Keypoints:
- New 500,000 tpa smelter begins heat-up at Kamoa-Kakula
- First copper concentrate feed expected before year end
- Facility branded Africa’s largest and greenest smelter
IVANHOE Mines has fired up what it describes as Africa’s largest and greenest copper smelter, marking a major step forward for the Kamoa-Kakula complex in the Democratic Republic of Congo. The heat-up phase began on November 21, 2025, following a traditional blessing ceremony at the site. The milestone was reported by MINING.COM, with further operational details confirmed by Ivanhoe Mines.
First copper output expected soon
The 500,000-tonnes-per-annum direct-to-blister smelter is now entering the crucial commissioning phase, during which the furnace is raised to operating temperatures and key systems are tested. Ivanhoe says it remains on track to introduce the first concentrate feed before the end of the year, with the first batch of 99.7 per cent-pure blister anodes expected shortly thereafter.
Once fully operational, the smelter will handle all concentrate produced by the Kamoa-Kakula Phase 1–3 concentrators. Any surplus is set to be transported to the Lualaba Copper Smelter in Kolwezi. According to the company, on-site copper inventory — previously estimated at around 37,000 tonnes — will gradually ease to roughly 17,000 tonnes as the smelter ramps up through 2026.
Powered by hydropower and efficient metallurgy
Ivanhoe is projecting the facility as not only the largest copper smelter on the continent but also its most environmentally efficient. The smelter is fuelled by renewable hydropower sourced from the Inga II dam and uses a high-efficiency flash-smelting system supplied by Metso Outotec. Company officials say this significantly reduces energy consumption compared to traditional smelting technology.
At the launch ceremony, founder and co-chair Robert Friedland struck a symbolic tone, noting that the facility’s commissioning comes nearly two decades after the company first encountered high-grade copper mineralisation in the region. Friedland said the new plant reflects a long-term push to add value within the DRC rather than exporting raw concentrate.
Value addition for the DRC’s mining future
The smelter’s start-up lands at a strategic moment for the global copper market, where demand is rising sharply due to electrification, the expansion of renewable energy systems and increased infrastructure spending. With bottlenecks emerging in refining capacity worldwide, the new Kamoa-Kakula plant could help ease pressure by adding significant processing capability from within Africa.
By exporting refined copper rather than concentrate, Ivanhoe aims to lower carbon intensity while boosting the DRC’s position within the global copper value chain. Analysts say the project represents one of the strongest examples of local value addition in the region’s mining sector.
The smelter also strengthens Ivanhoe’s internal supply chain, reducing its exposure to logistics backlogs and third-party smelting constraints. Company executives expect the asset to underpin higher, more stable output from Kamoa-Kakula in the coming years.
Regional implications
Industry observers note that the launch may catalyse similar investments across the region, especially as governments push for cleaner refining capacity and local beneficiation. For the DRC, which hosts some of the world’s richest copper and cobalt deposits, the project could mark the beginning of a broader shift away from raw-material exports.
Ivanhoe Mines has positioned the smelter as a cornerstone for long-term expansion at Kamoa-Kakula — a complex that has rapidly become one of the most significant copper operations on the planet. As commissioning continues and full output draws nearer, the new facility’s impact is set to be felt both in global supply markets and across the Congolese mining economy.
