Rio Tinto, the UK-Australian mining giant, plans to invest $165 million to refurbish two carbon-anode baking furnaces at its Grande-Baie aluminum smelter in Quebec, Canada. This initiative is part of the company’s larger strategy, which includes developing inert anode technology at its Arvida plant.
The refurbishment will involve rebuilding the Péchiney furnaces’ concrete shell and refractory lining in two phases over 2025 and 2026. These furnaces are vital, supplying approximately 60% of the 280,000 anodes needed annually for the 816 pots at Rio Tinto’s Grande-Baie and Laterrière smelters. To maintain production during the phased shutdowns, Rio Tinto will utilize a third furnace with different technology, stockpiled anodes, and market purchases, ensuring no impact on aluminum production.
Although the overhaul will decrease Rio Tinto’s demand for calcined petroleum coke (CPC) over the next two years, long-term CPC demand is expected to stabilize as the refurbished equipment will serve the smelters for decades. The upgraded furnaces are projected to have a lifespan of about 25 years.
Simultaneously, Rio Tinto is making significant progress in commercializing inert anode technology. Last month, the company announced a substantial investment to advance this technology, which could eventually render carbon anodes and the traditional Hall-Héroult smelting process obsolete. Rio Tinto has obtained the first technology license to use the Elysis process at its Arvida smelter. Elysis, a joint venture between Rio Tinto and Alcoa, aims to commercialize inert anode technology. Together with the Quebec government, Rio Tinto will invest a total of $285 million to design, engineer, and construct a 10-pot, 2,500 t/yr plant as a pilot project to demonstrate the Elysis technology. This project is considered a critical step in Rio Tinto’s journey towards full-scale industrialization, with first production targeted for 2027. Alcoa has an option to purchase a portion of the aluminum produced during the first four years. Additionally, Elysis plans to launch industrial prototype cells using inert anodes at Rio Tinto’s Alma smelter later this year.
Elysis is leading the effort to replace CO2-emitting carbon anodes, made from anode-grade calcined petroleum coke, with inert anodes that release oxygen. Other companies, such as Germany-based Trimet, are also developing similar technologies.
Despite these advancements, carbon anodes are expected to remain in use for the foreseeable future. Rio Tinto’s investment in the Grande-Baie baking furnaces underscores this reality. One market participant described it as a public setback for inert anode technology, noting that it signals Rio Tinto’s intent to continue using carbon technology for the next 10-20 years. Another participant suggested that inert anode technology might not significantly impact carbon anode demand until after 2030, possibly even 2035.
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