Mining in Zambia
Encyclopedia
Mining in Zambia
Centres of mining operations include Konkola
and Kitwe
.
The largest underground mine in Africa, the Mufulira Mine employs 10,000 people; includes a concentrator, a refinery and a smelter; and produces 300,000 tons of copper each year through the process of open stopping. The copper is then taken to the concentrator.
The concentrator crushes ores coming from the Mufulira mine consisting of 46% copper, waters it, and then does the process of floatation so the waste material can be removed.
The smelter melts the copper mixed with limestone in the Isasmelt furnace. The copper is pressurised by the air, then oxidised, and finally poled. The copper is then taken to the refinery.
The copper is cast into anodes so the process of electrolysis can take place during refining.
Nkana mine is one of the largest in Africa, a copper mine located 1 km south-west of Kitwe. The mine is underground as well as open pit and is in operation since 1932 and has produced 6,000,000 tons of copper so far. Its reserves underground include 69,000,000 tons of grading, 16,000,000 tons of copper, and 98,000 tons of cobalt. Its resources include 126,000,000 tons of grading, 43,000,000 tons of copper, and 300,000 tons of cobalt. Copper and cobalt mineralisation occur within the ore shale. Copper mineralisation in the deposits changes from mostly chalcopyrite in the South Orebody, to chalcopyrite-bornite in the Central area and to bornite-chalcopyrite at Mindola. Cobalt occurs as carrollite and cobaltiferous pyrite in approximately equal proportions. The mine produces copper and cobalt from three sources: Mindola Shaft, Central Shaft and South Orebody Shaft. Vertical crater retreat is the predominant mining method while sublevel open-stopping and sublevel caving methods are also used. Other metallurgical facilities, under a management contract by an affiliate of the Anglo American Group, include the Nkana smelter (not owned by Mopani), acid plant (not owned by Mopani) and copper refinery (not owned by Mopani). There is extensive mine tailings
around this mine.
Nkana Concentrator of Mopani mines, located in Kitwe, treats copper-cobalt sulphide ore using a bulk flotation and segregation flotation flowsheet to produce separate copper and cobalt concentrates. Nkana Concentrator is the most important mineral processing unit of Mopani, as it contributes about 65% of cobalt concentrates treated at the Nkana and Chambeshi Cobalt plants to produce high purity cobalt metal.
The cobalt plant treats 65% of the cobalt concentrates to produce high purity cobalt metal. The two cobalt plants are Nkana Cobalt Plant and Chambeshi Cobalt Plant.
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 in 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.
This smelter was part of the Konkola Copper Mine's operation at privatisation and has subsequently closed.
The Nkana Copper Refinery produces electrolytically refined copper in the form of cathodes. The copper meets the LME premium quality grade. The tankhouse has a capacity of about 180,000 tons of finished copper per annum.
There are two single contact sulphuric acid plants at Smelterco, namely the No.3 and No.4 plants. No.3, the largest, is still operational. The plant has a design capacity of 1,050 tons of acid per day.
, chalcopyrite
and libethenite
.Other minerals mined are Bornite, Pyrite, Chalcocite.
There is extensive mine tailings
around this mine.
See Copperbelt Province
for the history of the copper-mining industry in this region.
mines in the area.
town centre, is now closed but metals are still extracted from old tailings. A study by the Blacksmith Institute
found Kabwe to be one of the ten worst polluted places in the world due mostly to heavy metal (mostly zinc and lead) tailings making their way into the local water supply.
Centres of mining operations include Konkola
Konkola
Konkola is an area of Zambia, near Chingola, on the border with Congo. It has large copper reserves.There is a copper smelter at Nchanga.-Konkola Copper Mines:Konkola Copper Mines established a major mine in the area; it is now controlled by Vedanta....
and Kitwe
Kitwe
Kitwe is the second largest city in terms of size and population in Zambia. With a population of 547,700 Kitwe is one of the most developed commercial and industrial areas in the nation, alongside Ndola and Lusaka...
.
Mining in Kitwe
Mopani Copper Mines
Mopani Copper Mines Plc (Mopani) is a joint venture company based in Kitwe as 95% of its operations are located there, comprising Glencore International AG (73.1%), First Quantum Minerals Ltd. (16.9%) and Zambian Consolidated Copper Mines Limited (10%). Mopani operates the Mufulira mine, smelter, concentrator and copper refinery and the Nkana mine, concentrator and cobalt plant. MCM produced 134,800 tons of copper and 2,040 tons of cobalt in 2003. MCM is investing in a number of oxide copper projects at several of its properties, including an in-situ leaching project at Mufulira and heap leaching at Nkana, and has achieved significant production increases at its underground mining operations in Kitwe and Mufulira. Copper production from internal sources was supplemented by the purchase of some 18,000 tons of copper in high-grade oxide concentrate bought from the Democratic Republic of the Congo. The company aims to rebuild the Mufulira smelter during 2004 and 2005, and also plans to add a new gas collection facility and acid plant at a total cost of US$95 million.- Mufulira Mine
The largest underground mine in Africa, the Mufulira Mine employs 10,000 people; includes a concentrator, a refinery and a smelter; and produces 300,000 tons of copper each year through the process of open stopping. The copper is then taken to the concentrator.
- Mufulira Concentrator
The concentrator crushes ores coming from the Mufulira mine consisting of 46% copper, waters it, and then does the process of floatation so the waste material can be removed.
- Mufulira Smelter
The smelter melts the copper mixed with limestone in the Isasmelt furnace. The copper is pressurised by the air, then oxidised, and finally poled. The copper is then taken to the refinery.
- Mufulira Refinery
The copper is cast into anodes so the process of electrolysis can take place during refining.
- Nkana Mine
Nkana mine is one of the largest in Africa, a copper mine located 1 km south-west of Kitwe. The mine is underground as well as open pit and is in operation since 1932 and has produced 6,000,000 tons of copper so far. Its reserves underground include 69,000,000 tons of grading, 16,000,000 tons of copper, and 98,000 tons of cobalt. Its resources include 126,000,000 tons of grading, 43,000,000 tons of copper, and 300,000 tons of cobalt. Copper and cobalt mineralisation occur within the ore shale. Copper mineralisation in the deposits changes from mostly chalcopyrite in the South Orebody, to chalcopyrite-bornite in the Central area and to bornite-chalcopyrite at Mindola. Cobalt occurs as carrollite and cobaltiferous pyrite in approximately equal proportions. The mine produces copper and cobalt from three sources: Mindola Shaft, Central Shaft and South Orebody Shaft. Vertical crater retreat is the predominant mining method while sublevel open-stopping and sublevel caving methods are also used. Other metallurgical facilities, under a management contract by an affiliate of the Anglo American Group, include the Nkana smelter (not owned by Mopani), acid plant (not owned by Mopani) and copper refinery (not owned by Mopani). There is extensive mine tailings
Tailings
Tailings, also called mine dumps, slimes, tails, leach residue, or slickens, are the materials left over after the process of separating the valuable fraction from the uneconomic fraction of an ore...
around this mine.
- Nkana Concentrator
Nkana Concentrator of Mopani mines, located in Kitwe, treats copper-cobalt sulphide ore using a bulk flotation and segregation flotation flowsheet to produce separate copper and cobalt concentrates. Nkana Concentrator is the most important mineral processing unit of Mopani, as it contributes about 65% of cobalt concentrates treated at the Nkana and Chambeshi Cobalt plants to produce high purity cobalt metal.
- Cobalt Plant
The cobalt plant treats 65% of the cobalt concentrates to produce high purity cobalt metal. The two cobalt plants are Nkana Cobalt Plant and Chambeshi Cobalt Plant.
Konkola Copper Mine
Konkola Copper Mine (KCM) is the largest copper mining company in the country. Although based in Chingola, 15% of its operations—namely Nkana Refinery, Nkana Acid Plants and Nkana Smelter (the largest smelter in the nation) -- are located in Kitwe. The Nkana Smelter is the largest primary copper production plant in Zambia. The plant treats concentrates mainly from Nkana, Nchanga, and Konkola mines, which are wholly owned by KCM to produce up to 150,000 tons of new copper.- Nkana Smelter
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 in 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.
This smelter was part of the Konkola Copper Mine's operation at privatisation and has subsequently closed.
- Nkana Refinery
The Nkana Copper Refinery produces electrolytically refined copper in the form of cathodes. The copper meets the LME premium quality grade. The tankhouse has a capacity of about 180,000 tons of finished copper per annum.
- Nkana Acid Plants
There are two single contact sulphuric acid plants at Smelterco, namely the No.3 and No.4 plants. No.3, the largest, is still operational. The plant has a design capacity of 1,050 tons of acid per day.
Rokana Mine
Rokana Mine is a mining company that owns Mindola Underground Mine, which mines minerals such as carrolliteCarrollite
Carrollite, CuCo2S4, is a sulfide of copper and cobalt, often with substantial substitution of nickel for the metal ions, and a member of the linnaeite group. It is named after the type locality in Carroll County, Maryland, USA, at the Patapsco mine, Finksburg, Sykesville.- Unit cell :Space group:...
, chalcopyrite
Chalcopyrite
Chalcopyrite is a copper iron sulfide mineral that crystallizes in the tetragonal system. It has the chemical composition CuFeS2. It has a brassy to golden yellow color and a hardness of 3.5 to 4 on the Mohs scale. Its streak is diagnostic as green tinged black.On exposure to air, chalcopyrite...
and libethenite
Libethenite
Libethenite is a rare copper phosphate hydroxide mineral. It forms striking, dark green orthorhombic crystals. It was discovered in 1823 in Ľubietová, Slovakia and is named after the German name of that locality .-References:...
.Other minerals mined are Bornite, Pyrite, Chalcocite.
There is extensive mine tailings
Tailings
Tailings, also called mine dumps, slimes, tails, leach residue, or slickens, are the materials left over after the process of separating the valuable fraction from the uneconomic fraction of an ore...
around this mine.
See Copperbelt Province
Copperbelt Province
Copperbelt Province in Zambia covers the mineral-rich Copperbelt, and farming and bush areas to the south. It was the backbone of the Northern Rhodesian economy during British colonial rule and fuelled the hopes of the immediate post-independence period, but its economic importance was severely...
for the history of the copper-mining industry in this region.
Other mining
There are two small tailings dams right in the city centre. There are also small-scale emeraldEmerald
Emerald is a variety of the mineral beryl colored green by trace amounts of chromium and sometimes vanadium. Beryl has a hardness of 7.5–8 on the 10 point Mohs scale of mineral hardness...
mines in the area.
Environmental issues
The Broken Hill Mine, which occupies a 2.5 km² site just 1 km south-west of KabweKabwe
Kabwe is the capital of the Zambian Central Province with a population estimated at 210,000. Formerly named Broken Hill, it was founded when the Broken Hill lead and zinc deposits were discovered in 1902. Kabwe also has a claim to being the birthplace of Zambian politics...
town centre, is now closed but metals are still extracted from old tailings. A study by the Blacksmith Institute
Blacksmith Institute
Founded in 1999, Blacksmith Institute is an international non-for-profit organization dedicated to eliminating life-threatening pollution in the developing world. Blacksmith identifies and cleans up the world's worst polluted places, focusing on communities where children are most at risk. Based in...
found Kabwe to be one of the ten worst polluted places in the world due mostly to heavy metal (mostly zinc and lead) tailings making their way into the local water supply.