There is one electro-metallurgical process that has made possible
the production in commercial form and for ordinary use of a metal
that once was little more than a chemical curiosity. In 1885 there
were produced 3.12 tons of aluminum, and its value was roughly
estimated at about $12 a pound. By 1908 America alone produced
over 9,000 tons valued at over $500,000,000, while European
manufacturers were also large producers. In 1888 the electrolytic
manufacture of aluminum was commenced in America and in the
following year it was begun in Switzerland. Aluminum is formed by
the electrolysis of the aluminum oxide in a fused bath of cryolite
and fluorspar. The aluminum may be obtained in the form of
bauxite, and is produced in large rectangular iron pots with a
thick carbon lining. The pot itself is the cathode, while large
graphite rods suspended in the bath serve as the anodes. After the
arc is formed and the heat of the bath rises to a sufficient
degree the material is decomposed and the metal is separated out
so that it can be removed by ladling or with a siphon. The
application of heat to obtain this metal previous to the invention
of the electric furnace could only be considered a laboratory
problem and the expense involved did not permit of commercial
application. Now, however, aluminum is universally available and
with the expiration of certain patents, the material has sold as
low as 25 cents a pound.
Electrolytic methods serve also for the refining of nickel and for
the production of lead, and as in other fields of metallurgy,
these processes are attracting the attention of chemists and of
engineers. While tin as yet has not yielded to electrolytic or
electro-thermal methods with any success, the removal of tin from
tin scraps and cuttings has been carried on with considerable
success. With zinc the electrolytic and electro-thermal processes
have not been able yet to compete with the older metallurgical
method of distillation, but an important industry is electro-
galvanizing, where a solution of zinc sulphate is deposited on
iron and gives a protective coating. Experimental methods with the
use of electricity in extracting zinc from its ores are being
tested at various European plants, but the matter has not yet
reached a commercial scale.
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