TSX-listed Ivanhoe Mines has announced that the first copper anodes were produced by Kamoa-Kakula’s on-site, state-of-the-art 500 000 t/y direct-to-blister copper smelter, in the Democratic Republic of Congo (DRC), on December 29.

This comes about five weeks after the start of the smelter’s heat-up and one week after the first feed of concentrate.

“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 $1.1-billion 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,” says Ivanhoe executive co-chairperson Robert Friedland.

Ivanhoe, in a January 2 media statement, says the ramp-up of the Kamoa-Kakula copper smelter will continue throughout this year, with completion expected towards year-end.

As announced on December 3, the company notes that Kamoa-Kakula’s copper production is estimated at between 380 000 t and 420 000 t of copper this year, with the mid-point of 400 000 t of copper representing about 80% of the smelter’s total capacity.

Ivanhoe says Kamoa-Kakula’s management team will prioritise the processing of concentrates produced by the Phase 1, 2 and 3 concentrators through the on-site smelter, with any excess concentrate toll-treated at the Lualaba Copper Smelter (LCS), near Kolwezi, in the DRC.

The company says heat-up and completion of hot commissioning of the smelter furnace, as well as boiler, steam systems, acid circuit and the concentrate dryer were completed in line with expectations.

Ivanhoe says the furnace successfully reached its operating temperature of 1 250 °C for five days prior to the first feed of concentrate.

Prior to the first feed of concentrate into the smelter, Kamoa-Kakula’s on-site concentrate inventory contained about 37 000 t of copper.

Total unsold copper in concentrate at the smelter, held in stockpiles and the smelting circuit, is expected to be reduced to about 17 000 t during this year as the smelter ramps up.

Therefore, Ivanhoe says 2026 copper sales are expected to be about 20 000 t higher than copper production as the on-site inventory of unsold copper concentrate is destocked, predominantly during the first half of this year.

As destocking occurs, the company says Kamoa-Kakula’s management aims to capitalise on near-record-high copper prices.

The installation of the uninterruptible power supply (UPS) facility was completed prior to the first feed of concentrate into the smelter, which took place on December 21.

The 60 MW UPS is designed to provide up to two hours of instantaneous back-up power to the smelter, protecting the operation from voltage fluctuations in the domestic DRC grid.

In addition, Ivanhoe says construction of Kamoa-Kakula’s 60 MW on-site solar PV facilities continues to progress well. The company says the solar site, with battery storage, is expected to be the largest of its kind in sub-Saharan Africa.

The solar facilities are expected to be operational from the second quarter of this year, providing 24 hours a day of uninterruptible power, in addition to about 180 MW of on-site diesel-powered, back-up generator capacity already in place.

OPERATING MARGINS

Meanwhile, Ivanhoe notes that Kamoa-Kakula’s margins are expected to expand as the smelter ramps up, as concentrates produced by the Phase 1, 2, and 3 concentrators are smelted on-site, rather than being exported before being beneficiated.

The company says Kamoa-Kakula’s logistics costs are expected to approximately halve as the copper content per truck load exported more than doubles, from about 45% contained copper in concentrate to 99.7%-pure copper anodes.

Further savings are expected to be achieved through the significant revenues generated from sulphuric acid sales.

In addition to the first production of copper anodes, Ivanhoe says the Kamoa-Kakula smelter also produced its first batch of by-product sulphuric acid.

The smelter is expected to produce up to 700 000 t/y of high-strength sulphuric acid at steady-state operations, which will be sold locally.

The company notes that Sulphuric acid is in high demand by other mining operations across the Central African Copperbelt, especially following the export ban of acid by Zambia in September 2025.

Ivanhoe explains that spot acid prices have reached as high as $700/t in Kolwezi in recent months. The first sale of acid by Kamoa-Kakula has already taken place, with the first delivery expected in the coming weeks.

DEWATERING

Meanwhile, Ivanhoe says that Stage Two dewatering activities are complete, with the first pair of high-capacity submersible dewatering pumps (pumps 3 and 4) running dry.

As announced on December 3, following an underground survey, pumps 3 and 4 were repositioned lower in late November to enable an additional Stage Two dewatering.

Since then, the water level has declined by a further 19 m.

Ivanhoe says the second pair of Stage Two pumps (pumps 1 and 2), which are about 20 m lower in elevation compared with pumps 3 and 4 are expected to run dry this month.

Stage Three dewatering activities will follow the Stage Two dewatering, and consist of recommissioning the existing, water-damaged underground horizontal pump stations, which are used for steady-state operations.

The rehabilitation work consists of fitting new pump motors, substations and electrical cabling.

The company notes that all required equipment is on site, and installation will begin once access to the horizontal pump stations becomes available.

Ivanhoe says there is currently 5 600 l a second of installed pumping capacity at the Kakula mine, excluding the Stage Two pumping infrastructure.

Stage Three dewatering activities are expected to continue into the second quarter of this year and will not be on the critical path for Kakula’s mining operations.

In addition, the western side of the Kakula mine has been dewatered, enabling the mining of higher-grade areas.

Ivanhoe says head grades from mining areas on the western side of Kakula are expected to increase from 3.5% copper this month to about 4% copper by the end of the first quarter of this year.

In addition, selective mining on the eastern side of the Kakula mine began ahead of schedule at the end of December.