The plant annually produces 2,500 tons of aluminum without carbon emissions.

Rio Tinto’s Arvida smelting complex in Quebec, Canada is set to adopt new Elysis carbon-free technology, as reported by Interesting Engineering on July 1, in an effort to accelerate the transition to more environmentally friendly production methods. The new pilot plant, equipped with Elysis technology, will use a process that separates aluminum from its compounds and emits only oxygen. This innovative technology aims to replace traditional aluminum production methods, reducing greenhouse gas emissions and producing oxygen instead.

The pilot plant, which will have 10 furnaces operating at 100 kiloamperes, will be designed and built at Rio Tinto’s Arvida complex. Unlike conventional electrolysis chambers in which aluminum and oxygen compounds are separated with the help of a carbon anode, Elysis technology uses an inert anode, eliminating the carbon component entirely. By removing carbon from the process, the separation of aluminum from oxygen results in the emission of oxygen only, minimizing the environmental impact.

Elysis technology is expected to significantly reduce carbon emissions associated with the production of everyday goods like consumer products, construction materials, transportation components, and electricity industry products. In Canada alone, this new technology could potentially reduce approximately 7 million tons of greenhouse gases annually, equivalent to removing 1.8 million cars from the road and shifting to more sustainable practices.

In addition to reducing carbon emissions, Elysis technology is touted to enhance occupational health and safety, lower capital and operating costs, and boost productivity levels. This new technology has the flexibility to be retrofitted onto existing as well as new smelting facilities. Rio Tinto anticipates the pilot plant to begin operations in 2027, capable of producing up to 2,500 tonnes of commercial-quality aluminum without any direct greenhouse gas emissions. The company is also developing larger 450kA test chambers using Elysis technology at its Alma smelter for further research and advancements in environmentally friendly aluminum production.