© Springer Nature Switzerland AG 2020.Aluminum is the third most common element and the crust’s most abundant metal. Nowadays, aluminum is an important metal in industrial production. Due to the lightweight, corrosion resistance, low density, and easy working probability, combine with its compatibility for recycling, support its position as the material of option for many utilization and it begins more favored in automotive, spacecraft components, and architectural construction with its extensive utilization area. In this work, the aim was targeted to evaluate the energy consumption in manufacture of the primary aluminum. The life of aluminum electrolysis cell, carbon cathode wear against arc blow, cryolite and abrasion of aluminum film was studied. It was found that TiB2–BN composite was a better option as cathode due to wear resistance, high electrical conductivity and machinability.