Canadian mining company Ivanhoe Mines has reported that the Phase 1, 2, and 3 concentrators at the Kamoa-Kakula Copper Complex in the Democratic Republic of Congo (DRC) achieved a combined monthly production record of 41 800 t of copper in concentrate, and a combined monthly milling record of 1.2-million tonnes in October.

Copper production from Kamoa-Kakula now totals 345 042 t of copper for the year to October 31.

On October 12, Ivanhoe says, the Phase 1, 2, and 3 concentrators combined milled a record 50 253 t of ore and produced a record 1 720 t of copper.

This is equivalent to an annualised milling rate of 16.9-million tonnes a year and an annualised production rate of about 580 000 t of copper, after accounting for availability.

Over the same 24-hour period, the company notes that the Phase 1 and 2 concentrators milled a record 31 463 t of ore, equivalent to an annualised milling rate of 10.6-million tonnes a year, which is 15% above the debottlenecked nameplate capacity of 9.2-million tonnes a year, after accounting for availability.

"Kamoa-Kakula production is accelerating into year-end. In October, we reached a remarkable milestone by exceeding the annualized production rate of 500 000 t of copper, placing us among the top-tier of copper producers globally.

“Our successful three-phase delivery of the world's newest and greenest Tier 1 copper mining complex was consistently achieved ahead of schedule . . . a triple-crown achievement that is a pink unicorn in our industry . . . Ivanhoe's growth story is just beginning. . .

“We're nearing completion of the engineering for Kamoa-Kakula's Phase 4 expansion and making significant strides across our Western Foreland exploration licences with 11 drill rigs turning,” says Ivanhoe founder and executive co-chairperson Robert Friedland.

The Phase 3 concentrator also milled a record 448 478 t of ore during October, which was a month-on-month increase of 30%.

Ivanhoe says total tonnes milled by the Phase 3 concentrator for the month is equivalent to the nameplate milling rate of five-million tonnes a year, after accounting for availability.

Moreover, the company notes that, on October 21, the Phase 3 concentrator milled a record 19 198 t of ore over 24 hours.

The record is equivalent to an annualised milling rate of about 6.5-million tonnes a year, and 30% higher than the design capacity of five-million tonnes a year.

Copper produced by the Phase 3 concentrator during October was 10 533 t of copper in concentrate, a 42% month-on-month increase.

Ivanhoe adds that construction of the Kamoa 1 and 2 underground-to-surface ore conveyor system, similar in design to that at Kakula, as well as the first underground truck tip, are now complete and undergoing commissioning.

This enables ore mined from the Kamoa 1 and 2 underground mines to be fed directly into the Phase 3 concentrator, rather than drawing on surface low-grade stockpiles that were regularly used during ramp-up.

The company says the Phase 3 concentrator will now be fed predominantly with run-of-mine (RoM) ore from the Kamoa 1 and 2 underground mines, supplemented, where necessary, by surface stockpiles.

The Phase 3 concentrator recovery rate averaged 83% during October. Ivanhoe says, going forward, recovery rates are expected to increase in line with the nameplate recovery rate of 86% as higher volumes of RoM ore are processed.

The direct-to-blister copper smelter is over 94% complete with construction on schedule for completion by year-end. The smelter is located adjacent to the Phase 1 and 2 concentrators and will be fed by a blend of concentrate from Phase 1, 2, and 3 concentrators.

The final stages of construction completion are underway at the smelter, including the insulation of the off-gas ducting system. Off-gases, which contain acid as well as waste heat, are captured from the furnace building and recycled.

Ivanhoe says captured sulphuric acid from the smelter’s furnace building will be sold to mining operations on the DRC Copperbelt. The smelter is expected to produce about up to 700 000 t of high-strength sulphuric acid yearly as a by-product.

Construction of the smelter’s fugitive-off-gas handling building, located adjacent to the furnace building, is nearing completion.

Waste heat captured from the furnace building is recycled to generate 8 MW of electricity, which will be used as supplementary power for the smelter operations.