Global metals miner Rio Tinto has successfully commissioned its $1.5-billion AP60 smelter expansion at the Complexe Arvida operation, in Québec, marking a major milestone for the deployment of low-carbon aluminium smelting technology.

The startup, 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 about 160 000 t/y of primary aluminium for a total of 220 000 t/y produced with the AP60 technology.

The AP60 expansion, together with the planned aluminium recycling centre at Arvida, will more than offset the loss of production associated with the closure of Rio Tinto’s older Arvida potrooms, which is expected to be completed in June.

The expansion will directly support 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 Québec through spending with contractors and suppliers.

Representing the next chapter of Rio Tinto’s century-long history in Québec, it strengthens its ability to supply customers in North America with low-carbon, high-quality aluminium for transportation, construction, electrical applications and consumer goods.

Developed by Rio Tinto’s research and development teams, the AP60 technology 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 one-sixth of the greenhouse gas (GHG) emissions per tonne of aluminium, when 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% in fine particulate matter.

The AP60 expansion supports the transition to carbon-free aluminium 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 Québec in partnership with government, through Investissement Québec, to advance this breakthrough technology, which eliminates all direct GHG emissions from aluminium smelting and produces oxygen as a by-product.

Rio Tinto aluminium and lithium CE Jérôme Pécresse says for 100 years, Québec has been at the heart of the aluminium 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 aluminium project in the West in more than a decade and demonstrates Rio Tinto’s ability to deliver world-class, low-carbon technologies,” he explains.

He adds that the newly expanded AP60 smelter reinforces the company’s competitiveness and offerings for customers in North America, while increasing the efficiency of the operations in Québec. The new plant will mitigate 290 000 t/y of carbon emissions compared to the old Arvida smelter.

The AP60 technology generates about 1.6 t of CO₂ equivalent per tonne of aluminium produced, compared to approximately 3.2 t of CO₂ equivalent per tonne of aluminium for the Arvida smelter’s current technology – compared with the industry average of 10.9 t of CO₂ equivalent per tonne of aluminium produced.

Together with the construction of the ELYSIS demonstration plant in Québec, 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.

Premier of Quebec Christine Fréchette comments that despite the economic uncertainty related to US tariffs, the inauguration once again demonstrates that government and Rio Tinto believe in Québec’s potential.

“Today, we are securing the future of Québec’s aluminium industry by ensuring the modernisation and gradual decarbonisation of a sector that is vital to our economy. More than ever, Québec is establishing itself as a global leader in sustainable aluminium and a true technological trailblazer.”