Aluminum was discovered in 1827 by Friedrich Wohler. Although it is the foremost common metal on Earth, it is usually found tightly latched in compounds. There were continual failures in the efforts of its extraction through electrolysis. For years, aluminum remained an exotic metal utilized in jewelry and for a few special functions like capping monuments.

The race for a commercially viable route for aluminum extraction was won in 1886 by Paul Heroult in France and Charles M. Hall in the United States. Thus, the name became the Hall-Heroult method. The problem researchers experienced in aluminum extraction antecedently was that electrolysis of an aluminum salt dissolved in water yields aluminum hydroxide. Heroult avoided this drawback by dissolving aluminum oxide in a very new solvent known as cryolite (Na_3AlF_6)(Na
3
​
AlF
6
​
). This resulted in the immediate dramatic fall in the worth of aluminum from $12, to $0.75, all the way down to $0.30. This meant aluminum went from being considered rare to becoming a widely used commodity.

Pure alumina, when electrolyzed at 2000°C, reduces, giving the metal aluminum in its liquid form. However, this was a costly and less affordable procedure. Heroult suggested the use of molten cryolite by which the extraction of aluminum became possible at a comparatively lower temperature of 1000°C.

The cryolite used is placed in a carbon lined iron vat that acts as a cathode to which carbon anodes are inserted. The release of COâ‚‚ and CO states the consumption of carbon electrodes in the process. Thus, this creates a cycle of replacement for the carbon electrode. As a final product, aluminum is found settled and accumulated near the cathode.

Paul Heroult’s Electric Arc Furnace
Paul Heroult developed the primary electric arc furnace in France in the year 1899 and introduced it in the United States in 1904. In 1907, industrial plants were established supporting this electric arc furnace. The Sanderson brothers shaped the Sanderson Steel Co. in Syracuse, New York, putting in a primary electric arc furnace in the U.S. At first, electric steel from the electric arc furnaces was a specialty product for such uses as machine tools. However, electric arc furnaces were presently employed in World War II for production of alloy steels. It was later that electric steelmaking began to expand.

The electric arc furnace has a chamber that heats charged material using an electrical arc. Arc furnaces range in size from little units of roughly one ton capacity (used in foundries for manufacturing forged iron products) up to 400 ton units used for secondary steel creation. The cylinder-shaped furnace has a thick plate forming its lower portion and a hanging bulgy roof customized with a cooling system that uses water. Three carbon rods tunneled into the cylindrical furnace are clamped to the roof. These carbon electrodes get used subsequently. Certain alterations in the position of the carbon rods are facilitated as per the construction of the furnace.

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