Rio Tinto has reached a major milestone in its long-term growth and sustainability strategy with the successful commissioning of its US$1.5 billion AP60 aluminium smelter expansion at Complexe Arvida in Quebec. The project strengthens the company’s position as a leading supplier of low-carbon aluminium while reinforcing Quebec’s role as one of the world’s most important aluminium-producing regions.
Commissioning activities began in March and are expected to continue through the end of 2026, when all 96 new electrolytic pots are scheduled to be fully operational. Upon completion, the expansion will add approximately 160,000 metric tonnes of annual primary aluminium production capacity, bringing total AP60 output at the facility to roughly 220,000 metric tonnes per year.
The investment forms a key component of Rio Tinto’s modernization program in Quebec and, together with the company’s planned aluminium recycling centre at Arvida, is expected to more than compensate for production associated with the closure of older potrooms at the site. The modernization effort is designed to improve operational efficiency, strengthen competitiveness and support growing customer demand for low-carbon materials.
During construction, the project generated more than 1,500 jobs at peak activity and contributed over $1 billion to Quebec’s economy through contracts awarded to suppliers, contractors and service providers. The completed facility will support approximately 100 permanent jobs while helping sustain employment throughout the regional supply chain.
Developed through Rio Tinto’s research and development programs, AP60 technology represents one of the most advanced commercial-scale aluminium smelting processes available today. Powered by renewable hydroelectricity, the technology produces significantly lower greenhouse gas emissions than conventional aluminium manufacturing methods. Compared with industry averages, emissions intensity is reduced dramatically, while particulate emissions are expected to decline by up to 90 percent.
Jérôme Pécresse, Chief Executive of Rio Tinto Aluminium & Lithium, described the commissioning as a defining milestone that reinforces the company’s leadership in low-carbon aluminium production. He noted that the expansion enhances Rio Tinto’s ability to serve North American customers with high-quality, sustainably produced aluminium while strengthening the efficiency and environmental performance of its Quebec operations.
The project also complements the development of ELYSIS, a next-generation carbon-free aluminium smelting technology being advanced in Quebec through a partnership involving Rio Tinto. Supported by federal and provincial governments, the initiative aims to eliminate direct greenhouse gas emissions from aluminium production while generating oxygen as the only by-product. The AP60 expansion positions Rio Tinto to meet growing global demand for sustainable materials used in transportation, construction, electrical infrastructure and consumer products, while contributing to the long-term competitiveness of Canada’s aluminium industry.
