons) (thousands)

2001:

Brazil 530 $914 42,000 $125,000 12 $10 42,600 $126,000

Canada 87,000 134,000 459,000 1,170,000 215,000 206,000 761,000 1,510,000
China 270 1,370 33,300 88,000 177,000 156,000 210,000 246,000

France 161 454 7,130 35,000

-- -- 7,290 35,500 Germany 987 9,800 2,530 17,900 1,740 7,490 5,250 35,200 Hong Kong 1,510 2,580 2,020 14,400 11,400 16,300 14,900 33,300 Italy 29 117 2,120 13,800 258 189 2,410 14,100 Japan 8,580 19,200 9,420 85,800 23,700 26,400 41,700 131,000 Korea, Republic of 1,880 4,170 13,500 59,300 50,600 54,500 66,000 118,000
Mexico 85,700 131,000 131,000 416,000 52,100 64,000 269,000 610,000
Netherlands 83 471 2,190 10,700 161 199 2,430 11,400 Philippines 51 160 764 3,240

-- -- 815 3,400
Russia 9 106 578 2,480

-- -- 588 2,590
Saudi Arabia 107 225 9,320 24,300 19 4 9,450 24,600 Singapore 40 176 2,930 12,600 122 269 3,090 13,100
South Africa 4 13 169 1,090 13 150 187 1,250
Taiwan 335 927 5,200 21,700 28,500 29,100 34,000 51,700
Thailand 1,250 1,840 11,000 28,800 1,250 1,900 13,500 32,600 United Kingdom 726 4,590 15,200 96,000 2,950 4,490 18,900 105,000
Venezuela 21 82 12,600 31,900 107 511 12,700 32,500

Other r 2,610 8,090 51,700 219,000 15,500 19,900 69,800 247,000
Total 192,000 320,000 814,000 2,480,000 580,000 588,000 1,590,000 3,390,000

2002:

Brazil 116 328 29,300 79,700 18 18 29,500 80,000
Canada 97,800 158,000 471,000 1,180,000 202,000 193,000 771,000 1,530,000
China 114 551 32,300 75,100 206,000 170,000 238,000 245,000

France 113 272 5,120 30,400 8 110 5,240 30,700 Germany 1,410 9,440 2,810 23,300 264 965 4,480 33,700 Hong Kong 162 1,200 4,060 13,600 8,190 10,500 12,400 25,400 Italy 14 90 1,960 9,600 39 55 2,010 9,740 Japan 3,350 10,100 9,060 64,000 27,100 31,100 39,600 105,000 Korea, Republic of 725 1,970 7,540 35,100 43,900 48,200 52,200 85,300
Mexico 98,800 143,000 114,000 367,000 85,300 107,000 299,000 617,000
Netherlands 129 791 800 4,930 314 961 1,240 6,680 Philippines 1 15 560 2,510

-- -- 560 2,520
Russia 19 53 30 387 9 5 58 445
Saudi Arabia (3) 4 14,500 32,800

-- -- 14,500 32,800 Singapore 239 897 2,040 9,630 194 236 2,470 10,800
South Africa 61 282 142 810

-- -- 204 1,090
Taiwan 233 1,280 6,430 17,200 27,200 28,300 33,800 46,700
Thailand 1 34 8,940 23,800 831 680 9,780 24,600 United Kingdom 647 3,110 8,890 64,800 661 941 10,200 68,800
Venezuela 6 54 7,900 19,700 1 6 7,900 19,800
Other 1,630 5,920 38,800 161,000 11,600 11,500 52,000 178,000

Total 206,000 337,000 766,000 2,220,000 613,000 603,000 1,590,000 3,160,000 TABLE 8
U.S. EXPORTS OF ALUMINUM, BY COUNTRY 1

Metals and alloys, crude Plates, sheets, bars, etc. 2 Scrap Total

1 Data are rounded to no more than three significant digits; may not add to totals shown. rRevised. -- Zero.

Source: U.S. Census Bureau. 3 Less than 1/2 unit. 2 Includes castings, forgings, and unclassified semifabricated forms.5.16 U.S. GEOLOGICAL SURVEY MINERALS YEARBOOK—2002 Quantity Value Quantity Value
Class (metric tons) (thousands) (metric tons) (thousands)
Crude and semicrude:

Metals and alloys, crude 192,000 $320,000 206,000 $337,000 Scrap 580,000 588,000 613,000 603,000 Plates, sheets, bars, strip, etc. 751,000 2,120,000 706,000 1,880,000 Castings and forgings 18,100 149,000 19,200 132,000 Semifabricated forms, n.e.c. 44,500 215,000 41,500 205,000

Total 1,590,000 3,390,000 1,590,000 3,160,000
Manufactures:

Foil and leaf 59,200 225,000 60,800 213,000
Powders and flakes 8,660 40,100 8,850 40,100
Wire and cable 28,300 84,100 30,800 76,700

Total 96,200 349,000 100,000 330,000
Grand total 1,680,000 3,740,000 1,690,000 3,490,000

Source: U.S. Census Bureau. 1 Data are rounded to no more than three significant digits; may not add to totals shown. TABLE 9
U.S. EXPORTS OF ALUMINUM, BY CLASS 1

2001 2002

Quantity Value Quantity Value
Class (metric tons) (thousands) (metric tons) (thousands)
Crude and semicrude:

Metals and alloys, crude 2,560,000 $3,930,000 2,790,000 $4,040,000

Plates

, sheets

, strip, etc.

, n.e.c. 2 553,000 1,320,000 630,000 1,410,000 Pipes, tubes, etc. 16,400 90,400 17,000 94,900
Rods and bars 114,000 352,000 149,000 417,000 Scrap 497,000 552,000 466,000 502,000

Total 3,740,000 6,250,000 4,060,000 6,460,000
Manufactures:

Foil and leaf 3 86,600 306,000 105,000 337,000
Powders and flakes 5,360 16,300 3,570 14,200
Wire 91,700 162,000 118,000 190,000

Total 184,000 484,000 227,000 541,000
Grand total 3,920,000 6,740,000 4,280,000 7,000,000 TABLE 10
U.S. IMPORTS FOR CONSUMPTION OF ALUMINUM, BY CLASS 1

2001 2002

1 Data are rounded to no more than three significant digits; may not add to totals shown.

Source: U.S. Census Bureau. 3 Excludes etched capacitor foil. 2 Includes plates, sheets, circles, and disks.ALUMINUM—2002 5.17 Quantity Value Quantity Value Quantity Value Quantity Value Country (metric tons) (thousands) (metric tons) (thousands) (metric tons) (thousands) (metric tons) (thousands)

2001:

Argentina 53,800 $88,000 105 $216 2,840 $3,910 56,700 $92,100

Australia 121,000 188,000 125 549 18 12 121,000 189,000
Bahrain 8,210 13,200 16,100 32,600

-- -- 24,300 45,800 Belgium 60 279 3,210 10,100 37 52 3,310 10,400
Brazil 35,000 55,500 4,360 8,810 20,900 29,700 60,200 94,000
Canada 1,670,000 2,590,000 405,000 928,000 283,000 315,000 2,360,000 3,830,000
China 1,620 2,760 6,870 20,500 447 776 8,940 24,000

France 691 4,810 5,250 23,000 7,840 6,810 13,800 34,600 Germany 677 4,300 50,300 189,000 7,140 7,490 58,200 200,000 Italy (3) 8 2,730 11,000 62 61 2,790 11,100 Japan 501 1,020 11,100 47,400 386 693 12,000 49,100 Korea, Republic of 766 1,380 6,810 20,600 59 142 7,630 22,100
Mexico 3,930 6,190 16,500 67,000 67,000 70,100 87,400 143,000
Netherlands 644 1,940 2,490 7,420 2,710 4,620 5,840 14,000 Norway 7,850 13,300 1,160 1,910 1,680 2,970 10,700 18,200

Panama

-- -- 972 3,040 5,820 6,070 6,790 9,110
Russia 377,000 533,000 37,700 81,300 39,700 45,200 454,000 660,000
Slovenia

-- -- 3,350 10,600

-- -- 3,350 10,600
South Africa 19,400 27,700 26,300 62,800 31 42 45,800 90,500 Spain 802 1,130 71 867 37 26 910 2,030
Ukraine 11,000 19,300 1 4 840 970 11,800 20,300 United Arab Emirates 62,500 105,000

-- -- 3,140 3,470 65,600 109,000 United Kingdom 3,660 7,740 11,900 46,900 4,290 4,190 19,900 58,800
Venezuela 159,000 236,000 17,400 33,200 7,890 7,640 184,000 277,000

Other r 23,200 33,400 52,900 161,000 41,900 41,900 118,000 236,000
Total 2,560,000 3,930,000 683,000 1,770,000 497,000 552,000 3,740,000 6,250,000

2002:

Argentina 82,300 118,000 773 1,290 479 579 83,500 120,000
Australia 95,500 139,000 108 785 125 130 95,700 140,000
Bahrain 18,200 26,500 19,100 36,800

-- -- 37,200 63,300 Belgium (3) 5 8,670 20,800 450 691 9,120 21,500
Brazil 41,000 61,600 2,910 5,390 14,800 19,400 58,700 86,300
Canada 1,580,000 2,320,000 453,000 997,000 293,000 312,000 2,330,000 3,630,000
China 562 1,130 16,500 45,800 1,220 820 18,300 47,800

France 1,160 5,900 6,280 23,400 3,520 3,100 11,000 32,400 Germany 2,360 8,260 61,000 205,000 4,970 4,830 68,300 218,000 Italy 80 122 2,520 9,820 42 45 2,640 9,980 Japan 548 1,150 9,150 39,800 249 769 9,950 41,700 Korea, Republic of 3,510 5,160 5,450 14,500 99 135 9,060 19,800
Mexico 4,690 8,670 15,100 63,600 62,000 61,300 81,800 134,000
Netherlands 440 1,460 2,710 8,310 1,570 2,080 4,730 11,900 Norway 3,810 6,170 125 433

-- -- 3,930 6,600

Panama

-- -- 801 2,560 3,710 3,670 4,510 6,230
Russia 634,000 863,000 60,800 110,000 25,400 33,600 720,000 1,010,000
Slovenia 1 16 3,390 8,860

-- -- 3,390 8,870
South Africa 15,900 21,300 31,900 72,300 8 4 47,800 93,600 Spain 624 1,450 244 1,300

-- -- 868 2,750
Ukraine

-- -- 20 30

-- -- 20 30 United Arab Emirates 61,200 95,400

-- -- 777 841 61,900 96,300 United Kingdom 1,230 1,930 7,870 29,000 4,490 4,860 13,600 35,700
Venezuela 203,000 294,000 21,800 36,000 7,330 6,580 232,000 337,000
Other 39,800 56,900 66,100 186,000 41,800 46,300 148,000 289,000

Total 2,790,000 4,040,000 797,000 1,920,000 466,000 502,000 4,060,000 6,460,000

1 Data are rounded to no more than three significant digits; may not add to totals shown. rRevised. -- Zero. TABLE 11
U.S. IMPORTS FOR CONSUMPTION OF ALUMINUM, BY COUNTRY 1

Metals and alloys, crude Plates, sheets, bars, etc. 2 Scrap Total

Source: U.S. Census Bureau. 3 Less than 1/2 unit. 2 Includes circles, disks, rods, pipes, tubes, etc.5.18 U.S. GEOLOGICAL SURVEY MINERALS YEARBOOK—2002 Country 1998 1999 2000 2001 2002 e Argentina 187 206 262 245 r, e 250
Australia 1,627 1,718 1,769 1,798 1,836 3

Bahrain 501 503 509 522 r 517

Bosnia and Herze g ovina e, 4 28 70 95 r 96 r 104
Brazil 1,208 1,250 1,271 1,131 1,318 3

Cameroon 82 e 90 r 96 r 81 80
Canada 2,374 2,390 2,373 2,583 2,709 3

China e 2,340 2,530 2,800 3,250 4,300

Croatia4 16 14 14 15 e 15 Egypt 195 193 193 e 189 r, e 190

France 424 455 441 462 450 Germany 612 634 644 652 650
Ghana 56 104 156 162 132

Greece 146 170 168 163 e 165 Hungary 35 34 34 r 35 e 35

Iceland 5 173 220 r 224 r 243 264

India 6 542 614 644 624 r 650

Indonesia e, 6 133 106 160 180 160

Iran 124 137 140 e 140 e 130 Italy 187 187 189 187 180

Jap an 7 16 11 7 7 e 7

Mexico 6 62 63 61 r 52 r 60 Mozambique

-- -- 54 266 273 3

Netherlands 264 e 286 302 294 300
New Zealand 318 327 328 322 335

Ni g eriae 20 16

-- -- -- Norway 996 1,020 1,026 1,068 1,096 3

Poland 8 54 51 47 45 r 50

Romania9 174 174 179 182 r 180
Russia 3,005 3,146 3,245 3,300 e 3,347 3

Serbia and Montene gro 4 60 73 88 100 r 104 3

Slovakia 6 108 109 110 110 e 112

Slovenia4 74 77 100 100 e 88
South Africa 677 689 673 r 662 r 676 3 Spain 362 364 366 376 380

Suriname e 29 3 6

-- -- -- Sweden 96 99 101 102 101
Switzerland 32 34 35 e 35 e 36 Tajikistan 196 229 300 289 r 308

Turkey e 62 62 61 r 61 r 62

Ukraine 9 107 115 119 106 r 112

United Arab Emirates

, Dubai e 352 3 440 470 500 536 United Kingdom 258 272 305 341 340
United States 3,713 3,779 3,668 2,637 2,707 3

Venezuela 585 570 569 571 r, e 570

Total 22,600 23,600 24,400 24,300 r 25,900

2 Primary aluminum is defined as "The weight of liquid aluminum a s tapped from pots, excluding the weight of any alloying 1 World totals and estimated data are rounded to no more than three significant digits; may not add to totals shown. eEstimated. rRevised. -- Zero. TABLE 12
ALUMINUM, PRIMARY: WORLD PRODUCTION, BY COUNTRY 1, 2

(Thousand metric tons)

9 Primary unalloyed metal plus primary alloyed metal, thus including weight of alloying material. 8 Primary unalloyed ingot plus secondary unalloyed ingot. 2000--40,956; 2001---26,586; and 2002--25,000 (estimated). definitions. For those countries for which a different definition is given specifically in the source publication, that practices vary from country to country, some nations conformingto the foregoing definition and others using different materials as well as that of any metal produced from either returned scrap or remelted materials." International reporting

7 Excludes high-purity aluminum containing 99.995% or more as fol lows, in metric tons: 1998--35,063; 1999--34,893; 6 Primary ingot. 5 Ingot and rolling billet production. 4 Primary ingot plus secondary ingot. 3 Reported figure. definition is provided in this table by footnote. Table includes data available through May 9, 2003.