Ivanhoe Mines announces record copper production and increased power at Kamoa-Kakula, DRC

Ivanhoe Mines announces record copper production at Kamoa-Kakula, DRC, and increased power supply

Ivanhoe Mines executive co-chairman Robert Friedland and president and CEO Marna Cloete have announced that the Phase 1, 2, and 3 concentrators at the Kamoa-Kakula Copper Complex in the Democratic Republic of the Congo (DRC) achieved a combined monthly production record of 50,176 tonnes of copper in concentrate during April. The concentrators processed 1.35 million tonnes of ore with an average feed grade of 4.19% copper.

The newly ramped-up Phase 3 concentrator exceeded its design rate, achieving a recovery rate of 87.4% in April, surpassing its 86% target. Since mid-March, copper production has increased to an average of approximately 12,000 tonnes per week, which equates to an annualised production rate of roughly 625,000 tonnes, exceeding the midpoint of 2025 production guidance by about 12%.

Power boosts production

This outperformance was supported by initiatives in the first quarter that enabled the Phase 3 concentrator to be consistently fed at higher rates. In the first quarter, Phase 3 milled a record 1.51 million tonnes of ore, equivalent to an annualised milling rate of 6.1 million tonnes, more than 20% above its design capacity of 5 million tonnes per year.

The DRC operation reached a significant milestone in the first quarter, with a notable increase in imported hydroelectric power, which gave Kamoa-Kakula’s management the confidence to proceed with the final commissioning of the smelter. The start-up of the new on-site copper smelter is expected in the coming weeks.

During the first quarter, power demand for the Phase 1, 2, and 3 operations ranged from 130 MW to 140 MW. At the start of March, Kamoa-Kakula was drawing 50 MW from domestic hydropower and another 50 MW from imported sources. The remaining power was provided by on-site, diesel-generated backup power, with a capacity of around 160 MW. Power requirements for the smelter will increase gradually, from 45 MW during the first concentrate feed, to 70 MW once at full capacity.

In March, a power agreement was reached to increase imported hydroelectric power via the Zambia-DRC interconnector, resulting in an additional 20 MW, which increased to 70 MW by April. Combined with about 50 MW of domestic hydropower, Kamoa-Kakula now has around 150 MW of stable hydropower, enough to power the Phase 1, 2, and 3 operations. Further increases in grid power are expected throughout 2025 as the smelter ramps up. The extra power will be largely sourced from Mozambique via a wheeling agreement through the Southern Africa Power Pool network.

As previously announced, wet commissioning of Turbine #5 at Inga II, with a generation capacity of 178 MW, is expected to begin in the second half of 2025. Once commissioned, Kamoa-Kakula will receive an additional 71 MW of hydroelectric power, which will increase to 178 MW as grid improvement initiatives are completed in 2026.

Emerson's cutting-edge dust collector monitoring solution. (Image source: Emerson)

Emerson, a global leader in industrial automation, has introduced a sophisticated dust collector monitoring and control solution aimed at improving operational efficiency, cutting maintenance costs, and ensuring environmental compliance across multiple industries

By integrating proven mechanical and automation technologies, this intelligent system delivers real-time diagnostics and seamless compatibility with existing plant systems, enabling operators to optimise performance and prolong equipment life.

Industries including cement, mining, chemicals, food production, and power generation manage materials that generate substantial dust and particulate emissions. These airborne particles threaten worker safety, equipment reliability, and environmental standards, making effective dust collection systems essential.

Conventional dust collectors use filters that require periodic cleaning with compressed air and eventual replacement, which can lead to expensive maintenance and unexpected downtime if not properly monitored.

Emerson’s innovative solution addresses these issues through automation. By employing advanced algorithms and predictive diagnostics, it optimises filter cleaning, identifies faults early, and reduces energy consumption. Extending filter life by up to a year can save businesses as much as US$18,000, while avoiding downtime that may cost thousands per hour.

A robust automation suite

The solution combines a range of Emerson’s trusted products, such as ASCO™ pulse valves, AVENTICS™ air flow sensors, Rosemount™ pressure sensors, and PACSystems™ programmable logic controllers (PLCs). These components enable precise control of pulse valve operations and automated cleaning cycles across multiple filter lines.

Additional features include Movicon.NExT SCADA for remote monitoring, alerts, and reporting, and QuickPanel+ human-machine interfaces (HMIs) that provide real-time diagnostics and early fault detection. The system also incorporates ASCO P152 particle concentration sensors to detect low dust levels and filter issues, alongside differential pressure monitoring with optional 4-20 mA compatibility.

“With this world-class and easily implemented solution, we aim to help our end users achieve greater operational efficiencies and gain valuable insights that reduce reactive maintenance, lower the risk of downtime, minimise energy consumption, and extend equipment life while addressing the knowledge gap by providing easily accessed information for operations personnel,” said Samuele Oliva, product marketing manager for dust collectors and alternative energy with Emerson’s discrete automation business.

Delivering operator benefits

Emerson’s solution provides several key advantages. Optimised pulse valve usage extends the lifespan of valves and filter bags, reducing compressed air waste and safeguarding equipment. Predictive maintenance capabilities monitor compressed air, pressure, temperature, dust levels, and energy usage, allowing early intervention to prevent costly failures.

The system’s scalability, with licensing based on pulse valve count (up to 500), makes it adaptable to facilities of varying sizes. Its Floor-to-Cloud connectivity ensures seamless integration with existing automation systems, offering a comprehensive operational overview and supporting compliance with environmental regulations.

In addition to cost savings, the solution advances sustainability by lowering energy and compressed air consumption. Smart filter cleaning reduces waste, while early detection of failed filters helps avoid regulatory penalties. These features align with increasing industry demands for environmentally responsible practices.

Schneider Electric South Africa introduces TeSys Deca Advanced to improve motor efficiency and industrial reliability. (Image source: Schneider Electric)

Schneider Electric South Africa has introduced the TeSys Deca Advanced, a next-generation contactor designed to elevate motor management through increased efficiency, reliability, simplicity, and sustainability

As a key player in digital transformation for energy management and automation, Schneider Electric’s latest innovation addresses evolving industrial needs with cutting-edge technology.

A standout feature of the TeSys Deca Advanced is its wide-band coil technology, capable of handling input voltages from 24V to 500V AC/DC. This allows the contactor to adapt seamlessly to voltage fluctuations while reducing energy consumption, resulting in lower CO₂ emissions and cost savings.

According to Thapelo Manthata, Offer Manager Power Products (PPCTR) at Schneider Electric South Africa, the solution is tailored for a wide array of industrial uses. “By combining digital capabilities, reduced energy consumption and more simplified installation, the unit is engineered to help optimise motor management while supporting sustainability and operational resilience.”

“The ideal applications for the TeSys Deca Advanced are robust, high industrial environments. As a contractor, it can be used for hoisting, pumps, HVAC systems, elevators and packaging applications. Additionally, it is suitable for mining and wastewater environments, among others,” says Manthata.

Engineered with ease-of-use in mind, the contactor features a user-friendly three-layer structure that improves wiring visibility and access. This streamlines setup and maintenance, reducing the need for highly specialised installation skills.

“So, it was designed for diverse industrial applications and simplifies installation and maintenance processes. Its ergonomic three-layer setup organises wiring for optimal visibility and accessibility, streamlining operations and minimising the need for specialised skills in the workforce,” added 

The TeSys Deca Advanced also incorporates one-click connection technology that cuts installation time by up to 75%, making it ideal for time-sensitive deployments. It supports direct PLC control, reducing both complexity and the need for extensive inventory by 80%.

Reliability meets predictive maintenance

“TeSys Deca Advanced is built for reliability, having gone through comprehensive testing to guarantee peak performance. It supports predictive maintenance by offering real-time diagnostics, allowing users to foresee and address potential problems before they cause any downtime,” concluded Manthata.

By focusing on key industries such as manufacturing, HVAC, and broader industrial operations, Schneider Electric ensures that the TeSys Deca Advanced contributes to greater uptime and streamlined performance.

“The TeSys Deca Advanced unit is designed to improve operational efficiency in various sectors, including manufacturing, HVAC, and industrial facilities. By integrating advanced technology with a strong emphasis on sustainability, we remain committed to maximising uptime and providing exceptional value.”

Solar Photovoltaic systems have a role to play in increasing South Africa’s power generation capacity

Solar Photovoltaic (PV) systems have a significant role to play in increasing South Africa’s power generation capacity, explainsShaniel Lakhoo, a senior electronic engineer for WSP in Africa

However, the PV power generation profile used in recent long-term planning simulations does not accurately represent the current and expected future PV power generation in the country.

South Africa is at a critical juncture in its energy transition.

With Eskom predicting that solar PV’s contribution to generation capacity will grow to 19% by 2030, it is clear that solar energy will play a pivotal role.

Understanding the power production profile for PV plants is critical in ensuring the right decisions are made on the generation technology mix to best meet the nation’s electricity demand.

Deploying the right mix is also critical to provide a stable lowest-cost electricity solution for the country.

A key decision when it comes to utility-scale PV plant centres on how the modules are set up on the site and whether the modules are fixed in place and angled to compensate for the latitude (fixed-tilt) or track the sun during the day on a single horizonal axis (single-axis tracking).

The choice has significant implications for cost-effectiveness, energy output and ultimately influences when and how much power may be injected into the grid.

The importance of accurate PV power generation profiles

The accuracy of PV power generation profiles is crucial for long-term power generation capacity expansion planning. These profiles inform the broader energy mix and capacity planning for the future.

The country’s studies, included in the Integrated Resource Plan (IRP) 2019, show the predominant use of fixed-tilt systems, with the IRP 2023 not providing sufficient information to conclude the profile used. This is despite the growing use of single-axis trackers in real-world projects.

Single-axis trackers, which follow the sun’s path throughout the day, generally outperform fixed-tilt systems in terms of energy production.

In my research, I found energy gains of 12.9% to 20.1% could be achieved annually by using single-axis tracking systems as opposed to fixed-tilt systems. By analysing the Levelised Cost of Energy (LCOE) — a measure of the average net present cost of electricity generation for a plant over its lifetime — my research aimed to determine which configuration would offer the lowest LCOE.

Across all scenarios and locations, single-axis trackers consistently emerged as the most cost-effective solution. Despite the higher upfront costs, the energy gains from using trackers more than offset these expenses. This resulted in a lower LCOE compared to fixed-tilt systems.

Part of this research included a sensitivity analysis to understand the most significant factors impacting LCOE. The analysis revealed that the Balance Of System (BOS) costs and the Ground Coverage Ratio (GCR) are the most critical variables.

Interestingly, the cost of land had only a minor influence on LCOE. This was true even with the upper band equivalent to more than four times the profits that could be expected from using the land for agricultural purposes.

Bifacial modules were explored in my analysis as these become more prevalent in the market and are being deployed in new projects. However, my simulations found the additional energy produced by bifacial modules does not justify the 6% premium over single axis trackers. For fixed tilt systems, the added energy was sufficient to make this the lower LCOE solution.

These insights are crucial for decision-makers. The analysis showed that even in scenarios with lower GHI (Global Horizontal Irradiance), single-axis trackers with mono-facial modules remained the most cost-effective choice. Additionally, the plant design can be optimised based on GCR, knowing the cost of land is not a significant factor, thereby improving the overall feasibility of solar projects.

Creating a representative power profile

One of the valuable outcomes of the research was the development of a representative PV power generation profile for South Africa. This was achieved by weighting the contributions from the 11 Renewable Energy Development Zones (REDZ) across the country, against the expected deployment of PV according to the Integrated Resource Plan (IRP) 2019. The resultant profile blends these contributions to create a profile reflecting the anticipated future solar generation.

This new profile is based on the most cost-effective solution identified in simulations (single-axis trackers with mono-facial modules) and provides a revised profile that forms a more reliable basis for future energy planning. It is a step towards ensuring our long-term energy forecasts are grounded in the realities of the technologies we’re deploying.

The journey of exploring PV tracking choices has underscored the importance of aligning our energy planning with the latest technological and market advancements. As South Africa moves towards decarbonisation, it is crucial long-term planning reflects realistic predictions, rather than solely historical data or outdated assumptions.

The transition to renewable energy is not just about adopting innovative technologies. It comes down to making informed decisions that will shape the sustainability of our energy systems for decades to come.

In the case of utility-scale PV power plants, that means ensuring representative profiles are used when completing long-term planning simulations.

Shaniel Lakhoo is a senior electronic engineer for WSP in Africa

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