Rio Tinto and Alcoa announce world's first carbon-free aluminium smelting process

(Posted on 14/05/18)

Rio Tinto and Alcoa Corporation has announced a revolutionary process to make aluminium that produces oxygen and eliminates all direct greenhouse gas emissions from the traditional smelting process.

Executives of Rio Tinto, Alcoa and Apple were joined by Canadian Prime Minister Justin Trudeau and Premier of Québec Philippe Couillard for the announcement, which signals the most significant innovation in the aluminium industry in more than a century.

To advance larger scale development and commercialisation of the new process, Alcoa and Rio Tinto are forming Elysis, a joint venture company to further develop the new process with a technology package planned for sale beginning in 2024.

Elysis, which will be headquartered in Montreal with a research facility in Quebec's Saguenay–Lac-Saint-Jean region, will develop and license the technology so it can be used to retrofit existing smelters or build new facilities.

When fully developed and implemented, it will eliminate direct greenhouse gas emissions from the smelting process and strengthen the closely integrated Canada-United States aluminium and manufacturing industry. The new joint venture company will also sell proprietary anode and cathode materials, which will last more than 30 times longer than traditional components.

Canada and Quebec are each investing $60 million (CAD) in Elysis. The provincial government of Quebec will have a 3.5 percent equity stake in the joint venture with the remaining ownership split evenly between Alcoa and Rio Tinto.

Apple is providing an investment of $13 million (CAD). The company helped facilitate the collaboration between Alcoa and Rio Tinto on the carbon-free smelting process, and Apple has agreed to provide technical support to the JV partners.

Rio Tinto and Alcoa will invest $55 million (CAD) cash over the next three years and contribute specific intellectual property and patents.

The patent-protected technology, developed by Alcoa, is currently producing metal at the Alcoa Technical Center, near Pittsburgh in the United States, where the process has been operating at different scales since 2009. The joint venture intends to invest up to $40 million (CAD) in the United States, which would include funding to support the supply chain for the proprietary anode and cathode materials.

Vincent Christ, an experienced leader with more than 30 years' experience at Rio Tinto Aluminium, has been named Chief Executive Officer of Elysis. Most recently, he has served as head of technology, research and development and automation programmes. He holds an engineering degree in electronics and industrial information technology.

Prime Minister of Canada Justin Trudeau said, "Today's announcement will create and maintain thousands of jobs for Canadians, significantly reduce Canada’s carbon footprint, and further strengthen the aluminium industry in North America. It is a truly historic day for the aluminium industry – and for all Canadian aluminium workers – who play such an important role in our economy and our country’s future."

"This is a revolutionary smelting process that can deliver a significant reduction in carbon emissions. It builds on the key role aluminium has to play in driving human progress, by making products infinitely recyclable, stronger, lighter and more fuel efficient. Rio Tinto is proud to work with Alcoa, Apple and the governments of Canada and Quebec, to drive an innovation that can transform the industry and our customers' supply chains," said Rio Tinto chief executive J-S Jacques

Alcoa President and CEO Roy Harvey said, "This discovery has been a long-sought goal for the aluminium industry, and this announcement is the culmination of the work from many dedicated Alcoa employees. Today, our history of innovation continues as we take aluminium’s sustainable advantage to a new level with the potential to improve the carbon footprint of a range of products from cars to consumer electronics."

Latest News

NGFA thanks lawmakers for including industry priorities in ‘One Big Beautiful Bill’

The National Grain and Feed Association (NGFA) in the USA has applauded Congress for including a slate... Read more

Fertilizers Europe: Commission announcement on CBAM falls short

Fertilizers Europe’s have released their reaction to the European Commission announcement on the... Read more

Bunge completes sale of its North America corn milling business

Bunge Global SA has confirmed that it has completed the previously announced sale of its North America... Read more

SSAB secures additional EUR 430 million green financing for Luleå

Following the successful debt raising at the end of April 2025, SSAB has secured an additional EUR 430... Read more

Soaring demand opens up investment opportunities across West Africa

Despite China’s dominant position in securing commodities across Africa, there are still many... Read more

Rio Tinto and Hancock Prospecting invest $1.6 billion in Pilbara iron ore project

Rio Tinto and Hancock Prospecting will invest $1.61 billion (Rio Tinto share $0.8 billion) to develop... Read more

SSAB postpones commissioning of new steel mill in Luleå by 12 months

SSAB has commenced preparatory work to build a new, state-of-the-art steel mill in Luleå, Sweden... Read more

Anglo American streamlines leadership team to reflect portfolio progress

Anglo American plc has streamlined its executive leadership team to reflect substantial progress with... Read more

NeoSmelt welcomes Government support for steel decarbonisation project

NeoSmelt, a consortium of leading resources, energy and manufacturing companies working together on... Read more

Telestack announces new iron ore project

Northern Ireland based Telestack have announced that they have been awarded a contract for the supply... Read more