Alcoa flags 'pretty aggressive' cost cuts at alumina refineries

Alcoa chief executive Bill Oplinger told Wall Street the US aluminium specialist could take strong action to boost profits from alumina, most of which it refines in Western Australia.

Picture of an Alcoa sign on Saint Georges Terrace, Perth. In 2025 Alcoa moved its Australian headquarters from suburban Booragoon to central Perth.
Alcoa has recently moved its Australian headquarters into central Perth. Image: P MIlne.

Alcoa chief executive Bill Oplinger has signalled a cost-cutting drive at the company's alumina refineries, which Western Australia - home to the majority of production - would be unlikely to escape.

The price the Pittsburgh-based company received for the aluminium smelter feedstock dropped 12 per cent in 2024, cutting earnings from its alumina division by a third.

🔢
KEY NUMBERS - Alcoa 2025

Profit - $US1,170 million, ⬆️ from $US60 million in 2024
Revenue - ⬆️ 8% to $US12.8 billion
Bauxite - 25.8 million tonnes mined in WA, ⬇️ 7%
Alumina
- production ⬇️ 4% (mainly the Kwinana closure)
- price ⬇️ 12%
- adjusted EBITDA ⬇️ 36% to $US901 million
Aluminium
- production ⬆️ 4% (due to smelter restarts)
- price ⬆️ 19%
- adjusted EBITDA ⬆️ 61% to $US1058 million

Alcoa's WA refineries, Pinjarra, Wagerup and Kwinana, which closed in 2024, typically produce more than 70 per cent of the company's alumina.

When queried by Wall Street analysts last week on plans to cut costs and boost efficiency at Alcoa's refineries, Oplinger said that he understood where his alumina division was in the commodity cycle.

'We've shown in the past ... that we can get pretty aggressive around costs," Olplinger said.

However, Oplinger indicated that at least one of his predecessors had gone too far in response to previous low prices.

"What we won't do this time around is really put any of our plants in jeopardy for the future," he said.

Alcoa's WA operations - the Huntly mine that feeds the Pinjarra refinery and the Willowdale mine that supplies the Wagerup refinery further south - employs about 4000 people.

Low prices hit Alcoa's alumina refineries

Olpinger was speaking after the $22 billion company released its 2025 financial results that showed a falling financial performance of its alumina business countered by a much better year from its aluminium smelters.

Graph showing the Platts global benchmark price for alumina over 2025 and 2025 - set by WA production - plunged in early 2025 from a peak of about $US800 a tonne to about $US300 a tonne.
The global benchmark price for alumina - set by WA production - plunged in early 2025. Source: Alcoa Q4 2024 presentation

The global prices index for alumina which is based on WA production from Alcoa and South32 fell heavily in the first four months of 2025.

Oplinger said the Chinese government had discouragred large-scale curtailment of production at its refineries despite about 60 per cent of them having difficulties at current pricing.

"Alcoa is exceptionally well positioned to navigate market volatility, thanks to our low-cost mining and refining portfolio and our strong operational performance," Oplinger said.

All of Alcoa's refineries are in the lowest 25 per cent of global production costs.

A cost curve of the world's alumina refineries in 2025 showing all of Alcoa's refineries are in the lower quartile of breakeven price and half of global capacity is losing money at current prices.
All of Alcoa's alumina refineries - including Pinjarra and Wagerup in WA - have low production costs. Source: Alcoa Q4 2024 presentation

He praised his teams at WA's Pinjarra and Wagerup alumina refineries for continuing to increase production despite the low bauxite grade Alcoa is currently mining in WA until it gains environmental approval to clear new swathes of jarrah forest.

A pie chart of Alcoa's cost to produce alumina in the fourth quarter of 2025 - bauxite 25%, caustic 17%, natural gas 18%, other energy 5% and conversion 35%.
Mining accounted for only a quarter of Alcoa's alumina production costs in Q4 2025. Source: Alcoa Q4 2024 presentation

The low grade of bauxite in WA means to produce a tonne of alumina Alcoa needs more ore, more caustic, and more natural gas.

WA approvals or bust for Alcoa

WA's Environmental Protection Authority (EPA) is assessing Alcoa's current mining and a planned expansion of the Huntly mine that is increasingly encroaching of the water catchments that supply Perth.

In January Alcoa provided responses to the EPA to the almost 60,000 submissions the independent watchdog received.

Oplinger said he expected the EPA to publish its recommendations by mid-year and for Alcoa to receive the go-ahead from WA and Federal environment ministers by December.

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Read Boilng Cold's breakthrough revelations on how the WA government is doing all it can to put Alcoa before WA's forests and water supply.

Alcoa is betting everything on getting those approvals to continue its six decades of mining WA's jarrah forest that accounts for more than 70 per cent of its bauxite and alumina production.

Oplinger said Alcoa had no plans to develop new mines or refineries.

"Refining capital costs are still fairly high and certainly, at today's prices, it makes it difficult for a greenfield expansion."

However he said Alcoa has opportunities for "brownfield" expansiion of existing mines, refineries and smelters.

To continue mining in WA Alcoa will have to counter concerns about its failure to complete the rehabilitation of a single hectare of forest in six decades and the high chance its mining could contaminate Perth's water supply.


Key documents

Alcoa Q4 and full year 2025 results

Alcoa Q4 and full year 2025 results presentation

Transcript of Alcoa conference call with investment analysts

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