Africa’s largest copper smelter reaches milestone output. (Image source: Ivanhoe Mines)
Ivanhoe Mines announced the production of the first copper anodes from its state-of-the-art 500,000-tonne-per-annum direct-to-blister smelter at Kamoa-Kakula
This milestone comes roughly five weeks after the smelter’s heat-up and one week after the first feed of concentrate, marking a defining moment for the project.
“The first production of copper anodes from our world-class smelter is a defining moment for Kamoa-Kakula… This achievement is the culmination of a US$1.1bn investment, 18 million man-hours of disciplined execution, and an outstanding health and safety record that reflects the professionalism and commitment of everyone involved.
“This facility will proudly deliver the highest-quality Congolese copper anodes to the international markets, setting a new global benchmark for scale, efficiency, and sustainability. I want to extend my sincere thanks to the extraordinary Kamoa Copper team, as well as our contractors and partners from across the world whose expertise, innovation, and teamwork made the design and delivery of this state-of-the-art facility possible. Together, we have built something exceptional that will serve global consumers for generations to come,” said Robert Friedland, founder and executive co-chairman of Ivanhoe Mines.
The smelter is now in ramp-up mode and is expected to achieve a steady-state annualised production of 500,000 tonnes of 99.7%-pure copper anodes, establishing it as the largest copper smelter in Africa. Copper production for 2026 is projected at 380,000–420,000 tonnes, with the midpoint of 400,000 tonnes representing roughly 80% of capacity.
Kamoa-Kakula’s management will prioritise processing concentrates from Phase 1, 2, and 3 concentrators through the on-site smelter, while any surplus will be toll-treated at the Lualaba Copper Smelter (LCS) near Kolwezi. The smelter heat-up, furnace commissioning, boiler, steam systems, acid circuit, and concentrate dryer were completed as scheduled, with the furnace reaching 1,250°C (2,282°F) for five days prior to the first concentrate feed.
The on-site inventory of copper concentrate currently totals approximately 37,000 tonnes and is expected to decline to around 17,000 tonnes during 2026 as the smelter ramps up, resulting in copper sales exceeding production by roughly 20,000 tonnes in H1 2026. This provides an opportunity to benefit from near-record-high copper prices.
Supporting uninterrupted operations, a 60 MW uninterruptible power supply (UPS) facility was installed, providing up to two hours of backup power against DRC grid fluctuations. Construction of a 60 MW on-site solar PV facility with battery storage is progressing, expected to become Sub-Saharan Africa’s largest solar-powered smelter supply, complementing the 180 MW diesel generator backup.
Kamoa-Kakula’s smelter also produced its first batch of by-product sulphuric acid, with annual production expected up to 700,000 tonnes, meeting strong local demand following Zambia’s acid export ban. Spot prices in Kolwezi have recently reached US$700 per tonne, with the first deliveries scheduled soon.
The smelter project maintained industry-leading health and safety standards, recording only one lost time injury over 18 million man-hours, resulting in a lost-time injury frequency rate of 0.054 per million hours. The previous Phase 3 concentrator project, completed in mid-2024, recorded zero LTIs.
Meanwhile, Stage Two dewatering of the Kakula Mine has been completed, with selective mining underway in the eastern section. Stage Three dewatering, involving the rehabilitation and recommissioning of water-damaged underground pump stations, will commence once access becomes available.
