An Aluminum Smelter Hasn’t Been Built In The U.S. In 45 Years

Smelting furnaces in an aluminum plant (Adobe Stock photo)

Aluminum is versatile, abundant and light, and it is in hundreds of commercial items, including appliances, zippers, golf clubs and indoor furniture. Despite its excellent manufacturing properties, the raw material has production drawbacks — its smelters use loads of electricity and the fossil fuels used to create that electricity harm the environment, reports Maddie Stone of Grist. However, in the United States, the way aluminum is made may soon change. Century Aluminum Company, a global aluminum producer, is negotiating with the Department of Energy for up to $500 million in grant money to build a new aluminum smelter.

Promoted as the “green aluminum smelter,” the facility would be “the nation’s first new aluminum smelter in 45 years, which could double the amount of virgin, or primary, aluminum the country produces while emitting 75% less CO2 than older smelters, thanks to increased efficiency and the use of renewable electricity,” Stone writes. “The grant, which is awaiting finalization, is a ‘huge vote of confidence and a shot in the arm’ for the industry, said Annie Sartor, the aluminum campaign director at Industrious Labs, a nonprofit focused on industrial decarbonization.”

Protecting the environment while supplying the U.S. with tons more aluminum means the production process matters for aluminum, which requires extreme amounts of electricity. Rebecca Dell, an industrial decarbonization expert with the nonprofit ClimateWorks, told Stone, “We’re talking about truly eye-watering amounts of electricity. . . . The first, most important thing to do is to use clean electricity.”

Creating a climate-friendly smelter means Century Aluminum must find a site to support its clean energy demands. “According to the DOE, Century Aluminum’s preferred site is in Kentucky, a state with lackluster clean energy credentials,” Stone writes. “Sartor says she expects a plant of this size to require ‘somewhere in the neighborhood of a gigawatt’ of power.'” Sartor added, “The only way that will happen is if gargantuan amounts of clean energy get built in Kentucky. . . . There’s no other way around this.”

While Kentucky is the favored location, Century Aluminum hasn’t decided. “Locations within the Ohio and Mississippi River basins are also reportedly under consideration,” Stone reports. “Dell believes that brings an interesting political dimension to the project because Century Aluminum expects the smelter to create more than 1,000 full-time union jobs and another 5,500 construction jobs.”