Apple and ELYSIS: Pioneering Commercial-Scale Low-Carbon Aluminum
Apple and ELYSIS collaborate to revolutionize aluminum manufacturing by eliminating carbon emissions and introducing groundbreaking green technologies.
Apple and ELYSIS Usher In a New Era of Low-Carbon Aluminum Production
The global demand for aluminum remains high as industries continue to pursue lighter, more versatile, and durable materials. However, the traditional aluminum smelting process is energy-intensive and a significant contributor to global carbon emissions. In a pioneering move, Apple has partnered with ELYSIS to introduce the world’s first commercial-purity, low-carbon aluminum, marking a transformational moment for both industrial manufacturing and environmental responsibility.
Why Aluminum Production Matters for Climate Action
Aluminum is used in everything from electronics and automobiles to packaging and construction. Despite its recyclability, primary aluminum production is notorious for its substantial carbon footprint due to the conventional smelting process, which uses carbon anodes and emits large quantities of carbon dioxide. With the world urgently seeking solutions to climate change, transforming the aluminum sector has become a major sustainability priority.
- Aluminum demand is projected to remain robust for decades, making decarbonizing its supply chain essential.
- Traditional smelting—a process dating back over a century—normally releases 1.6 tons of CO2 per ton of aluminum produced.
- Renewable energy integration and process innovation are both required to bring the sector in line with global climate goals.
The ELYSIS Breakthrough: Carbon-Free Aluminum Smelting
In 2018, a landmark joint venture named ELYSIS was launched by Alcoa and Rio Tinto, with decisive funding and support from Apple, and the governments of Canada and Quebec. ELYSIS developed a technologies that replaces the traditional carbon anode with an inert anode material. This innovation results in the release of pure oxygen instead of CO2 as a by-product.
- ELYSIS’s process eliminates all direct greenhouse gas emissions from the smelting step.
- This is the first time that commercial-grade, primary aluminum has been produced at industrial scale with zero net carbon emissions.
- Montreal, Canada-based ELYSIS produces this aluminum at its Industrial Research and Development Centre in Quebec, utilizing renewable hydropower for even lower environmental impact.
Apple’s Role: Accelerating Green Innovation
Apple has a longstanding commitment to environmental innovation, demonstrated by its investments and partnerships to transform material supply chains. In the ELYSIS venture, Apple:
- Participated as a founding partner and provided both funding and technical support.
- Purchased the first commercial batch of ELYSIS aluminum in 2019, which was used in the 16-inch MacBook Pro.
- Committed to using the latest batch of low-carbon aluminum in the iPhone SE, marking the material’s debut at industrial scale in a mass-market consumer product.
Vincent Christ, CEO of ELYSIS, highlighted this milestone as demonstration of genuine market demand and the technology’s potential to “make lasting changes in how aluminum is produced.” Apple executives view this as central to their ongoing mission to build a net zero value chain.
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Decarbonizing the Aluminum Value Chain
The ELYSIS innovation is part of a broader revolution across the aluminum lifecycle. Both upstream and downstream processes are being reimagined to drive carbon neutrality:
- Mining & Refining: Initiatives like Alcoa’s ASTRAEA™ project aim to refine aluminum scrap into ultra-high-purity metal, further reducing reliance on newly mined ore.
- Recycling: Apple’s products, including every iPad, MacBook, Mac mini, and Apple Watch, now use 100% recycled aluminum enclosures wherever possible.
- Green Power: Hydro-powered smelting and the use of renewable energy sources have dramatically lowered the emissions footprint of the production process itself.
Market and Industry Impact: A Sustainable Trend
Apple’s adoption of ELYSIS aluminum sets a powerful precedent for the electronics industry, encouraging suppliers and competitors to prioritize carbon-free materials. The broader automotive sector has already begun following suit. For instance:
- ELYSIS aluminum and Alcoa’s EcoLum have been used in collaboration with Audi and RONAL Group for the wheels of the Audi e-tron GT sports car.
- Major manufacturers are assessing inert anode technology for existing and future smelters to lower costs, boost capacity, and slash emissions.
- ELYSIS technology is expected to become commercially available to the wider market by 2024, paving the way for rapid scaling.
| Feature | Traditional Smelting | ELYSIS Process |
|---|---|---|
| Carbon Emissions | ~1.6 tons CO2 per ton aluminum | Zero (releases pure oxygen) |
| Main Byproduct | Carbon dioxide (CO2) | Oxygen (O2) |
| Energy Source | Often fossil-based electricity | Hydropower (renewable) |
| Scalability | Established, mature | Commercial scale, pioneering |
Apple’s Emission Reductions: Progress in Numbers
Since 2015, Apple has decreased its carbon emissions associated with aluminum by nearly 70%. This achievement is attributed to:
- Switching to recycled and green-sourced aluminum for its devices.
- Setting a supply chain precedent by integrating carbon-neutral materials into mass consumer electronics.
- Continuously supporting research and development in materials science and sustainable manufacturing.
The Bigger Picture: Toward a Carbon-Free Future
The partnership between Apple and ELYSIS represents just one step in the transformation of heavy industry. But its implications extend far beyond electronics:
- Cross-sector influence: Energy, mobility, and construction industries can benefit from similar decarbonization breakthroughs.
- Climate policy leadership: The involvement of the Canadian and Quebec governments demonstrates the vital role of policy and public investment in propelling industry transformation.
- Scalable impact: As ELYSIS technology matures, it offers a roadmap for retrofitting or building new smelters worldwide with the potential to phase out one of the largest remaining sources of industrial greenhouse gases.
Looking Forward: The Next Generation of Green Manufacturing
What does this mean for consumers? Products like the new iPhone SE don’t just symbolize technical achievement—they mark the everyday adoption of sustainable solutions by millions. For manufacturers, these advances foster competitive differentiation, supply chain resilience, and compliance with increasingly stringent regulations.
The ELYSIS breakthrough is poised to set a new industry standard, with real-world applications spreading quickly as costs fall and the environmental imperative grows stronger.
Key Takeaways
- Apple and ELYSIS have introduced commercial-scale, zero-emissions aluminum to mainstream consumer electronics.
- This innovation replaces CO2 emissions with pure oxygen, driven by an inert anode process powered by renewable energy.
- Apple has already cut its aluminum-related emissions by 70% since 2015, and new supply chain standards are taking hold industry-wide.
- Full commercial deployment is expected by 2024, opening new opportunities for decarbonizing global heavy industry.
Frequently Asked Questions (FAQs)
Q: What makes ELYSIS aluminum ‘low-carbon’?
A: ELYSIS aluminum is considered ‘low-carbon’ because its carbon-free smelting process emits oxygen rather than carbon dioxide. Additionally, the process is powered by hydroelectricity to further reduce environmental impact.
Q: Where is the new low-carbon aluminum produced?
A: The aluminum is produced at the ELYSIS Industrial Research and Development Centre in Quebec, Canada, using local hydropower resources.
Q: How is Apple using this new aluminum?
A: Apple uses ELYSIS aluminum in selected products, most notably the iPhone SE and earlier, in the 16-inch MacBook Pro. It’s increasingly integrating low-carbon and recycled aluminum across device portfolios.
Q: What is the environmental benefit of ELYSIS technology?
A: ELYSIS technology eliminates greenhouse gas emissions from the smelting process, reducing overall industrial carbon footprints and contributing toward global climate goals.
Q: Can ELYSIS technology be used in other industries?
A: While first adopted in consumer electronics and automotive wheels, the technology is scalable and suitable for any industry that depends on aluminum, including construction, transport, and packaging.
References
- https://www.apple.com/newsroom/2022/03/apples-four-point-seven-billion-in-green-bonds-support-innovative-green-technology/
- https://www.apple.com/si/newsroom/2022/03/apples-four-point-seven-billion-in-green-bonds-support-innovative-green-technology/
- https://www.alcoa.com/global/en/stories/releases?id=2022%2F03%2Fapple-to-use-elysis-zero-carbon-aluminum-for-the-latest-iphone-se
- https://www.engadget.com/apple-iphone-se-low-carbon-aluminum-142911451.html
- https://grist.org/energy/apples-low-carbon-aluminum-is-an-climate-game-changer/
- https://elysis.com/en/elysis-strengthens-its-ties-with-apple
- https://elysis.com/en/what-is-elysis
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