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Aluminium was so expensive in the past because it was extremely difficult to prepare it in a metallic form. First metallic aluminium was prepared by Oersted (1825) and subsequently by Wohler (1827). Deville found a way to make a metallic aluminium cheaper in 1854. Anyway, even shortly before Hall-Heroult process in 1890 one kilogram was worth of 33 $. (Huge money at that time.) After Pittsburgh Reduction Company started commercial production the price dropped to 1$ per kilogram - less than today's price !

Production of one kilogram of metallic aluminium needs 4 kilograms of bauxite and consumes approx. 15 kilowatts-hours of energy.

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Q: Why was aluminum cutlery so expensive in the 18th century?
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