Rio Tinto started commissioning its US$1.5 billion AP60 smelter expansion at its Arvida Complex in Quebec, Canada. This marks a major milestone for the deployment of its state-of-the-art, low-carbon aluminum smelting technology.
“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,” said Jérôme Pécresse, chief executive of Rio Tinto Aluminium & Lithium. “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.”
AP60 Technology
Developed by Rio Tinto’s Research and Development teams, the AP60 technology is among the most efficient and lowest-carbon technologies currently available at commercial scale. When combined with the hydropower used at Rio Tinto’s operations in Canada, it generates approximately 1.6 t CO2e/t Al of aluminum produced, compared to approximately 3.2 t CO2e/t Al for the Arvida smelter’s current technology. This is around one-sixth of the industry average (10,9 t CO2e/t Al). Therefore, it is expected to deliver significant improvements, including an expected reduction of up to 90% in fine particulate matter.
The start-up, which began in March, is expected to be completed by the end of 2026 with all 96 new pots operating. This will increase the plant’s production capacity by approximately 160,000 tonnes of primary aluminum annually for a total of 220,000 tonnes produced with the AP60 technology. Representing the next chapter of Rio Tinto’s century-long history in Quebec, it strengthens Rio Tinto’s ability to supply customers in North America with low-carbon, high-quality aluminum for transportation, construction, electrical applications and consumer goods.
“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,” said Pécresse. “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 aluminium the world needs.”
The AP60 expansion, together with the planned aluminum recycling centre at Arvida, will more than offset the loss of production associated with the closure of the older Arvida potrooms, which is expected to be completed in June.
In addition, the AP60 expansion supports the transition to carbon-free aluminum electrolysis technology being developed by ELYSIS in Saguenay–Lac-Saint-Jean, Québec, a partnership that includes Rio Tinto. 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 this breakthrough technology, which eliminates all direct greenhouse gas emissions from aluminum smelting and produces oxygen as a by-product.
Supporting Local Jobs
The expansion will directly support approximately 100 permanent high-quality 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.
“For 100 years, Rio Tinto has been a cornerstone of Quebec’s industrial strength, creating good jobs and supporting communities across the country,” noted Honorable Mélanie Joly, Canada’s Minister of Industry. “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.”