Rio Tinto AP60 Expansion Lifts Quebec Low-Carbon Aluminium Capacity

Rio tinto

Rio Tinto AP60 expansion will add 160,000 t/yr of aluminium capacity at the company’s Quebec smelter, strengthening Canada’s position as a major source of lower-emissions metal. The $1.5bn project began start-up in March and is expected to be completed by the end of 2026.

Rio Tinto AP60 expansion will lift the smelter’s nameplate capacity to 220,000 t/yr. The additional metal will target transportation, construction, electrical and consumer goods markets.

Rio Tinto AP60 expansion is strategically important because aluminium buyers are increasingly comparing suppliers on carbon intensity as well as price and availability. Quebec’s power system gives Rio Tinto a strong base for producing lower-emissions primary metal.

The company is also developing recycling and new smelting technology at the Arvida complex, creating a broader platform that combines primary production, secondary aluminium and future low-emission electrolysis.

AP60 Capacity Supports North American Aluminium Supply

The additional AP60 capacity will partly offset the closure of older potlines scheduled for June. This allows Rio Tinto to modernise its production base while maintaining regional supply.

Replacing older capacity with newer smelting technology can improve energy efficiency, productivity and emissions performance. It also supports long-term competitiveness in markets where customers are under pressure to reduce supply-chain carbon.

Transportation is an important demand sector because automakers continue to use aluminium for lightweighting. Electrical applications are also becoming more significant as grids, renewable projects and electrification expand.

Construction and consumer goods provide additional demand diversification. This reduces dependence on any single end market and strengthens the commercial case for higher-capacity production.

The expansion also supports North American supply security. Additional Canadian output gives US and regional manufacturers access to primary aluminium from an established trade partner.

Recycling and Elysis Add a Second Decarbonisation Route

Rio Tinto plans an aluminium recycling centre at the same Arvida complex. This adds secondary metal capability alongside primary smelting.

The combination is important because future aluminium supply will increasingly depend on blending primary and recycled metal. Primary production provides chemistry control and volume, while recycling lowers energy use and embedded emissions.

Canada is also supporting a separate Quebec demonstration plant for Elysis aluminium electrolysis technology with $100mn in government funding.

Elysis was developed with Alcoa and is designed to eliminate direct greenhouse gas emissions from the conventional aluminium smelting process. If successfully commercialised, the technology could materially change the emissions profile of primary aluminium.

The three elements — AP60 expansion, recycling and Elysis — show a broader industrial strategy. Rio Tinto is not simply increasing aluminium output; it is building a more flexible and lower-carbon production system.

That matters as customers increasingly demand traceable aluminium with lower emissions intensity. Producers able to combine scale, renewable power, recycling and advanced smelting technology could gain a stronger competitive position.

The Metalnomist Commentary

Rio Tinto’s Quebec strategy shows where aluminium competition is heading: more capacity, more recycling and lower smelting emissions. The advantage will increasingly belong to producers that can deliver both physical metal and credible carbon reduction.