The company stated that this milestone represents an important step in the broader deployment of state-of-the-art low-carbon aluminum smelting technology.
The commissioning process, which began in March, is expected to be completed by the end of 2026 through the gradual start-up of a total of 96 new pots. The expansion will increase the facility’s annual primary aluminum production capacity by approximately 160,000 metric tons, bringing total AP60 production capacity to 220,000 metric tons per year.
When considered together with the aluminum recycling center planned for Arvida, the AP60 expansion project will more than offset the production loss resulting from the closure of the older Arvida production facilities, which is expected to be completed in June. As such, the project not only ensures production continuity but also represents a transition to a more modern and environmentally friendly production infrastructure.
The economic impact of the project is also significant. The expansion will directly support approximately 100 permanent, highly skilled jobs at the local level. In addition, it is expected to contribute to workforce consolidation across the supply chain. At the peak of construction activity, the project provided employment for more than 1,500 people, while expenditures through contractors and suppliers contributed more than $1 billion to the Quebec economy.
Representing a new chapter in Rio Tinto’s more than 100-year history in Quebec, the investment significantly strengthens the company’s ability to supply low-carbon, high-quality aluminum to customers across North America serving the transportation, construction, electrical applications, and consumer goods sectors.
Developed by Rio Tinto’s Research and Development teams, AP60 technology is among the most efficient and lowest-carbon aluminum production technologies currently available at commercial scale. Combined with the hydroelectric power used in Rio Tinto’s Canadian operations, the technology reduces greenhouse gas emissions per ton of aluminum produced to approximately one-sixth of the industry average. It also cuts emissions by half compared to the older smelting technology at Arvida while reducing fine particulate matter emissions by up to 90%.
The AP60 expansion project also supports the transition toward the carbon-free aluminum smelting technology being developed by ELYSIS. As part of this initiative, in which Rio Tinto is one of the partners, a demonstration facility is being built in the Saguenay–Lac-Saint-Jean region. Supported by the Government of Canada’s Strategic Innovation Fund and carried out in collaboration with Investissement Quebec, the project aims to completely eliminate direct greenhouse gas emissions generated during the aluminum production process. One of the most notable features of the technology is that it releases only oxygen as a by-product during production.
Commenting on the project, Rio Tinto Aluminium and Lithium CEO Jérôme Pécresse said that Quebec has been one of the centers of the aluminum industry for more than a century and that AP60 technology positions the company strongly for the decades ahead. Pécresse noted that the investment represents the first major primary aluminum project developed in the Western world in more than a decade, highlighting Rio Tinto’s ability to deliver low-carbon and advanced technology solutions.
Pécresse also stated that the expanded AP60 facility will strengthen the company’s competitiveness in the North American market, broaden its product offering, and improve the efficiency of its Quebec operations. He added that the new facility is expected to reduce carbon emissions by approximately 290,000 tons annually compared with the older Arvida smelter. Together with the construction of the ELYSIS demonstration plant, Rio Tinto is reinforcing its position as a reliable and innovative supplier of low-carbon aluminum.
Mélanie Joly stated that Rio Tinto has been a cornerstone of Quebec’s industrial infrastructure for a century and highlighted the company’s contribution to employment and local communities. She added that, at a time of increasing global competition, the government remains committed to working with partners such as Rio Tinto to strengthen the aluminum sector and support innovative technologies.
Speaking on behalf of the Quebec government, Christine Fréchette said that despite global uncertainty related to U.S. tariffs, the investment demonstrates both the government’s and Rio Tinto’s confidence in the Quebec economy. Fréchette noted that the project contributes to the modernization and gradual decarbonization of the aluminum industry, which is of critical importance to the province’s economy, and reinforces Quebec’s position as a global leader in sustainable aluminum production.
According to technical data, each ton of aluminum produced using AP60 technology generates approximately 1.6 tons of CO2e emissions, compared with around 3.2 tons for the existing older technology at Arvida. The global industry average is estimated at approximately 10.9 tons of CO2e per ton of aluminum produced. These figures demonstrate that AP60 technology represents a major advancement in both environmental performance and production efficiency within the industry.
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