Rio Tinto will invest $1.1 billion (C$1.4 billion) to expand its state-of-the-art AP60 aluminum smelter at the Jonquière complex in Quebec, Canada. This expansion will enable Rio Tinto to continue meeting customers’ demand for low-carbon, high-quality aluminum for use in transportation, construction, electrical, and consumer goods.
“This investment is aligned with our strategy to decarbonize our value chains and grow in materials essential for the energy transition,” said Jakob Stausholm, chief executive of Rio Tinto. “Our AP60 technology is already proven and producing some of the lowest carbon aluminum in the world, thanks to the expertise of our highly qualified workforce and access to renewable hydropower. This is the most significant investment in our aluminium business for more than a decade and it will further strengthen Rio Tinto’s high-quality and low-carbon offering to our customers as they also work to reduce their own carbon footprint.”
The AP60 smelting technology was developed by Rio Tinto’s Research and Development teams and is among the most efficient and lowest carbon technology currently available at commercial scale. When combined with the hydropower used at Rio Tinto’s operations in Canada, it generates approximately 1.6 tonnes of CO2e per tonne of aluminum produced, compared to approximately 3.2 tonnes of CO2e per tonne of aluminum for the Arvida smelter’s current technology — and over 12 tonnes of CO2e per tonne of aluminum for the industry average.
The new investment project will add 96 new AP60 pots, increasing capacity by approximately 160,000 tonnes of primary aluminum per year — enough for 400,000 electric cars. As a result, there will be a total of 134 AP60 pots and a capacity of approximately 220,000 tonnes per annum. (This new AP6o capacity will offset the 170,000 tonnes of capacity lost through the gradual closure of potrooms at the Arvida smelter from 2024.)
The project will generate up to 1,000 jobs during the peak of construction and approximately 100 permanent jobs will be maintained as a result of the expanded smelter. The Quebec government is providing up to $113 million (CAN$150 million) of financial support for the project.
“I would like to thank both the Government of Canada and Government of Quebec for their support in progressing this project,” said Stausholm. “We are also continuing to work together on the future implementation of the ELYSIS™ zero carbon smelting technology at our Quebec facilities.”
Quebec Premier François Legault added, “A great momentum is building in our regions for our green economy. The aluminum industry in Saguenay-Lac-Saint-Jean has always been a real source of pride and has created considerable wealth in the region. Today’s announcement will breathe new life into this industry with greener, less polluting processes. The use of AP60 pots will halve GHG emissions in aluminium production. With the upcoming ELYSIS technology, Quebec aims to become the world champion of green aluminum.”
Construction on the new pots will run over two and a half years, with commissioning of the new pots expected to start in the first half of 2026 and the smelter fully ramped up by the end of 2026.
Additional Investments in Quebec
Rio Tinto is currently working to add 30,000 tonnes of new capacity through the commissioning of the previously announced recycling facility at Arvida in the first quarter of 2025. These facilities will ensure the casting facilities at the company’s Jonquière complex will continue to provide value-added products that meet customers’ needs, including integrating recycled post-consumer aluminum into primary aluminum alloys.
In addition to the investment in recycling and low-carbon AP6 aluminum, Rio Tinto is working with the governments of Canada and Quebec to enable the deployment of the ELYSIS zero carbon aluminum smelting technology at its Saguenay–Lac-Saint-Jean facilities. With the current development pathway, ELYSIS aims to have its technology available for installation from 2024 and the production of larger volumes of carbon-free aluminum approximately two years later.
Rio Tinto and the Canadian government have also signed an MOU that deepens their commitment to strengthen supply chains for low-carbon primary metals, critical minerals, and other value-added products. The cooperation will also aim to support projects that have the potential to grow Rio Tinto’s activities in Canada, including the current and future decarbonization of the aluminum supply chain.
“Canada has all it takes to be the global green supplier of choice. And that is why our government is collaborating with key industry actors like Rio Tinto to produce the world’s greenest aluminum,” said Honourable François-Philippe Champagne, Canada’s minister of Innovation, Science and Industry. “By supporting the production of green metals, we ensure Canada will remain at the forefront of the economy of tomorrow. When economic benefits are paired with a commitment to developing green solutions, it’s a win for our industry, our cleantech ecosystem, and our workers.”