The first copper anode has been cast at Konkola Copper Mines’ Nchanga Smelter, marking the return of smelting operations after a 106 day shutdown.
The restart follows an approximately US$40 million rehabilitation programme, described by KCM as the first major refurbishment of the smelter in more than eight years.
The shutdown was originally planned to last 60 days. But once the plant was opened and detailed inspections began, engineers identified additional critical work that needed to be completed before the smelter could safely return to operation.
The programme was therefore extended to 106 days.
KCM Deputy Chief Executive Officer Satish Kumar said the decision was necessary to address the condition of the plant properly and strengthen its long term reliability.
“This is more than the restart of a smelter. It is visible evidence of Vedanta’s commitment to rebuilding KCM and securing the long term future of its operations,” Kumar said.
More than 1,500 people from KCM and its business partners were involved in the rehabilitation.
According to KCM Smelter and Refinery Director Yoram Kapai, the extensive programme was completed without a major injury.
The work covered several critical areas of the facility, including the flash smelting furnace and slag cleaning furnace. Engineers also upgraded the anode casting wheel, repaired the waste heat recovery boiler and electrostatic precipitators, replaced a heat exchanger at the sulphuric acid plant and replaced molecular sieves at the oxygen plant.
With the first anode now cast, KCM says the immediate focus is on stabilising the smelter and maintaining safe, reliable and efficient operations.
The Nchanga Smelter has an annual production capacity of 311,000 tonnes.
The facility was originally commissioned in 2010 after Vedanta invested approximately US$350 million in its development.
The latest rehabilitation adds another major investment to the facility as KCM works to improve operational reliability and support its copper production growth plans.
For the workforce, the restart also marks the return of a critical part of KCM’s operations.
Mineworkers Union of Zambia Nchanga Branch Chairman Ernest Lesa commended management and workers for completing the shutdown and called for the health, safety and operational standards established during the rehabilitation to be maintained.
KCM says the refurbished smelter will support its wider production strategy and contribute to Zambia’s ambition of producing three million tonnes of copper annually by 2030.