Kinda was an interesting read on the process. It also explains why the recyclers are so keen to get aluminum for recycling as Hall-Heroult process is not need to remelt already extracted aluminum as it is already extracted from the ore.
Many large plants have extremely large start-up costs but once running uses considerably less electricity. I was told that a local cotton gin cost nearly 10,000 USD just to equipment up. This explains why they wait to the last minute to them up and run 24/7 until all the incoming cotton is process. Usually around two months but I see one run for a little over 3 months during a bumper crop year.
The amount of electricity available and costs in my area explains why the only smelter is right at the hydroelectric [Censored] and can be supplied by the nuclear plant near them. I moved about two years ago in a different electric district and my electric rates are 50% higher as they have no nuclear plants supplying the district system; just hydro and coal/gas fired generators.
