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Acid Plant Database February 21, 2018
Owner | Konkola Copper Mines PLC (KCM) | |
Location |
Kitwe |
|
Background |
KCM is a subsidiary of Vedanta Resources Plc, a London listed FTSE 100
metals and mining group. 1970 Prior - Anglo American Corporation and
Roan Selection Trust owned the mines. After negotiations between the Zambian
Government and the two mining groups, the mines were reorganised into
Nchanga Consolidated Copper Mines Limited (NCCM) and Roan Consolidated Mines
Limited (RCM). Through Mining and Industrial Development Corporation Limited
(MINDECO), the Government acquired a 51 per cent interest and Zambia Copper
Investments (ZCI) acquired the remaining 49 per cent in NCCM. Venanta Resources: 51% |
|
Website | www.kcm.co.zm | |
Plant | Nkana Smelter |
|
No. 3 Plant | No. 4 Plant | |
Coordinates* | 12° 50' 34" S, 28° 12' 14" E | - |
Type of Plant | Metallurgical | - |
Gas Source | Copper Converters | - |
Plant Capacity | 1050 MTPD | - |
SA/DA | - | - |
Emissions | - | - |
Status | Shutdown | Shutdown |
Year Built | - | - |
Technology | - | - |
Contractor | - | - |
Remarks | - | - |
Pictures | ||
General |
Konkola Copper Mines Plc (KCM) is the largest mining and metals company in
Zambia with annual capacity of 200,000 metric tonnes of copper. The smelter produces high grade anodes, which are electrolytically refined. Sulphur dioxide gas produced by the Converters is converted into sulphuric acid which is then used at the Tailings Leach Plant, Nchanga for recovering oxide copper. The smelter also produces discard slag from the reverbs that is rich in cobalt which is stored for future reclamation. www.grinaker-lta.com - 2001 - This project consisted of the upgrading of the existing 600 tpd Teniente converter to accept the injection of bone dry concentrate in order to increase throughput to 1200 tpd of copper produced. The wet concentrate is dried in a flash dryer and is then pneumatically conveyed and injected through tuyeres into the reactor vessel. The project also included the major overhaul of a 1000 tpd sulphuric acid plant in two 30 day shutdown periods, viz July 2001 and August 2003. Refurbishment included the replacement of the drying tower, acid recirculation tank and main gas ductwork. |
|
References | Cutler, C.J., Natarajan, M., Mponda, E. and Eksteen, J.J., "Phasing Out Reverberatory Furnace Operations at KCM Nkana", Souther African Pyrometallurgy 2006, Johannesburg, March 5-8, 2006. | |
News |
February 21, 2018 - Zambia’s
largest integrated copper producer Konkola Copper Mines (KCM), subsidiary of
LSE-listed diversified miner Vedanta Resources recently hosted a tour of its
operations in Chingola for a delegation of Finnish companies conducting
business in the mining industry. The tour was led by Finnish Ambassador to
Zambia Timo Olkkonen as a means for the two countries to collaborate on
business opportunities.Olkkonen has hailed KCM’s plans to expand its
operations and increase production to 500 000 tpa, stating that the
expansion of operations was not only good for the company but also a cause
for optimism for the country’s mining sector.“It’s been a very interesting
and valuable visit. KCM’s plan to invest more and expand operations is
definitely a cause for optimism for the mining industry and Zambia as a
whole. I can see that KCM clearly has a bright future in Zambia.”Olkkonen
also commended KCM for investing in clean technology at the smelter as this
was good for the environment.“The Nchanga Smelter speaks for itself. It’s
one of the cleanest in the world. I think it’s good for KCM and other mining
companies to use efficient and clean technology in their operations,” he
said.The Nchanga smelter employs technology from Finland and captures 99.7%
of sulphur dioxide to make it as one of the best processing plants.KCM CEO
Steven Din said the company had set in motion plans to ramp up production
and reach the target of 500 000 tpa.“Reaching this tagert will not only be
beneficial to KCM but will also help Zambia to regain its top position as a
copper producer in Africa which was lost to the Democratic Republic of
Congo,” Din said.The Finnish delegation includes Geological Survey of
Finland, Robit, A- insinoorit, Business Finland, Ima Engineering, Sleipner
and Normet.The delegation is in the country to explore business
opportunities and strengthen existing business relationships with firms like
KCM, which has procured a lot of technology and some equipment from Finland. March 28, 2017 - The Zambia Environmental Management Agency has issued two separate Compliance and Environmental Restoration Orders to Konkola Copper Mines to address various environmental issues by end of this month. And documents obtained from KCM’s Legal Department show that the mining giant has been emitting sulphur dioxide and cadmium which are 10.3 times and 13.41 times above statutory limits respectively. According to leaked copies of the orders, ZEMA now wants KCM to take measures to reduce or eliminate the risk on human health and the environment. In 2015 an eight year long legal battle by 2000 contaminated residents finally ended when the Supreme Court of Zambia confirmed the High Court’s opinion that KCM was guilty of ‘gross recklessness’ and damaging villagers’ health. However, the $2 million in damages earlier awarded by the High Court was removed, leaving the residents short of real justice. Subsequently London law firms filed for damages from Vedanta Resources on behalf of approximately 3000 of the contaminated villagers, and the shocking story of years of pollution has reached the Guardian and BBC. In its Environmental Restoration Order dated 3rd March 2017, ZEMA has ordered KCM to complete the water recycling project at the Mutimpa Tailings Dam to prevent the continuation of or cause of water pollution especially with high levels of sulphates in the affluent by the 31st March 2017. The agency has also ordered KCM to cease the discharge of affluent from Mutimpa Tailings Dam containing regulated parameters that are above the respective statutory limits by 31st March 2017. It has also ordered KCM to submit to a detailed plan of work for de-silting of the Chingola stream, Mushishima stream and Mutimpa Stream highlighting in particular the de-silting process and the management of the generated silt/waste by 15th March 2017. ZEMA further wants KCM to restore the flow channels of the three streams namely, Chingola Stream, Mushishima Stream and Muntimpa Stream by de-silting their stream beds by 30th April 2017. The agency has also ordered KCM to develop and implement a programme for continuous de-silting of the three streams and the Pollution Control Dam to prevent their continuation of cause of water pollution by 15th March 2017. It also wants the mining giant to conduct the Environmental Impact Assessment of Chingola Stream, Mushishima Stream and Hippo Pool by the 31st day of May 2017. And according to the Compliance Order dated 1st March 2017, ZEMA has ordered KCM to comply in full with the conditions of the Emission Licence number “NDL/EMM/00708/Z10/2014”. The agency has now ordered KCM to immediately ensure that the effluent and emission parameters are compliant with their respective statutory limits especially sulphur dioxide and cadmium emissions which were 10.3 times and 13.41 times above statutory limits respectively as the time of the returns for July to December 2016. It also wants ZEMA to immediately cease discharging the Pregnant Liquor Solution and the pollution Control Dam. ZEMA has also ordered KCM to install online monitoring equipment to monitor all regulated parameters and procure and install a monitoring equipment for mercury with a detention limit lower than the statutory limit of 0.002 mg/l by 30th April 2017. The environmental agency also wants KCM to develop a continuous programme of de-silting of the Mushishima Stream and submit to the Agency by the 15th March 2017. It also wants the Chingola based firm to conduct investigations on why the ground water quality were non-compliant for pH, Manganese, TSS and Co and submit the report to ZEMA by 31st March 2017 and develop a programme to clean up the ground water contamination and submit the programme to ZEMA by 15th March 2017.
November 11, 2013
February 19, 2009 - Zambia's Konkola Copper Mines (KCM) has
shut its Nkana Smelter and cut 677 jobs, a company spokesman said on
Thursday. KCM spokesman Rahur
Kharkar said the Nkana smelter had been shut after the company started to
rely on the new Nchanga smelter in Chingola, north of Lusaka.
"Yes we have," Kharkar said in response to a question on whether the
smelter, with an annual capacity of 150,000 tonnes of copper, had been shut
down. Kharkar said shifting to
Nchanga would help cut costs.
"At Nchanga, the processing route is faster and it will help us to cut
(production) costs by 50 cents per pound," he said.
He said 677 miners who could not be absorbed at the new smelter had been
made redundant. Kharkar said
the Nchanga smelter, which has an annual capacity of 300,000 tonnes of
copper, was also producing 1,800 tonnes of acid each day.
KCM, which is majority owned by London-listed Vedanta Resources Plc is
Zambia's largest copper producer.
KCM operates the Nchanga open pit and Konkola copper mines, the Nchanga
smelter and the Fitwaola satellite copper mine.
December 9, 2003 - Zambia's Konkola
Copper Mines (KCM) announced a further reduction in its copper output for
2003 because of a shutdown in July of its Nkana Smelter plant.
It said in the firm's official publication, however, it would enter 2004 in
a much stronger position through stringent cost-cutting measures and
investment. "The $10-million
refurbishment carried out at Nkana Smelter during the shut down has put the
plant in good stead for the projected target of 229 000 t (finished copper)
in 2004," chief financial officer Jordan Soko said. Production for 2003 was now expected to drop further to 191
000 t from the earlier revised annual output of 200 000 t of finished
copper, Soko said in Konkola News.
KCM, which accounts for some 67% of total Zambia's metals output, said in
October its production would slide to 200 000 t from 226 000 due to fuel and
acid shortages that hit Zambia in mid-2003.
"KCM is currently predicting to achieve a finished copper production of 191
000 t," Soko was quoted as saying.
He also said 2004 copper production had been forecast at 229 000 t and that
the miner's budget for capital investment had been projected at $70-million.
"The production cost of 65 cents a pound must be achieved to support the
ambitious $70-million capital investment that will set the company on the
right footing," Soko said. He
said the production shortfall was mainly due to the month-long Nkana
shutdown and a shortage of sulphuric acid supplies to the Tailings Leach
Plant (TLP), coupled with the high cost of importing acid.
KCM operates the Nchanga open-pit and Konkola copper-mines and the Nampundwe
pyrite-mine. |
MTPD - Metric Tonne per Day
STPD - Short Ton per Day
MTPA - Metric Tonne per Annum STPA - Short Ton per
Annum
SA - Single Absorption
DA - Double Absorption
* Coordinates can be used to
locate plant on Google Earth