Elysis aluminium

Carbon-free aluminium smelting is a step closer

Revolutionising the way aluminium is made


Last updated: 5 August 2024

 

One of the challenges of producing aluminium responsibly is finding ways to decarbonise the way it’s made.

While aluminium is essential for low-carbon solutions, including lightweight cars and energy efficient buildings, it takes a lot of energy to produce.

We are partnering with Anheuser-Busch to pilot beer cans made from our sustainably produced aluminium; it is low-carbon, and certified as meeting the highest industry standards.

In 2018 we partnered with Alcoa, supported by Apple and the Governments of Canada and Quebec, on ELYSIS, a joint venture to help further develop breakthrough aluminium smelting technology that produces no greenhouse gas (GHG) emissions. The technology will eliminate all direct GHGs from the traditional aluminium smelting process, instead producing oxygen.

It has the potential to transform the aluminium industry through a significant reduction in its carbon footprint. In Canada alone, using the ELYSISTM technology has the potential to reduce GHG emissions by 6.5 million metric tons – the equivalent of removing 1.8 million cars from the roads.

The technology – which can be used in both new and existing aluminium smelters – will also reduce operating costs at aluminium smelters, while increasing production capacity.

Importantly, it will also help aluminium customers to decarbonise their supply chain, in line with growing demand from consumers. The aluminium produced has been used in trials by Apple, Corona Canada and Michelob Ultra.

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Working together to tackle climate change

Climate change is one of the biggest challenges facing our customers and our supply chains, and it will take a coordinated effort to make meaningful progress.

We have a range of R&D and supply chain partnerships to both reduce our footprint and meet customer needs across a wide range of environmental, social and governance challenges – from carbon emissions to extracting critical minerals from waste.

Making progress

In November 2021, ELYSIS achieved a major milestone by successfully producing aluminium without any direct GHG emissions at its Industrial Research and Development Center in Saguenay, Quebec, Canada. There is still more work to do before the technology can be used at a commercial scale.

We recently announced that we will use the first technology licence issued by the ELYSIS joint venture to install carbon free smelting cells at our Arvida smelter in Quebec, Canada. We will design, engineer and build a demonstration plant with the capacity to produce up to 2,500 tonnes of commercial quality aluminium per year without direct greenhouse gas emissions. This critical step will support the ongoing development of the ELYSISTM technology and enable us to build expertise in its installation and operation.

The focus of the joint venture is on accelerating the scale-up of the technology towards the demonstration of even larger commercial-size cells. ELYSIS has completed the construction of prototype 450 kA cells at the end of an existing potline at Rio Tinto’s Alma smelter. This is the commercial scale for many large, modern aluminium smelters, and a larger size than what has already been successfully operated. ELYSIS has begun commissioning activities, with the start-up sequence set to begin in 2024.

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About ELYSIS

ELYSIS is a technology company created through a partnership between Alcoa and Rio Tinto. ELYSIS’ goal is to revolutionise the way aluminium is produced across the globe. Our process eliminates all direct greenhouse gases from aluminium smelting, and instead produces oxygen. Alcoa, Rio Tinto, the Government of Canada and the Government of Quebec provided a combined investment of C$228 million to create ELYSIS and to see this technology reach commercial maturity.

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