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From ore to ingots: Meet the top 5 aluminium smelters in the world

Contributed by: Team AlCircle

calendarJanuary 12, 2024

In the global aluminium industry, continuous expansion is driven by the world's top five largest aluminium-producing companies, each contributing greatly to the sector's robust growth. As we delve into the intricacies of these industry leaders, the soaring demand for aluminium, fuelled by flourishing downstream industries such as automotive, packaging, electrical applications, construction, and consumer products, undergirds the pivotal role these industry leaders play.

Geographically, the Asia-Pacific region is the powerhouse of the global aluminium industry, spearheaded by the two giants China and India. Their dominant position is attributed to massive urbanisation, increasing income levels, and rapid industrial development in the region.

China, in particular, stands as the primary driver, boasting the largest aluminium market in terms of both production and consumption. The sheer scale of China's economic activities and infrastructure development fuels a lion's share of the global aluminium demand.

As we study the key players shaping the aluminium market, it is evident that their influence extends beyond national borders, impacting the world's economic performance. This article delves into the global aluminium industry, focusing on the top five leading companies in production and their contributions to the market.

Chinalco

Aluminium Corporation of China Limited (Chinalco), known as Chalco, is a multinational aluminium company headquartered in Beijing, People's Republic of China. As the world's largest aluminium producer in 2021, surpassing competitors like China Hongqiao Group, Rusal, and Shandong Xinfa, Chinalco is a public company listed on the Hong Kong and New York stock exchanges, with its primary listing on the Shanghai Stock Exchange.

The company's involvement in aluminium extraction, electrolysis, and diversified business segments places it among the industry's key players. The company, a state-backed enterprise, was established in 2001 to be the primary aluminium producer in China. Despite challenges, the company continues to play a prominent role in the global aluminium industry through strategic investments and diversified business segments. It had a massive workforce of 103,493, producing 6.7 million tonnes in 2021. By the end of 2022, Chinalco's total assets had grown to RMB 625 billion, with its sales revenue totalling RMB 517.6 billion.

Hongqiao Group

China Hongqiao Group Limited, established in 1994 and currently headquartered in George Town, Cayman Islands, is the world's second-largest aluminium producer, following Chinalco. The company originated from Shandong Hongqiao, focusing on jeans and yarn-dyed denim production before shifting to aluminium in 2001. It produced a commendable 5.7 million tonnes in 2021. In December 2022, China Hongqiao Group achieved ASI Performance Standard V2 (2017) Certification for its subsidiary operation, Shandong Hongchuang Aluminium Industry Holding Co., Ltd., along with its three wholly-owned subsidiaries.

Founded by Zhang Shipping, the former chairman, the company is now led by his son, Zhang Bo. With main production activities in Shandong and new development in Yunnan Province, China Hongqiao has grown to possess 6.46 million tonnes of licensed primary aluminium capacity and around 16 million tonnes of total alumina capacity. The company has diversified into recycling, downstream aluminium processing, and lightweight innovation projects.

Committed to sustainability, China Hongqiao has integrated green production and energy conservation into its strategy. It includes plans to relocate capacity to Yunnan for cleaner power sources and set ambitious climate goals for net-zero emissions before 2055.

UC Rusal

United Company RUSAL, an international public joint-stock company, stands as the world's third-largest primary aluminium producer, contributing nearly 9% to global primary aluminium output and alumina production. Established through the merger of RUSAL, SUAL, and Glencore's alumina assets in March 2007, the company operates in 13 countries across five continents, boasting a workforce of 61,000 and a production of 3.8 million tons in 2021.

While initially incorporated in Jersey, with its financial centre headquartered in Moscow, Russia, UC Rusal subsequently shifted its registration to Kaliningrad in September 2020. Publicly traded on the Moscow Stock Exchange, Hong Kong Stock Exchange, and European Stock Exchange, the company announced in 2021 its intention to demerge high carbon assets and undergo a name change to AL+. In 2022, RUSAL remained among the largest producers of primary aluminium and alloys globally.

Shandong Xinfa

Xinfa Group, also known as Shandong Xinfa Aluminium Group, was the world's third-largest aluminium producer by equity production and the second-largest in China in 2022. In alumina, the company ranked third in the world. With a vast supply chain, Xinfa Group boasts a 3.6- million-ton capacity, with over half of it, approximately 1.9 million tons, produced in the Uyghur Region.

Established in 1972 and headquartered in Shandong Province, Xinfa Group has grown to own 73 subsidiaries, specialising in power generation, alumina, refining, carbon production, and downstream aluminium product manufacturing. Its principal assets include companies like Chipping Huaxin Aluminium Industry, Shandong Xinfa Hope Aluminium (under East Hope Group), and Guangxi Xinfa Aluminium.

Rio Tinto Alcan

Rio Tinto Alcan, a Canadian-based mining company headquartered in Montreal, Quebec, is a key player in the global aluminium industry and a subsidiary of the renowned Rio Tinto mining conglomerate. Formed on November 15, 2007, through the merger of Rio Tinto's Canadian subsidiary and the Canadian company Alcan, it has evolved into one of the world's leading aluminium mining and production entities, ranking fifth in output.

The company's primary aluminium smelters are located in Canada, Australia, New Zealand, Iceland, and the Middle East, with a labour force of 68,000 (including joint ventures). It produced 3.2 million tons in 2021.

As per the most recent announcement made in 2023, Rio Tinto will invest US$1.1 billion to expand its aluminium smelter in Canada. This will boost its annual capacity by about 16,000 tonnes of primary aluminium.

Sustainability at the core

As these top five titans continue to invest in innovation, sustainability, and efficiency, their efforts will shape the global market's trajectory for the foreseeable future. The burgeoning demand for aluminium across various industries and regions bodes well for the industry's resilience and growth potential.