Rio Tinto's $1.5B smelter to add 160,000 tonnes of low-carbon aluminum annually
The AP60 smelter expansion at Complexe Arvida in Quebec supports the transition to carbon-free aluminum production
Rio Tinto has marked a major milestone with its low-carbon aluminum smelting technology with the commissioning of a US$1.5 billion AP60 smelter expansion at Complexe Arvida in Quebec.
The start-up, which began in March, is expected to be completed by the end of 2026 with all 96 new pots operating. The new smelter will increase the plant's production capacity by approximately 160,000 tonnes of primary aluminum annually. In total, the plant will produce 220,000 metric tonnes with AP60 technology.
The AP60 expansion, together with the planned aluminum recycling centre at Arvida, will outweigh the loss of production associated with the closure of the older Arvida potrooms, which is expected to be completed in June.
The AP60 aluminum smelter technology
Developed by Rio Tinto's research and development teams, the AP60 technology is designed for efficiency with low-carbon technologies.
When combined with the hydropower used at Rio Tinto's operations in Canada, it generates one-sixth of the greenhouse gas emissions per tonne of aluminum compared with the industry average, and half the emissions of the technology currently used at the adjacent older Arvida smelter. It will deliver significant improvements, including an expected reduction of up to 90 percent in fine particulate matter.
The AP60 expansion supports the transition to carbon-free aluminum electrolysis technology being developed by ELYSIS in Saguenay-Lac-Saint-Jean, Quebec, a partnership that includes Rio Tinto.
The province of Quebec ensures its recycling systems are up-to-date
The expansion will support approximately 100 permanent jobs locally and help consolidate positions across the supply chain. During its peak construction period, more than 1,500 jobs were created, and the project generated more than $1 billion in economic benefits for the province of Quebec through spending with contractors and suppliers.
Supported by the Government of Canada, through the Strategic Innovation Fund, a demonstration plant is being built in Quebec in partnership with the Government of Quebec, through Investissement Quebec, to advance the new technology, focusing on eliminating all direct greenhouse gas emissions from aluminum smelting and producing oxygen as a by-product.
Rio Tinto aluminum and Lithium Chief Executive Jérôme Pécresse said: "For 100 years, Quebec has been at the heart of the aluminum industry, and with AP60, Rio Tinto is now strongly positioned for decades to come with one of the most advanced smelting technologies operating at commercial scale. This milestone brings into production the first major primary aluminum project in the West in more than a decade and demonstrates Rio Tinto's ability to deliver world-class, low-carbon technologies."
"The newly expanded AP60 smelter reinforces our competitiveness, and the offer for our customers' position in North America increases the efficiency of our Quebec operations and reduces our carbon emissions by approximately 290,000 tonnes per year compared to the old Arvida smelter. Together with the construction of our ELYSIS demonstration plant in Quebec, using the first licence of this breakthrough technology, Rio Tinto is demonstrating its value as a secure, innovative, and reliable supplier of low-carbon aluminum the world needs."
Canada's Minister of Industry, The Honorable Mélanie Joly, said: "For 100 years, Rio Tinto has been a cornerstone of Quebec's industrial strength, creating good jobs and supporting communities across the country. Today, as global competition intensifies, our government is proud to work alongside partners like Rio Tinto to build on that legacy — strengthening our aluminum industry, advancing world-leading innovation, and ensuring Canadian workers remain at the forefront of a more resilient economy."
Premier of Quebec Christine Fréchette said: "Despite the economic uncertainty related to U.S. tariffs, today's inauguration once again demonstrates that our government and Rio Tinto believe in Quebec's potential. Today, we are securing the future of Quebec's aluminum industry by ensuring the modernization and gradual decarbonization of a sector that is vital to our economy. More than ever, Quebec is establishing itself as a global leader in sustainable aluminum and a true technological trailblazer."
