Kamoa-Kakula Phase 1 concentrator plant approaching steady- state-design performance
September 7, 2021
Kamoa-Kakula Phase 1 concentrator plant approaching steady- state-design performance
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14,815 tonnes of copper produced in August, bringing the year-to- date production to more than 36,700 tonnes
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Installation of an additional concentrate filter expected by end of October 2021, further boosting copper production ■
Phase 2 concentrator plant construction now 44% complete ■
Mining crews delivered 220,000 tonnes of ore grading a record 6.03% copper from August 1 to 20, including 85,000 tonnes grading 7.55% copper from the centre of the Kakula Mine ■
Surface ore stockpiles continue to grow; now hold 3.59 million tonnes grading 4.77% copper, containing more than 171,000 tonnes of copper
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All six new turbines at the Mwadingusha hydropower plant now operational and generating clean electricity for Kamoa-Kakula
KOLWEZI, DEMOCRATIC REPUBLIC OF CONGO – Ivanhoe Mines (TSX: IVN; OTCQX: IVPAF) Co-Chairs Robert Friedland and Yufeng “Miles” Sun are pleased to announce that hot commissioning and ramp-up of Kamoa-Kakula’s Phase 1, 3.8 million-tonne-per- annum (Mtpa) concentrator plant is progressing well and approaching nameplate steady-state-design performance.
During August, the plant achieved an average milling rate of more than 9,000 tonnes per day at an average feed grade of more than 6.0% copper. On August 29, the Phase 1 concentrator plant produced in excess of 600 tonnes of copper in filtered concentrate, which is the plant’s steady-state-design daily production rate.
During August, the concentrator plant produced concentrate containing 14,815 tonnes of copper. As of August 31, a total of 36,712 tonnes of copper had been produced year- to-date for delivery to either the Lualaba Copper Smelter near Kolwezi, or to international markets. All concentrate produced to date has been loaded onto trucks (either bulk for the Lualaba Smelter or in bags for international markets) and the concentrate backlog at the mine site has been cleared.
Chart 1: Monthly tonnes of copper produced May 2021 to August 2021.
Steve Amos, Kamoa Copper’s Head of Projects, commented: “The hot commissioning and ramp-up of the Phase 1 concentrator plant is going very well, with no significant issues encountered to date. Fast tracking of an additional concentrate filter will enable us to produce more concentrate and take advantage of the exceptional ore grades coming from the Kakula Mine, as well as any additional milling throughput in excess of design capacity. A third concentrate filter is being procured and will be incorporated into the Phase 2 plant.”
Copper recoveries improved to an average of 83% during August, with recoveries in excess of 86% achieved on multiple occasions. The Phase 1, steady-state-design copper recovery is approximately 86%.
Chart 2: Cumulative tonnes of copper produced May 2021 to August 2021.
Ivanhoe’s production guidance for contained copper in concentrate at Kamoa-Kakula in 2021 is 80,000 to 95,000 tonnes. The figures are on a 100%-project basis and metal reported in concentrate is prior to refining losses or deductions associated with smelter terms. The guidance assumes ramp-up from first production continues in line with published technical disclosures.
Daily concentrate grades in excess of the steady-state-design grade of approximately 57% copper also have been achieved on several occasions, with the monthly average exceeding 48% copper. The current focus of the commissioning team is on balancing and optimizing the flotation and regrind milling areas. This work is expected to further improve the consistency of concentrate grade and copper recoveries.
Commissioning and operation of the concentrator plant’s regrind mills is well underway. The regrind mills are the final pieces of equipment to be commissioned in the Phase 1 concentrator.
Kamoa-Kakula is fast tracking the installation of an additional concentrate filter, which already has been delivered to the mine site, to be able to take advantage of copper feed grades and milling rates in excess of design parameters. The additional concentrate filter is expected to be installed by the end of October 2021, enabling the Phase 1 concentrator to produce more copper than its design capacity of approximately 200,000 tonnes per year.
Watch a new video showcasing the ramp-up of copper production at Kamoa-Kakula and the production of blister copper at the local Lualaba Copper Smelter: https://vimeo.com/597748095/3e0676cb41
In early August, Ben Munanga, Kamoa Copper’s Chairman (right), welcomed Princess Adèle Kayinda Mahina, the Democratic Republic of Congo’s Minister of Portfolio, to the Kamoa-Kakula Copper Project. The DRC government’s 20% interest in the Kamoa-Kakula Copper Project is managed by the Portfolio Ministry.
Princess Adèle Kayinda Mahina (left) and Marna Cloete, Ivanhoe’s President and CFO, inside a scooptram bucket during an underground visit of the Kakula Mine.
Pouring Kamoa Copper blister ingots, containing approximately 99% copper, at the Lualaba Copper Smelter near Kolwezi, Democratic Republic of Congo.
An electronic chip affixed to a Kamoa Copper blister copper ingot for tracking and security.
Phase 2 overall project 44% complete, with civil works effectively complete and structural steel, mechanical, piping and platework (SMPP) erection and installation well underway
Construction of the second 3.8-Mtpa concentrator plant (Phase 2) is progressing well, with the overall project 44% complete; engineering and procurement activities are nearing completion. Civil construction works also is nearing completion with the focus now on erection of structural steel and the installation of platework and equipment. The primary and secondary ball mill discharge sumps, as well as the mill base plates, are being installed; mill installation is on the critical path. SMPP construction is on-going in all areas.
Deliveries of structural steel, platework and mechanical equipment continue daily with more than 321 truckloads already delivered to site and another 126 en-route.
Manufacturing of all long-lead items of equipment now is complete with several items already delivered to site and the remainder en-route. The final major contract for electrical, control and instrumentation (EC&I) supply and installation, has been awarded. The Phase 2 concentrator remains on track for completion in Q3 2022.
Lifting the Phase 2 flotation conditioning tank into position.
The Phase 2 concentrator plant under construction in the foreground, with the operating Phase 1 concentrator plant in the background.
The side-by-side Phase 1 and Phase 2 concentrator plants.
Chen Hong Tao (left) and Wang Pengfei installing the Phase 2 flotation base plates.
Shells for the Phase 2 ball mills arriving at Kamoa-Kakula.
Installation of the second Larox concentrate filter press, manufactured by Outotec, of Finland.
Mechanic Gretta Lusa Ngoie repairing a wheel at the Kakula Mine.
Mining continues ahead of schedule, adding to the surface ore stockpiles
An alignment of reporting dates for the mines and the concentrator has resulted in a truncated reporting period this month, from August 1 to 20. A total of 220,000 tonnes grading 6.03% copper was mined during this shortened period, and comprised 204,000 tonnes grading 6.16% copper from the Kakula Mine, including 85,000 tonnes grading 7.55% copper from the mine’s high-grade centre, and 16,000 tonnes grading 4.31% copper from the Kansoko Mine. For the month-long period from July 21 to August 20, 378,000 tonnes was mined grading 5.82% copper, a portion of which was included in last month’s total.
The project’s surface stockpiles now contain approximately 3.59 million tonnes of high- grade and medium-grade ore at an estimated, blended average of 4.77% copper. Contained copper in the stockpiles at the end of August now totals more than 171,000 tonnes (the current copper price is approximately US$9,400 per tonne).
As the plant ramps up to full Phase 1 design capacity, and the mine toward Phase 2 production capacity, the surface stockpiles are expected to continue to build at a reduced rate.
Surface ore stockpiles total 3.59 million tonnes grading 4.77% copper
Chart 3: Cumulative tonnes and grade of ore stockpiles at the Kakula and Kansoko mines – May 2020 to August 2021.
Chart 4: Growth in contained copper in ore stockpiles at the Kakula and Kansoko mines – May 2020 to August 2021.
Aerial view of the Kakula Mine, concentrator plant and accommodations with the main stockpiles at Kakula’s northern declines (in red circle). The blended stockpiles currently contain approximately 1.76 million tonnes grading 5.03% copper.
1.76 million tonnes @ 5.03% copper
Aerial view of the Kakula south decline and ore stockpiles containing a combined 1.34 million tonnes grading 4.77% copper (consisting of 663,000 high-grade tonnes @ 6.14% copper and 682,000 medium-grade tonnes @ 3.44% copper).
1.34 million tonnes @ 4.77% copper
Medium Grade High Grade
Aerial view of the Kansoko Mine and ore stockpiles containing a combined 485,000 tonnes grading 3.83% copper (consisting of 142,000 high-grade tonnes @ 5.88% copper and 343,000 medium-grade tonnes @ 2.98% copper).
High Grade
Medium Grade
485,000 tonnes @ 3.83% copper