The Kansanshi mine, the largest copper mine in Africa, is 80% owned by Kansanshi Mining PLC, a First Quantum subsidiary. The remaining 20% is owned by a subsidiary of ZCCM. The mine is located approximately 10 kilometres north of the town of Solwezi and 180 kilometres to the northwest of the Copperbelt town of Chingola.
The mine has undergone several expansions since it began operating in 2005. From an initial production capacity of 110,000 tonnes of copper, Kansanshi is now capable of producing 250,000 tonnes of copper and more than 100,000 ounces of gold per year. A multi-stage expansion project aims to increase copper output capacity to approximately 400,000 tonnes by 2015.
Mining and Processing
Mining is carried out in two open pits, Main and Northwest, using conventional open pit methods and employing hydraulic excavators and a fleet of haul trucks. Ore treatment is variable to allow for variation in ore type.
Sulphide ore is treated via crushing, milling and flotation to produce copper in concentrate. An expansion of the sulphide milling circuit in 2008 positioned Kansanshi to maintain finished copper production as oxide ore is depleted and sulphide ore grades begin to fall. Kansanshi can economically process all significant ore types, significantly reducing mining costs as transitional ores do not need to be stockpiled.
Oxide ore is treated via crushing, milling, flotation, leaching and the SX/EW process to produce a sulphidic and gold bearing flotation concentrate as well as electro-won cathode copper.
A gravity gold processing route developed in 2009 significantly increased the recovery of gold into bullion and other saleable products. The circuit combines efficient gravity concentration with pyro-metallurgical processing of lower-grade gravity products. This process complements the additional gravity concentrate streams being developed, raising overall gold recovery and improving revenue realized from the gold stream. The pyrometallurgical stage is still in development, but additional gravity processing capacity is installed and running well, with an additional 35% capacity installed in Q1 2010.
2010 Facts and Stats:
- Total copper production (tonnes): 231,124
- Concentrate grade (%): 24.9
- Gold produced (ounces): 109,629
- Unit cash cost of production: $1.10 per lb of copper
- Type of mine: open pit
- Current estimated mine life: 12 years
- Employees: 1,512
Multi-Phase Expansion:
Expansion in production capacity from 2011 to 2015 includes:
- Phase 1 – expansion to the oxide circuit to be complete by Q1 2012
- Next phases – further expansion to the oxide circuit due by end of 2012 and expansion of the sulphide facilities to be complete in 2014
Exploration:
- Stepping up the drill program with the objective of further expanding the mineral resources and upgrading known mineralization to reserves
- Updated reserve and resources estimate by the end of 2011