MINEX Forum

Tag: Copper Smelting

  • Kazakhmys and CNCEC Consortium to Construct New Sulfuric Acid Plant at Zhezkazgan Smelter

    Kazakhmys and CNCEC Consortium to Construct New Sulfuric Acid Plant at Zhezkazgan Smelter

    Kazakhmys, a leading player in the mining and metallurgy sector, has announced a significant development in its operations with the signing of an agreement with a consortium from the China National Chemical Engineering Company (CNCEC) to construct a new sulfuric acid plant at its Zhezkazgan copper smelter in Kazakhstan. The engineering, procurement, and construction (EPC) contract is valued at approximately $213.76 million, marking a substantial investment in the modernization of the facility.

    The decision to build the new sulfuric acid plant is part of a broader initiative aimed at modernizing the Zhezkazgan copper smelter and aligning it with contemporary environmental standards. The existing metallurgical gas utilization infrastructure, which dates back to the 1970s, is in dire need of technological upgrades. The project will not only involve the construction of the new production facility but also the modernization of the process gas capture and purification system, which will include the installation of advanced equipment such as converter enclosures, cooling towers, and electrostatic precipitators.

    One of the key goals of this project is to enhance the efficiency of gas capture, with expectations that the new system will achieve a capture rate of 99%. Furthermore, the residual sulfur dioxide concentration in the treated gases will meet the stringent requirements outlined in the international Best Available Techniques Reference Documents (BREF), significantly reducing SO₂ emissions and the overall environmental impact of the Zhezkazgan smelter.

    The new sulfuric acid plant is designed to have a production capacity of 350,000 tons per year and will be capable of processing up to 300,000 normal cubic meters of process gases per hour. The commissioning of the plant is tentatively scheduled for 2028, with full-scale mobilization and preparatory work expected to commence by the end of 2026. The construction and installation phase is projected to take around 29 months.

    This initiative is a crucial part of Kazakhmys’ long-term modernization program for the Zhezkazgan copper smelter, aimed at improving the reliability of the gas purification system and ensuring compliance with modern environmental regulations. Kazakhmys Group, known for its vertically integrated operations in mining and non-ferrous metallurgy, ranks among the top producers globally, holding the 20th position in copper-in-concentrate production and 12th in blister and cathode copper production, according to the company’s website.

  • Kazakhmys Invests Over 25.2 Billion Tenge in Modernisation of Zhezkazgan Copper Smelting Plant

    Kazakhmys Invests Over 25.2 Billion Tenge in Modernisation of Zhezkazgan Copper Smelting Plant

    Kazakhmys Corporation has announced a significant investment of over 25.2 billion tenge aimed at modernising the Zhezkazgan Copper Smelting Plant, a key metallurgical facility within the group. The investment will be allocated towards capital repairs, technical re-equipment, and the enhancement of production infrastructure, with the overarching goal of ensuring the plant’s sustainable operation, improving industrial safety, and enhancing both technological efficiency and environmental performance.

    The comprehensive modernisation programme encompasses major production workshops, energy management systems, infrastructure facilities, and social amenities. A substantial portion of the investment, amounting to 15.9 billion tenge, is dedicated to the capital repair of critical metallurgical equipment. This includes extensive renovations to the second ore-thermal furnace, anode furnaces, and converter blocks, which are expected to bolster the reliability of the technological processes and extend the lifespan of the equipment.

    Additionally, 3.6 billion tenge will be invested in upgrading technological equipment. This includes the installation of 234 polymer concrete baths in the copper electrolysis shop, replacement of the power transformer, and the installation of a new bridge crane. The smelting shop will see the replacement of the carousel casting machine, while the heat supply shop will upgrade its turbocharger.

    The development of production infrastructure is also a priority, with 4.4 billion tenge earmarked for this purpose. Projects include the capital repair of cooling tower No. 1, roof replacement in the copper electrolysis shop, and restoration of the converter department’s roofing. Concurrently, the renovation of shower facilities in the administrative and domestic complex of the smelting shop is being completed to improve the working conditions for employees.

    By the end of the year, Kazakhmys plans to allocate an additional 1.4 billion tenge for the capital repair of equipment in the charge preparation shop and the establishment of a specialised area for the safe maintenance of crane equipment. This comprehensive modernisation effort is part of Kazakhmys’s long-term investment programme aimed at enhancing its metallurgical enterprises, ensuring more reliable production processes, improving equipment efficiency, and creating a safer and more comfortable working environment for its workforce.

  • Kazakhstan to Build Copper Smelting Plant in Balkhash with 750 Billion Tenge Investment

    Kazakhstan to Build Copper Smelting Plant in Balkhash with 750 Billion Tenge Investment

    The government of Kazakhstan has approved an investment agreement for the construction of a copper smelting plant in Balkhash, Karaganda region, with a total investment of 750 billion tenge. The agreement was signed by Prime Minister Olzhas Bektenov and involves the Ministry of Industry and Construction along with Qazaq Smelter LLP. Construction is set to begin in 2027, with the plant expected to commence operations by 2030.

    The new facility will boast an annual production capacity of 300,000 tonnes of cathode copper, alongside the production of 10 tonnes of gold, 300 tonnes of silver, and over 1.5 million tonnes of sulphuric acid. This ambitious project is anticipated to create approximately 1,200 permanent jobs, significantly contributing to the local economy. The introduction of these new capacities is projected to increase Kazakhstan’s copper production by 50%, raising annual output to over 800,000 tonnes.

    Furthermore, the export of high-value-added products is expected to rise from 460,000 tonnes to 760,000 tonnes of copper annually. The plant will be equipped with modern technologies and digital solutions, aligning with global standards in the mining and metallurgy sectors. This initiative underscores Kazakhstan’s commitment to enhancing its mining industry and boosting economic growth through strategic investments.

  • Kazakhstan Announces Major Industrial Projects to Boost Metal Production

    Kazakhstan Announces Major Industrial Projects to Boost Metal Production

    Kazakhstan is focusing on metal production with several new industrial projects, according to the Ministry of Industry and Construction. Minister Kanat Sharlapayev outlined the details of these initiatives.

    The first project is the Mineral Product International plant, which will produce 160,000 tons of ferrosilicon annually. Additionally, the plant will produce 300,000 tons of direct reduced iron and 1 million tons of steel each year. This metallurgical cluster is currently in the site preparation stage, with construction and installation work underway, including the foundation being laid.

    The second project involves the modernization of Qarmet. Under an agreement with an investor, $3.5 billion will be invested by 2028, including $1.3 billion in 2024. By 2030, the goal is to increase steel production to 5 million tons, coal to 9 million tons, and iron ore concentrate to 5 million tons. The modernization aims to reduce emissions by 20% and increase iron concentrate output. A technical audit of the facility began in March and is expected to conclude in July, with a comprehensive modernization plan to follow.

    The third project is the construction of a new copper smelting plant, which will produce 300,000 tons of refined copper annually. This project is included in the national industrialization roadmap and is currently undergoing a feasibility study.

    The fourth project is the construction of a hot briquetted iron production plant. This project will increase the production of iron ore raw materials from 9.9 million tons to 15.5 million tons per year, enhancing the processing of these materials with high added value. A retail gas supply agreement between the Sokolovsko-Sarbaiskoye Mining and Beneficiation Association and KazTransGas Aimak is in the final stages of signing.

    The fifth project is Polymetal’s plan to build a new autoclave facility in Kazakhstan. This hydrometallurgical plant will process gold-containing high-carbon sulfide concentrates, a task previously impossible in the country. Engineering, geological, and geodetic work is currently underway in the Pavlodar Special Economic Zone.

    As of April 2024, metal production in Kazakhstan has grown by 5.1%. By the end of the year, steel production is expected to reach 4 million tons, smooth rolled products 2.6 million tons, and pig iron 3 million tons.

  • Irkaz Metal Corporation Plans Expansion of Copper Smelting Plant in Kazakhstan

    Irkaz Metal Corporation Plans Expansion of Copper Smelting Plant in Kazakhstan

    Irkaz Metal Corporation, an Iranian copper producer, is looking to construct the third phase of its copper smelting plant at the Borly deposit in the Karaganda region. The new facility will cover an area of 100 hectares, with construction set to commence in July 2024. This information was revealed on the AGMP portal. The hydro-metallurgical complex is expected to process 2.5 million cubic meters (approximately 4.6 million tons) of copper ore annually through heap leaching, enabling the company to produce 5,000 tons of cathode copper per year. The plant will require over 137,000 tons of sulfuric acid annually for processing. The Borly site currently hosts a shift camp for employees, who work in two 12-hour shifts year-round. Notably, the plant has a two-story fire station on-site. Irkaz Metal Corporation inaugurated the plant in November two years ago, with an initial project investment exceeding 9 billion tenge. Currently, the facility employs 140 individuals, with the copper smelting plant’s capacity standing at 5,000 tons.