Two months after completing the construction and the restart of the historic ultra high-grade Kipushi zinc/copper/lead/germanium mine in the Democratic Republic of Congo (DRC), diversified miner Ivanhoe Mines completed the first feed of ore into the new concentrator on May 31, 100 years after the mine first operated, and 31 years since it was placed on care and maintenance.

Dry commissioning of the new 800 000 t/y Kipushi concentrator started in early May, with first ore from the surface run-of-mine (RoM) stockpiles fed through the ball mill during the evening of May 31.

The first batch of concentrate production was achieved on June 14. Ramp-up to steady-state production is expected in the third quarter.

Going forward, basic engineering of a debottlenecking programme is underway, targeting a 20% increase in processing capacity of the concentrator.

The debottlenecking programme – expected to take about nine months, based on the ready availability of equipment – is expected to increase the processing capacity to 960 000 t/y.

Since mining started in late 2023, Ivanhoe Mines notes there is sufficient capacity to increase mining and hoisting rates to support an upsized concentrator.

As of June 30, about 336 000 t of ore at an average grade of 23.4% zinc was stored in surface RoM stockpiles adjacent to the Kipushi concentrator. This includes about 150 000 t of high-grade ore at an average grade of over 30% zinc.

The stockpiled ore, which contains nearly 80 000 t of zinc – a commodity currently trading at about $3 000/t – is now being used for the ongoing hot commissioning and ramp-up of the Kipushi concentrator.

In terms of fresh ore, underground mining rates are expected to significantly increase throughout the second half of the year to match the steady-state processing rate of the Kipushi concentrator.

Year-to-date underground mining rates have averaged just over 20 000 t a month, with rates expected to increase to 75 000 t a month, at an average grade of over 40% zinc, by year-end.

“Returning the historic Kipushi . . . mine to production alongside our DRC State-owned joint-venture partner Gécamines marks a century after Kipushi’s first operations. “The rebirth of the mine is a major and state-of-the-art achievement for our operations team, the people of the DRC and the local community in Kipushi Town,” says Ivanhoe Mines founder and executive co-chairperson Robert Friedland.

“We commend and congratulate everyone involved, especially the hardworking Congolese workforce, for their exceptional contributions towards this . . . with the construction and first concentrate milestones delivered substantially ahead of schedule,” he adds.

“The resumption of operations at the Kipushi mine . . . is yet another indication of Gécamines’ efforts for the revival of mining activity and community development in Haut-Katanga,” says Gécamines chairperson Guy-Robert Lukama Nkunzi.

Kipushi Sales

In terms of sales, offtake agreements for Kipushi’s high-grade zinc concentrate have been signed with Hong-Kong-based metallurgical feedstock supplier CITIC Metal and Singapore-based commodities supplier Trafigura Asia Trading.

In addition, further offtake agreements are expected to be signed in the coming months, Ivanhoe reports.

The Kipushi concentrate is expected to contain about 55% zinc, with low levels of impurities.

Initially, it is expected that about half of Kipushi’s concentrate will be delivered to Europe for smelting on a cost, insurance and freight basis, exported through the Port of Walvis Bay, in Namibia; while the remaining 50% will be a delivered at place basis, to the Port of Durban, in South Africa.

Friedland notes that Kipushi will be one of the world’s significant producers of high-grade, low-emissions zinc and associated metals. “The mine will follow Kamoa-Kakula’s example of being a leading employer and social driver for the region where we operate while maintaining Ivanhoe’s focus on strong community relations and sustainability.”

“It is not only high zinc grades that make Kipushi an extraordinary mine. Whilst at this stage only the big zinc deposit has been certified, the mine shows great potential for other metals that are critical to meet today’s global industrial needs,” notes Lukama Nkunzi.