Rio Tinto has begun commissioning its US$1.5 billion AP60 aluminium smelter expansion at Complexe Arvida in Saguenay, Québec, adding new primary aluminium capacity supported by hydroelectric power as the company expands production of lower-emissions metal. The commissioning process started in March and is scheduled for completion by the end of 2026, when all 96 new reduction pots are expected to be operational.
Once fully commissioned, the project will add approximately 160,000 tonnes per year of primary aluminium production capacity. Total production capacity based on AP60 technology at the facility will increase to about 220,000 tonnes annually.
Additional Capacity Targets Growing Aluminium Demand
The expansion comes as aluminium demand continues to be linked to transportation, construction, electrical infrastructure, packaging and renewable-energy supply chains. Primary aluminium remains one of the most energy-intensive industrial materials to produce, making access to reliable power sources an increasingly important factor in smelter competitiveness and production strategy. The Québec operation forms part of Rio Tinto’s Canadian aluminium network, which is supplied by hydroelectric power generation.
Hydropower Supports Lower-Emission Production
According to Reuters, Rio Tinto has stated that its AP60 smelting technology, when paired with hydropower, can produce aluminium with greenhouse-gas emissions of approximately one-sixth of the global industry average per tonne. The combination of modern smelting technology and renewable electricity infrastructure differentiates the Québec operation from facilities reliant on more carbon-intensive power systems. The AP60 expansion increases the volume of aluminium produced through that technology platform while expanding Rio Tinto’s lower-carbon production capacity.
Construction Activity Generates Regional Economic Impact
Rio Tinto reported that construction of the expansion created more than 1,500 jobs at peak activity. The company also stated that spending by contractors and suppliers associated with the project generated more than US$1 billion in economic benefits for Québec.
Following commissioning, the expansion is expected to support approximately 100 permanent jobs in the region.
Modernization Program Replaces Older Smelting Capacity
The AP60 development also forms part of a broader modernization strategy within the Arvida aluminium complex. The expansion helps compensate for the closure of older potrooms by replacing legacy production infrastructure with newer smelting technology.
The project increases the share of output generated through AP60 facilities while maintaining aluminium production capacity within Québec’s established aluminium industry cluster.
Processing Infrastructure Plays Expanding Role in Supply Chains
The development highlights the role of downstream processing infrastructure within industrial metals supply chains. In addition to mining operations, supply chains for metals used in energy transition technologies rely on smelters, refineries, power systems, recycling facilities and processing technologies. The commissioning of the AP60 expansion at Complexe Arvida adds new primary aluminium capacity while expanding Rio Tinto’s ability to produce aluminium using hydroelectric power and modern smelting technology in Québec.
