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.
soon our country turn into third world country commies running things here we should be building hitech gas fired power station we told we are largest gas exporter in the world now we told we have local gas shortage so our gas bills going through the roof I bet we sell the gas cheaper to overseas country's than to you and me