The electrochemical reduction of Al 2 O 3 has been investigated in molten CaCl 2 at 1123 K. To predict the electrochemical reduction behavior depending on the activity of O 2− ions, the potential-pO 2− diagram for the Al-Ca-O-Cl system is constructed from thermochemical data. In a Mo box-type electrode, an Al 2 O 3 tube is successfully reduced to liquid Al with a maximum purity of 98 at%. However, in the electrolysis of Al 2 O 3 powder in an Fe box-type electrode, Al 2 Ca is produced through the formation of Ca 12 Al 14 O 33 as an intermediate product. The different electrochemical reduction behaviors of the tube and the powder are explained by the different diffusion path lengths for O 2− ions from three-phase zone (Al 2 O 3 /CaCl 2 /cathode metal) to bulk CaCl 2 .