Rio Tinto has begun commissioning a $1.5bn expansion of its AP60 aluminium smelter in Quebec, Canada, marking a significant milestone in the deployment of its low-carbon aluminium production technology and strengthening North America’s supply of sustainable aluminium.
The expansion at the company’s Complexe Arvida facility in Saguenay–Lac-Saint-Jean is expected to be fully operational by the end of 2026, when all 96 new smelting pots are online. Once complete, the project will add around 160,000 metric tonnes of annual primary aluminium production capacity, bringing total output from AP60 technology to approximately 220,000 metric tonnes per year.
The investment comes as manufacturers across transportation, construction, electrical infrastructure and consumer goods sectors increasingly seek lower-carbon materials to support sustainability targets and regulatory requirements.
Rio Tinto said the AP60 expansion, alongside a planned aluminium recycling centre at Arvida, will more than compensate for production losses resulting from the closure of older potrooms at the site, which is due to be completed in June.
Developed by Rio Tinto’s research and development teams, AP60 is among the most efficient commercial-scale aluminium smelting technologies currently available. When powered by Quebec’s hydroelectric energy, the technology generates around one-sixth of the greenhouse gas emissions associated with the global industry average and approximately half the emissions of the older technology used at the adjacent Arvida smelter.
The company expects the expansion to reduce carbon emissions by approximately 290,000 tonnes annually compared with the legacy facility, while also cutting fine particulate matter emissions by up to 90%.
The project is expected to support around 100 permanent jobs and help sustain employment across the regional supply chain. During construction, more than 1,500 jobs were created and over $1bn in economic benefits were generated through spending with local contractors and suppliers.
Jérôme Pécresse, Chief Executive of Rio Tinto Aluminium & Lithium, described the project as a landmark achievement for the industry.
“For 100 years, Quebec 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.”
Jérôme Pécresse, Chief Executive of Rio Tinto Aluminium & Lithium.
The expansion also supports the development of ELYSIS, a breakthrough carbon-free aluminium smelting technology partnership involving Rio Tinto. A demonstration plant is currently under construction in Quebec with support from the Canadian and Quebec governments. The technology eliminates direct greenhouse gas emissions from aluminium smelting, producing oxygen as its only by-product.
Canada’s Minister of Industry, Mélanie Joly, said the investment would help strengthen the country’s industrial competitiveness while advancing innovation and supporting skilled jobs.
The announcement comes amid ongoing uncertainty surrounding North American trade and tariffs, with Quebec’s government highlighting the project as evidence of continued confidence in the province’s industrial future.
Quebec Premier Christine Fréchette said the investment would help secure the long-term future of the province’s aluminium sector through modernisation and decarbonisation, reinforcing Quebec’s position as a global leader in sustainable aluminium production.
