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Mining

Kamoa-Kakula’s senior management and projects team celebrating the completion of the on-site copper smelter and the first delivery of concentrate from Kamoa-Kakula to the concentrate blending facility. (Image source: Ivanhoe Mines)

Ivanhoe Mines executive co-chairman Robert Friedland and president & CEO Marna Cloete have provided an update on year-to-date production at the Kamoa-Kakula Copper Complex and the ultra-high-grade Kipushi zinc mine, both located in the Democratic Republic of the Congo (DRC)

In January, Kamoa-Kakula achieved near-record copper production of 45,477 tonnes, followed by 40,849 tonnes in February, despite the shorter month. Daily copper production averaged 1,467 tonnes per day (tpd) in January and 1,459 tpd in February, just below the record 1,518 tpd set in December 2024.

During the last week of February, copper production reached 11,122 tonnes, equating to an annualised rate exceeding 578,000 tonnes—positioning it at the upper end of the 2025 guidance range of 520,000 to 580,000 tonnes.

Power supply and backup generation

Kamoa-Kakula’s Phase 1, 2, and 3 operations have been powered by approximately 100MW of hydroelectric power, covering two-thirds of the required energy, with the remainder supplied by on-site diesel generators. Talks are in progress to increase imported hydroelectric power by an additional 20MW by the end of the month.

Water levels have improved at the Cahora Bassa hydroelectric dam in Mozambique, Kamoa-Kakula’s primary power source, as well as at Zambia’s Kariba dam.

According to the Club of Mozambique on March 4, 2025, "Current water levels in the Cahora Bassa reservoir guarantee the production of electricity until the last quarter of this year. This is the result of the water reserves accumulated during this rainy season, after levels fell to 19.18% in January, the lowest level in recent times." Cahora Bassa Hydroelectric Plant Chairman Tomás Matola stated, "With the rainfall that fell in February, we were able to recover and our hydro-meteorological forecasts show that more rain is coming and storage will naturally increase."

Kamoa-Kakula has 190MW of installed diesel backup power, with up to 50MW currently in use. Of this, 36MW of capacity is undergoing repair, as previously reported in January. The total power requirement for full operation of Phases 1, 2, and 3, along with the smelter, is approximately 240MW. Efforts to secure additional grid-supplied power for the smelter heat-up are ongoing, with the process expected to begin in May or June 2025.

Project 95 advancing on schedule

Kamoa-Kakula’s "Project 95" is progressing as planned, now 20% complete and on track for Q1 2026 completion. This initiative aims to enhance concentrator recoveries from 87% to 95% with a US$180mn capital investment. It is expected to boost annual copper production by up to 30,000 tonnes, with a capital intensity of $6,000 per tonne of copper.

Kipushi Zinc production update

The Kipushi concentrator ramp-up continues, achieving record zinc production of 16,063 tonnes in January and 11,903 tonnes in February. Annualized production is approaching the 2025 guidance range of 180,000 to 240,000 tonnes of zinc in concentrate.

Since early 2025, concentrator recoveries have averaged 88%, with a concentrate grade of approximately 53% contained zinc. The nameplate milling rate of 2,000 tonnes per day was reached in late February, with further production and recovery improvements expected in the coming months.

Kipushi aims to exceed 250,000 tonnes of zinc in concentrate by 2026 following the completion of a debottlenecking program, which remains on schedule for late Q3 2025.

Also read: Africa’s gold rush accelerates growth

Major gold producers like Ghana, Guinea, and Mali drive Africa’s mining growth, with new projects set to boost production from 2025 onward. (Image source: Adobe Stock)

Africa’s gold sector remains a key driver of foreign investment and revenue, with major producers like Ghana generating US$5bn from artisanal mining in 2024 alone

As the industry continues to contribute to sustainable development, African nations are strengthening global partnerships to launch new projects and unlock industrial opportunities.

African Mining Week (AMW), the continent’s leading mining industry event, will spotlight high-potential gold projects, investment opportunities, and emerging exploration basins. With new production facilities set to begin operations from 2025 onwards, AMW serves as a vital platform for global investors to connect with African stakeholders and explore the region’s expanding gold sector.

Africa's gold expansion

Ghana, the top gold producer in Africa, is reinforcing its leadership with the upcoming Cardinal Namdini Mine, operated by Cardinal Resources. Set for commercial production by mid-2025, the mine will yield 358,000 ounces annually, drawing from 5.1 million ounces in reserves over 15 years. Newmont is also targeting first production at its Ahafo South Mine in early 2025, with an expected annual output of 325,000 ounces. Additionally, Asante Gold Corporation has launched a US$525mn expansion to enhance production at its Bibiani and Chirano Mines, further strengthening Ghana’s prominence in gold mining.

In Guinea, Predictive Discovery is advancing the Bankan Gold Mine, a three-million-ounce project scheduled for production in early 2027, with an annual output of 269,000 ounces over 12 years. Meanwhile, Robex is preparing to begin gold production at the Kiniero Mine in 2025, adding 139,000 ounces to Guinea’s growing portfolio.

Mali, Africa’s third-largest gold producer, is set to expand its mining operations with Resolute Mining’s Syama Phase 2 Expansion Project. Once commissioned in the latter half of 2025, it will increase production to 400,000 ounces per year. In Burkina Faso, West African Resources is preparing to launch production at the Kiaka Gold Mine in Q3 2025, targeting an annual yield of 258,000 ounces over 19 years, while Orezone Gold’s Bomboré Gold Mine is expected to significantly boost the country’s mining sector.

As Africa ramps up gold production and strengthens its mining value chain, AMW will feature panel discussions, project showcases, and strategic investment forums, providing global investors with an exclusive opportunity to engage with key industry players and capitalize on the continent’s thriving gold sector.

A concept machine of a large dump truck equipped with a hydrogen combustion engine. (Image source: Komatsu)

Komatsu Ltd., led by president and CEO Hiroyuki Ogawa, has developed a concept version of its HD785 large dump truck, which boasts a maximum payload of approximately 92 metric tonnes, now equipped with a hydrogen combustion engine

The company has begun proof-of-concept testing at its Ibaraki Plant in Hitachinaka City, Ibaraki Prefecture. This initiative marks the world’s first instance of integrating a hydrogen combustion engine into a large dump truck. Through these trials, Komatsu seeks to deepen its understanding of hydrogen engine applications, paving the way for the advancement of hydrogen-powered construction and mining machinery.

Innovating with hydrogen technology

As part of its commitment to achieving carbon neutrality, Komatsu continues to explore and develop alternative power sources. In its pursuit of hydrogen engine technology, the company has leveraged the expertise of KEYOU GmbH, a German startup specialising in hydrogen engine solutions for heavy-duty trucks. The concept machine integrates a hydrogen combustion engine and hydrogen tank system co-developed by Komatsu and KEYOU. To optimise hydrogen storage, the tank is mounted on a platform beside the operator’s cab. Additionally, newly installed cameras and monitors both inside and outside the cab enhance visibility for the operator.

The proof-of-concept tests will assess key factors such as driving performance, operational duration, fuel efficiency, and safety measures associated with high-pressure hydrogen gas.

Advantages of hydrogen combustion engines

Compared to battery and hydrogen fuel cell alternatives, hydrogen combustion engines present a cost-effective solution for construction and mining equipment. This is largely due to the ability to retain powertrain components from conventional diesel-powered machines, reducing the need for extensive modifications. Moreover, with nearly zero CO₂ emissions, some mining operators have shown interest in adopting hydrogen engines as part of their carbon neutrality efforts.

Challenges remain, particularly in hydrogen supply infrastructure and safety management. Komatsu plans to collaborate with industry groups and key stakeholders to address these issues and support the wider adoption of hydrogen technology.

Commitment to carbon neutrality

Under its mid-term management plan, Komatsu aims to cut CO₂ emissions by 50% in both product use and production operations by 2030 (relative to 2010 levels), with the ultimate goal of achieving carbon neutrality by 2050. The company has already introduced hydraulic excavators, tethered electric hydraulic excavators, and battery-powered excavators across various sizes. Additionally, Komatsu is actively developing eco-friendly technologies, including carbon-neutral fuel solutions, battery-powered equipment power supply systems, hydrogen fuel cell-powered excavator trials, and a power-agnostic truck concept.

Komatsu remains dedicated to meeting diverse environmental demands through in-house research, open innovation, and strategic partnerships, reinforcing its commitment to a sustainable future.

Also read: Second Condra crane for Tongaat Hulett

Helium One receives approval for a 480km² Mining Licence, advancing Tanzania’s helium industry and global supply chain role. (Image source: Adobe Stock)

Helium One Global, Tanzania’s leading helium exploration company, has received an offer letter from the Mining Commission (MC) of Tanzania for the grant of a Mining Licence for its southern Rukwa Helium Project

The company also holds a 50% working interest in the Galactica-Pegasus helium development project in Colorado, USA.

Key highlights:

  • The offer letter grants a Mining Licence covering approximately 480km², encompassing the entire southern Rukwa Helium Project located in the Momba and Sumbawanga Districts of the southern Rukwa Basin.

  • This follows the approval by the Ministry of Minerals (MoM), which has permitted the MC to issue a larger-than-standard ML to support the project's full development.

  • The ML offer and terms are currently under review by Helium One.

Lorna Blaisse, CEO of Helium One, emphasised the significance of this milestone, stated, “This is a historic moment for both the company and Tanzania, marking the first-ever Mining Licence granted for helium in the country and on such a significant scale. We are grateful to the Ministry of Minerals and the Mining Commission for their trust in our vision to pioneer this vital sector. I also extend my thanks to our dedicated team and shareholders for their unwavering support.”

Project significance:

The ML offer follows the Itumbula West-1 discovery in 2023 and the submission of a feasibility study in September 2024, which highlighted the vast helium potential of the region. The approval from the MoM has allowed the full 480km² application, a substantial increase over standard ML areas typically granted for conventional mining operations. This decision reflects the geological uniqueness of the southern Rukwa Helium Project, characterised by gas-in-solution plays, extensive faulting mechanisms, and fracture networks. Including these elements within the ML area ensures Helium One can fully capitalise on the region’s helium resources.

The company continues to advance towards full-scale development, positioning itself as a key player in the global helium supply chain while contributing to Tanzania’s emerging helium industry.

Two years ago, Sandvik Mining and Rock Solutions introduced the DR412i rotary blasthole drill to Africa, setting new benchmarks in the field. (Image source: Sandvik Mining and Rock Solutions)

As the drive toward intelligent drilling accelerates, the Sandvik DR412i rotary drill rig, equipped with a scalable surface drill automation system, is redefining precision, productivity, efficiency, and safety in opencast mining 

Introduced in South Africa about two years ago, the Sandvik DR412i is a diesel-powered, self-propelled crawler-mounted blasthole drill designed for surface mining. It comes standard with rotary drilling capabilities, with an option for down-the-hole (DTH) hammer drilling.

“Designed for soft to medium/hard rock formations, the DR412i can drill 203 to 311 mm diameter blastholes with a single-pass capacity of 17.65 m or a multi-pass capacity of 75.5 m. Primarily used in surface mining, it can also be deployed in oil and gas applications,” explained Trinity Nkosi, sales engineer, surface drills department at Sandvik Mining and Rock Solutions.

Belonging to Sandvik’s i-Series range, the DR412i was developed in response to the growing demand for intelligent drilling solutions. It features a scalable surface drill automation system, allowing customers to select automation levels based on their operational needs.

Smarter drilling solutions

Sandvik provides different automation options, including iDrill (onboard operation) and AutoMine (remote operation). The onboard automation enables the rig to function semi-autonomously or fully autonomously, with operators overseeing the fleet and intervening only when necessary. This setup minimises human error and enhances operational safety.

The AutoMine suite—comprising Line-of-Sight, Control Room, and Autonomous modes—facilitates remote and autonomous drilling. Operators can simultaneously manage and monitor multiple surface drills from a secure control room,” added Nkosi.

While the DR412i stands out for its automation-ready features, it retains the durability of the KS-Series, its predecessor. With a robust steel body and a powerful engine, it is designed for longevity.

Enhanced 360-degree walkways provide improved drill access for easier inspections and routine maintenance. An optional hydraulic stairway can be added, allowing safer and more convenient access to the drill.

The advanced Compressor Management System optimizes engine performance by disengaging the compressor during non-drilling activities, reducing fuel consumption. This system can cut fuel use by up to 30%, lowering carbon emissions and extending the lifespan of the engine and compressor.

For example, in an Australian coal mining operation, the DR412i contributed to an 18 m per hour increase in penetration rate, resulting in a 43.4% reduction in fuel consumption per meter compared to other drills on-site.

“Having brought the first DR412i into Africa some two years ago, we are glad to report that it has consistently delivered high levels of power, precision, productivity, and efficiency in a coal mining application in South Africa, which is why the customer has expressed the desire to expand the fleet,” concluded Nkosi.

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