The ramp-up of copper/nickel/zinc and platinum group metals miner Ivanhoe Mines’ Kamoa-Kakula copper smelter in the Democratic Republic of Congo (DRC) will continue throughout this year, with completion expected towards year-end, report executive co-chairperson Robert Friedland and CEO Marna Cloete.

According to a company statement, the Kamoa-Kakula copper smelter is expected to deliver high quality copper anodes to international markets, setting a new global benchmark for scale, efficiency and sustainability.

Ivanhoe confirms that heat-up and completion of hot commissioning of the smelter furnace, as well as boiler, steam systems, acid circuit and the concentrate dryer were completed in line with expectations.

“The first production of copper anodes from our smelter is a defining moment for Kamoa-Kakula . . . This achievement is the culmination of a $1.1-billion investment, 18-million personnel-hours of disciplined execution, and an outstanding health and safety record that reflects the professionalism and commitment of everyone involved,” says Friedland.

“The furnace successfully reached its operating temperature of 1 250 oC for five days prior to the first feed of concentrate,” says Friedland.

He adds that, as announced on December 3, 2025, Kamoa-Kakula’s copper production is estimated at between 380 000 t and 420 000 t of copper in 2026, with the mid-point of 400 000 t of copper representing about 80% of the smelter’s total capacity.

The copper producer reports that Kamoa-Kakula’s management team will prioritise the processing of concentrates produced by the phase 1, 2 and 3 concentrators through the on-site smelter, rather than being exported unbeneficiated.

Ivanhoe intends for the smelter to ramp up to a steady-state yearly rate of 500 000 t of pure copper a year, positioning it as the biggest copper smelter in Africa.

Further, the construction of the copper smelter was completed with an exemplary health and safety record, with only one lost-time injury recorded over 18-million hours worked.

Plant Power

Ivanhoe Mines states that Kamoa-Kakula’s operating margins are expected to expand as the smelter ramps up, owing to reduced logistics costs from on-site smelting and additional revenues from by-product sulphuric acid sales.

“Logistics costs are expected to about halve as the copper content per truck-load exported more than doubles, from about 45% contained copper in concentrate to 99.7% - pure copper anodes,” the company reports.

In addition to the first production of copper anodes, the smelter has also produced its first batch of by-product sulphuric acid.

At steady-state operations, the smelter is expected to produce up to 700 000 t/y of high-strength sulphuric acid, which will be sold locally.

The company confirms that the first sale of sulphuric acid has already taken place, with delivery expected in the coming weeks.

Prior to the first feed of concentrate into the smelter on December 21, 2025, the installation of a 60 MW uninterruptible power supply (UPS) facility was completed.

The UPS is designed to provide up to two hours of instant back-up power, protecting the smelter from voltage fluctuations on the domestic grid in the DRC.

Further, the company also reports that the construction of Kamoa-Kakula’s 60 MW on-site solar PV facility, which will include battery storage, is progressing well.

Ivanhoe Mines notes that the solar installation is expected to be of comparatively significant scale in sub-Saharan Africa and is ready to become operational from the second quarter of 2026, providing 24-hour uninterruptible power, in addition to about 180 MW of on-site diesel-powered back-up generation capacity.