Ivanhoe begins copper anode production in DRC
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Ivanhoe Mines has achieved a key milestone at its Kamoa-Kakula copper complex in the Democratic Republic of Congo, announcing the first production of copper anodes at its on-site smelter. The event signals a major step forward in the region’s ambition to develop vertically integrated mineral operations that add value locally rather than exporting raw materials.
The first anodes were cast on December 29, 2025, less than six weeks after the initial heat-up of the 500,000-ton-per-year direct-to-blister smelter. The facility, which represents a $1.1 billion investment, is among the most advanced copper smelters on the continent. It is also one of the few in the world designed to run on renewable and backup hybrid energy systems, reflecting Ivanhoe’s broader commitment to sustainable copper mining.
“This is a defining moment for the Kamoa-Kakula project,” said executive co-chair Robert Friedland. “It represents years of engineering and disciplined execution. The quality of copper anodes from this plant will meet the highest international standards and serve a growing market for clean energy metals.”
The Democratic Republic of Congo has long been known for its vast copper and cobalt reserves, but this move marks a turning point. Until now, most Congolese concentrate was exported for processing, with little beneficiation occurring within the country. Ivanhoe’s decision to build an on-site smelter sets a precedent for how large-scale copper production can evolve in Central Africa.
Targeting full capacity in 2026
Copper production at the Kamoa-Kakula complex is expected to total between 380,000 and 420,000 tons in 2026. The midpoint of that guidance would see the smelter operating at approximately 80 percent of its full capacity. Ivanhoe has stated that all feedstock from its Phase 1, 2, and 3 concentrators will be processed on-site, while any excess concentrate will be toll-treated at the nearby Lualaba Copper Smelter.
The smelter’s ramp-up is structured to be incremental, ensuring that each part of the process, furnace, acid plant, boiler systems and the concentrate dryer, reaches steady-state conditions before further scale-up. Before the first feed of concentrate, Kamoa-Kakula had approximately 37,000 tons of copper in concentrate stored. This inventory is expected to fall to 17,000 tons by year-end as production and sales volumes align.
The company also anticipates that copper sales in 2026 will outpace production by around 20,000 tons as this stored inventory is drawn down. That destocking is well-timed with recent high copper prices, creating an opportunity to monetize inventory under favorable market conditions.
Energy and logistics advantages
A significant differentiator for the Kamoa-Kakula smelter is its power infrastructure. To guard against fluctuations in the domestic grid, Ivanhoe has commissioned a 60-megawatt uninterruptible power supply. This UPS system can deliver up to two hours of continuous power during outages, safeguarding sensitive smelting operations from voltage instability.
Looking ahead, Ivanhoe is developing a 60-megawatt solar photovoltaic plant with battery storage. Once operational in the second quarter of 2026, the solar site will become one of the largest of its kind powering an industrial mining operation in sub-Saharan Africa. It will complement the existing diesel-powered generator capacity of 180 megawatts, giving Kamoa-Kakula a robust and diverse power portfolio.
From a logistics standpoint, the shift from exporting 45 percent-grade concentrate to shipping 99.7 percent-pure copper anodes is expected to halve outbound logistics costs. More refined product per shipment means fewer trucks, lower emissions, and reduced handling fees. It also simplifies customs procedures and strengthens Ivanhoe’s position in global copper markets that demand traceable and ethically sourced metals.
By-product sulphuric acid adds revenue stream
In addition to copper, the smelter is already producing high-strength sulphuric acid as a by-product. At full capacity, the facility is expected to generate up to 700,000 tons per year. This acid is in high demand across the Central African Copperbelt, particularly since Zambia imposed a ban on sulphuric acid exports in September 2025.
Ivanhoe confirmed that the first sale of sulphuric acid from the Kamoa-Kakula smelter has already taken place, with deliveries expected to begin in the coming weeks. Spot prices for acid in Kolwezi have reached as high as $700 per ton, offering a high-margin side revenue that enhances the financial profile of the smelter.
The company also noted that the acid will be sold primarily into local markets, contributing to downstream industrial growth and reducing regional dependency on imports. This aligns with broader regional goals to capture more value from mining operations.
Unlocking higher-grade zones
In parallel with the smelter ramp-up, Ivanhoe is making progress on dewatering activities that will unlock new mining zones at the Kakula mine. Stage Two of the dewatering effort is nearly complete, with all four high-capacity pumps expected to run dry this month. Stage Three will focus on rehabilitating underground pump stations damaged by water ingress, with new motors and electrical systems already on site.
As water levels continue to drop, mining operations will expand into higher-grade ore zones. Current head grades average 3.5 percent copper, but Ivanhoe expects this to increase to around 4 percent by the end of the first quarter.
Selective mining on the eastern side of Kakula has also started ahead of schedule. These gains in ore grade will support higher copper yields and improve overall processing efficiency as the smelter continues its ramp-up through the rest of the year.
Positioning for long-term growth
Ivanhoe’s first anode production at Kamoa-Kakula is more than a technical milestone. It reflects a broader shift toward integrated, locally powered, and environmentally aware mining infrastructure in one of the most resource-rich regions of the world. With logistics costs falling, energy resilience rising, and by-product revenues coming online, the project now enters a new phase of commercial viability.
The company’s strategic investments in energy, processing, and dewatering are aligned with long-term global demand for copper. As nations accelerate their shift toward electric vehicles, renewable energy systems, and expanded infrastructure, copper remains a critical enabler.
Kamoa-Kakula is not just a mine. It is becoming a blueprint for how future copper projects in Africa might be built.
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