Copper Worldwide Vol 8 No 1 issue

JANUARY/FEBRUARY 2018

VOLUME 8 | 1

See Buyers Guide pp26-27

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n Key Words: Market Q&A for CRU n News: Katanga restarts Outotec Mutoshi Chinese capacity Rod plant data n Electrowinning: Process history State of the art METALEX Corner Power conversion n Spotlight: Chilean smelters on course to effect DS 28 n Rod, Tube, Wire: Italy looks to recover ground n Preview: Wire/Tube 2018 n In Profile: Holton Crest is CRE maker n Events: Asia Copper Week 31st ICC (MB) 17th WCC (CRU) Copper Alloys ALTA 2018 n Contracts: Jiandong CONTIROD CEO changes Albion performs Mine contracts n Supplier Directory Expanded format in this issue ISSN 2046-9438

www.copperworldwide.com

CONTENTS | 1

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Key Words

3,8

Market Q&A with CRU analysts

News

4

Glencore restarts Katanga; Aurubis figures and FCM plan; ICA and IWCC collaborate;

2017 mined output down; Outotec to deliver Shalina Mutoshi plant; Borgas to head WRA; New Chinese capacities; Vedanta record output; Rod plant statistics; EV and transmission breed optimism

Spotlight

9

Chilean smelter upgrade projects progress

Continuus-Properzi latest ETP-FRHC rod plant on stream. Photo courtesy of GIL ROD SHOMAL (see Page 4)

Inside this issue ELECTROREFINING / ELECTROWINNING

10 11,13

A history of design innovations in EW

Aurubis acquires Codelco’s share in Deutsche Giessdraht.

Photo: Aurubis (see Page 20)

Contracts & People

20

SMS group new faces; Glencore Technology Albion success; Reif tops

Otto Junker; Jiandong to get CONTIROD line; Staffas to head Boliden; Thompson ready for Rio Tinto; El Teniente in efficiency drive

Copper Rod, Tube and Wire

16-17

Jon Barnes looks at Italy’s recent struggles

Supplier Directory

26

New entries and categories

Zambia Update

28

Q&A with Zambian economic stakeholders in London

First part of METALEX electrowinning series;

Dynapower power conversion solutions

REFINERY TECHNOLOGY

12

Insight into Affinerie CCR in Montreal

WIRE/TUBE 2018 PREVIEW

14,15

Exhibitors at Dusseldorf in April

IN PROFILE

22,24

Holton Crest’s Malcolm Ladd is steering the CRE process

with new levels of engineering Copper Worldwide Vol 8 No 1

EVENT REVIEWS

18

Asia Copper Week saw a healthy debate; ALTA 2018 papers

EVENT PREVIEWS

19

31st International Copper Conference; Copper Alloys 2018; Copper Cobalt 2018

MELTING AND CASTING

25

Heraeus Electro-Nite molten metal expertise

Front Cover The “We help transfer wind power to your bathroom” ad on the front cover impressively shows how Aurubis copper, with its excellent conductivity, enables the production of wind power. Copper is ideal for use in electrical applications, electronics and telecommunications due to its high conductivity. The increasing interconnectedness of our offices, rising expectations for telecommunications at home and high standards of safety and comfort in today’s automotive engineering ensure that copper demand will continue to grow. www.aurubis.com

2 | COPPER WORLDWIDE A-Z

www. c op p e r wor l d w i de. co m

Companies COMPANY NAME

Volume No: 8 Issue No: 01 Date: January/February 2018

PAGE NO

COMPANY NAME

PAGE NO

COMPANY NAME

PAGE NO

ABB.................................................................... 20

Deutsches Kupferinstitut................................. 19

Otto Junker........................................................ 20

Publisher: Chris K Holding BSc BEng

Agellis Group....................................................... 7

Dynapower......................................................... 13

Outotec ................................................ 5, 7, 20, 21

ALTA 2018........................................................ 18

ENAMI............................................................. 7, 9

Publishing Consultant: John Clarke

Anglo American........................................ 5, 9, 21

European Copper Institute................................ 7

A.S. Metallurgy................................................... 5

First Quantum..................................................... 5

Circulation & Subscription Manager: subscriptions@copperworldwide.com

ASSOMET......................................................... 16

Gecamines............................................................ 3

PolyMet Solutions............................................... 7

13th Asia Copper Conference (MB Events)... 18

Glencore Plc.............................................. 4, 9, 12

Presezzi Extrusion Group................................ 15

6th Asia Copper Week...................................... 18

Glencore Technology........................................ 20

IT/www Contact: webmaster@copperworldwide.com

Atlantic Copper................................................. 19

Heraeus ElectroNite......................................... 25

Aurubis....................................................... 1, 4, 20

Holton Crest.......................................... 14, 22, 24

Managing Director: Chris K Holding

Beijing Antaike Information Development..... 5

International Copper Association (ICA).... 4, 7, 21

Rio Tinto........................................................ 5, 21

Beta LaserMike................................................. 15

31st International Copper Conference

SAIMM............................................................... 19

Paranapanema..................................................... 7 P. J. Mackey................................................... 9, 18

Rautomead......................................................... 15 RHI Magnesita................................................ 5, 7

copper@atrium5.plus.com

Boliden............................................................... 21

(MB Events)................................................... 19

Published by

CCR Refinery (Affinerie CCR)........................ 12

International Copper Study Group.....................

CESCO Week.................................................... 21

(ICSG).......................................................... 4, 7

CHALCO Southeast Copper........................... 21

IIMCh................................................................... 9

Southwire Company......................................... 17

Chinalco............................................................... 3

International Wrought Copper Council....... 4, 5

Swerea KIMAB.................................................. 19

Codelco.......................................5, 7, 9, 18, 20, 21

Jacobs Engineering........................................... 21

COM 2017.......................................................... 18

J. Barnes....................................................... 16, 17

Combilift............................................................ 15

Katanga Mining.................................................. 4

Continuus-Properzi...................................... 1, 14

KGHM................................................................ 21

Vedanta Resources.............................................. 5

Copper Alloys 2018........................................... 19

Metal Bulletin Events....................................... 19

Wire/Tube 2018.......................................... 14, 24

Copperbelt......................................................... 28

Metalex.................................................... 10, 11,13

2nd Copper Cobalt Africa (SAIMM).............. 19

Mettop.................................................................. 7

CRU Events..................................................... 3, 8

NDC Technologies........................................... 15

CRU Group...................................................... 3, 8

Nexans.................................................................. 7

(CRU Events)........................................ 3, 8, 21

Deutsche Giessdraht......................................... 20

OHL Group....................................................... 21

ZCCM ............................................................... 28

Metallic Media Ltd 5 Dennis Road Wimborne, Dorset BH21 3NF United Kingdom Tel: +44(0)7731 784798 e-mail: office@copperworldwide.com www.copperworldwide.com Distribution: free to managers involved in the various stages of the copper industry: Production of primary or secondary copper and associated refining; recycling, melting and casting operations; processing of copper by extrusion, rolling and tube/wire drawing for the manufacture of semi-finished products or fabrications; or involved in the manufacture of components and structures from copper alloys; and who are involved in the buying process for equipment and materials.

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The articles within Copper Worldwide are copyright and are the property of the publisher Metallic Media Limited and cannot be reproduced in any media form without permission of the publisher. Application should be made in writing to the above address, or by e-mail to office@copperworldwide.com Reprints of articles and advertisements are available, allow 28 days for delivery. PDF pages available by e-mail. Prices on application to the publisher.

Instead of Reader Reply cards, we are now including a contact website address with stories at the sole discretion of the Editor. You may submit your enquiries with the item titles, page and your full address, telephone, fax using the contact form on: www.copperworldwide.com

Magazine Production Toni Barrington, The Magazine Production Company Shoreham-by-Sea, West Sussex, BN43 5EG, UK Tel: +44 (0)1273 467579 info@magazineproduction.com

SMS group............................................... 7, 14, 20 Southern Copper Corporation (SCC)............... 3

Tongling Nonferrous........................................ 18 Upcast Oy........................................................... 14

World Bureau of Metal Statistics...................... 4 17th World Copper Conference

Advertisers COMPANY NAME

PAGE NO

COMPANY NAME

PAGE NO

COMPANY NAME

PAGE NO

Agellis................................................................. 26

31st International Copper Conference (MB).... 19

Alex Stewart International............................... 27

Kopar.................................................................. 25

Aurubis...................................................... Cover 1

Kumera Corporation............................ 25, 26, 27

Beta LaserMike (NDC).................................... 15

Küttner GmbH........................................ 8, 26, 27

Combilift...................................................... 15, 26

Metalex......................................................... 25, 27

Continuus Properzi....................................... 6, 14

Mettop.................................................... 25, 26, 27

TSK..................................................................... 25

Danieli Froehling....................................... 26, 27

MINO.................................................. Cover 2, 27

Upcast Oy........................................................... 14

EMA Indutec..................................................... 26

Otto Junker.................................................. 16, 23

HarbisonWalker International........................ 26

PolyMet Solutions............................................. 26

Heraeus ElectroNite......................................... 25

Presezzi Extrusion Group................................ 15

Holton Crest.......................................... 14, 23, 25

Primetals Technologies.................................... 27

17th World Copper Conference (CRU).....Cover 3

hpl-Neugnadenfelder........................................ 26

Rautomead......................................................... 15

ZIMEC 2018...................................................... 12

RHI Magnesita...........................8, 9, 26, Cover 4 Saint Gobain...................................................... 27 Schenck Process...........................Cover 1, 26, 27 SMS group......................................................... 14

UrbanGold................................................... 25, 26 Weir Minerals.................................................... 26

2018 may be your year of opportunities Discover the ISSUES affecting copper now!

The next Vol 8 No 2 issue of Copper Worldwide is published in May 2018. Scheduled features include Primary Smelting / 21st Century Smelting, Plant Integration and Control, Safety and Maintenance (from V8N1), Materials Handling, 2017 Managerial Review, Peru Update, New Frontiers, Conference / Exhibition Reviews, and more. Supporting website www.copperworldwide.com features issue summaries and event updates. Thank you to all advertisers once again. All correspondence welcome.

Copper Worldwide Vol 8 No 1

KEY WORDS | 3

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17th World Copper Conference Special Preview The original CRU company was founded in 1969 by Robert Perlman and John Horam, initially specialising in Copper Market research. CRU opened its Chilean Office in 2006. It moved its London Head Office to Chancery Lane in 2013.

1 Productivity in Chilean Mining was analysed in depth at the 16th World Copper Conference in 2017

What is CRU’s general forecast for 2018 production of primary mined production (concentrates), refined and electrowon (SX-EW) copper (cathode), and secondary copper (primarily from recycled scrap)?

This year, CRU forecasts mine production will grow by 1.5% to 20.47 million tonnes (Mt), recovering from the decline seen last year. The strongest growth will come from South America (see Figure 1), where Escondida is looking to raise production after a strike-hit 2017 and, in Peru, Southern Copper will look to double production at Toquepala.

There will also be solid mine production growth in Africa and higher output in North America, China and Australia. However, there could be significant disruptions in 2018 due to strikes, resource nationalism and political instability.

Blister and electro-refined production are both expected to increase by 3.1% in 2018, bringing total refined production to 23.58 Mt. In 2017, we estimate that scrap provided the feed for 18% (or 3.43 Mt) of refined copper output, a 7.5% increase on 2016 levels. However, with the changing import legislation in China volumes will come under pressure this year.

What key factors will be likely to have an effect on these market areas?

On the mine side, there is a large degree of risk posed by the number of labour contract negotiations in Chile and Peru, which could lead to strikes. CRU estimates that there are 20 mining operations which will try to renegotiate labour contracts with the unions this year. The operations concerned in Chile and Peru respectively account for 77% and 53% of domestic production (see Figure 2). Combined, they account for 28% of global mine supply.

We calculate, using the CRU Copper Mining Cost Service, that 99% of copper mine production is operating below current prices on a cash cost net-of-by-product basis (see Figure 3). Moreover, the 90th percentile cost position on CRU’s 2017 mine production cost curve is only US$ 5,100 /t, with the 75th percentile cost position sitting at around the US$ 3,700 /t mark. Certainly, it is safe to say that at current prices our cost analysis shows nearly every miner will see significant operating cash flows. Producers will do all they can to maximise volumes with such rich rewards available.

2 Chile and Peru mine production forecast for 2018 (without disruption rate) (Mt)

3 The current LME 3 month average is above 99% of the cost curve

Copper Worldwide Vol 8 No 1

Contd on page 8

4 | NEWS

Aurubis FCM on track

In its FY16/17 release (ending 30 September 2017), Aurubis said it intends to build its Future Complex Metallurgy (FCM) facilities in Olen (Belgium) and Hamburg (Germany), and that the firm will develop from a copper group into a multi-metal group in the coming year. New FCM elements are to include a submerged lance furnace, treatment furnace, as well as a leaching and extraction tankhouse. The production start is planned for 2021.

In the FY16/17 reporting period, BU Primary Copper processed 1.1 Mt concentrate at Hamburg and 1.32 Mt at Pirdop, whilst Hamburg operations produced 394 kt cathode and Pirdop 230 kt cathode. The BU Copper Products cathode outputs were 342 kt in Olen and 190 kt in Lünen. Total BU Copper Products rod output was 719 kt, with shapes 190kt, and flat rolled products and specialties a further 230 kt volume.

The Kayser Recycling System throughput was 270 kt at Lünen. www.aurubis.com

Rod maker relies on Properzi A second refining furnace, making use of a recent and patented design with charging door on the top and an automatised conveyor belt for loading the scrap into the furnace, will begin operation at Gil Rod Shomal Co. in Rasht, Iran. Foreseen production is around 30,000 tpy of 8 mm (FRHC) copper rod by a Properzi System already successfully working with cathodes (to make ETP rod) at 12.5 tph. www.properzi.com

Sourcing unites ICA and IWCC Responsible Sourcing is becoming ever more prominent on the agenda for the copper industry. The ICA has founded a Responsible Sourcing Task Force with the IWCC as one of the founding members of this group. The IWCC will be providing additional fabricator input into the Task Force to ensure that the needs of the fabricating industry are taken into account. The Task Force is expected to make final recommendations in April.

The ICA has also commissioned a g l o b a l s u r vey o n s c r a p contamination and has requested the support of IWCC for this major study from early 2Q 2018. www.copperalliance.org www.coppercouncil.org

www. c op p e r wor l d w i de. co m

Glencore restarts Katanga copper mine

Copper production at Luilu Metallurgical Plant

Katanga mine in the Democratic Republic of Congo produced its first copper cathodes on 11 December, after output was suspended in 2015. Total December 2017 mined output was 9,459 tonnes, Kamoto Concentr ator (K TC) yielded 5,061 tonnes of contained copper, whilst Luilu Metallurgical Plant was restarted with 2,196 tonnes of ‘finished’ copper. Two new

pipelines from KTC and Luilu for the deposition of tailings into the Mupine tailings storage facility were commissioned in Q4 of 2017. Design work progressed during the quarter on acid plant, cobalt debottlenecking and cobalt dryer projects.

A round 150,0 0 0 tonn e s of copper output is expected in 2018 and 300,000 t in 2019 from Katanga Mining. Cobalt production

was forecast at 11,000 t in 2018 and 34,000 t the following year.

Processing of copper and cobalt was suspended during the construction of the Whole Ore Leach Project (WOL Project).

Commissioning of phase 1 of the WOL Project was completed in November 2017. Phase 2 construction activities are progressing according to the 2018 project execution plan, with full commissioning expected in Q4 of 2018.

On 1 February, Glencore’s total own-sourced copper production for 2017 was reported at 1.31 Mt, an 8% reduction on its 2016 output. The custom metallurgical assets (Altonorte, Pasar, Horne, CCR) copper cathode production of 526,800 tonnes was 37,700 tonnes higher than in 2016, mainly reflecting Pasar’s expansion project, whilst copper anode production of 535,700 tonnes was up 3% of 2016 levels. www.katangamining.com www.glencore.com

Mine production decline to October 2017 According to International Copper Study Group (ICSG) preliminary data for October 2017, world mine production is estimated to have declined by 2.6% in the first ten months of 2017, with concentrate production declining by 2.2% and solvent extractionelectrowinning (SX-EW) declining by 4.3% respectively. Chilean mine output fell by 2%, and c o n c e n t r a t e p ro d u c t i o n i n Argentina, Canada and Mongolia fell by 55%, 17% and 17% respec tively, mainly due to planned lower grades. Argentina’s Alumbrera mine is approaching end of life. A temporary ban on Indonesian concentrate exports r a n from J a nu a r y to A p r il, causing a 15% decline. On the plus side, there were 32% and

3.5% increases in Kazakhstan and Peruvian concentrate output respectively, whilst Brazil, Mexico, Myanmar, Spain and Sweden also contributed to world growth.

World refined production is estimated to have remained essentially unchanged in the first ten months of 2017.

World primary refined production (electrolytic and electrowinning) declined by around 2%, and refined secondar y production (from scrap, particularly China) increased by 9%, in the period.

Overall China’s refined production rose 5%, with India (+7%) and some EU countries recovering from maintenance shutdowns in 2016. There was an 8% decline in Chilean primary electrolytic refined and electrowinning production, with

Japan (-4%) and the United States (-10%) also shrinking in output.

World apparent refined usage is estimated to have increased by 0.2% in the period, while Chinese apparent usage remained essentially unchanged. The world refined copper balance for the first ten months of 2017 indicates a deficit of about 175,000 t (including revisions to data previously presented).

This was mainly due to stagnant growth in world refined copper supply. The world refined copper balance adjusted for changes in Chinese bonded stocks (based on an average estimate of changes in unreported inventories provided by three consultants) indicates a deficit of around 150,000 t for January to October 2017. www.icsg.org

Small deficit seen to November 2017 The copper market recorded a deficit of 118.7 kt in January to November 2017, which follows a deficit of 102 kt in the whole of 2016, according to the latest World Bureau of Metal Statistics release. Repor ted stocks fell during November and closed 127 kt lower than at the end of December 2016. No allowance is made in the consumption calculation for unreported stock changes, particularly in the Chinese

government stockpile.World mine production for January to November 2017 was 18.6 million tonnes, which was 0.4 per cent lower than in the same period in 2016. Global refined production for the period was 21.57 Mt, up 1.3 per cent y-o-y, with a significant China increase (+ 500 kt) and reduction in Chile (- 182 kt).

Global consumption for January to November 2017 was 21.69 Mt compared with 21.52 Mt for the

Copper Worldwide Vol 8 No 1

same months of 2016. Chinese apparent consumption in January to November 2017 rose by 187 kt to 10,780 kt comparatively - just under 50 per cent of global demand.

EU28 production rose by 2.9 per cent and demand was 3,081 kt, just 1.8 per cent below the prior year total. In November 2017, refined copper production was 2,002.9 kt and consumption was 2,023.0 kt respectively. www.world-bureau.com

NEWS | 5

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DR Congo plant win for Outotec Outotec has been awarded a contract by Shalina Resources Limited for the delivery of copper and cobalt processing technology to the Mutoshi project near Kolwezi in the Democratic Republic of Congo. The EUR 65 million order was booked in Outotec’s 4Q 2017 intake. Scope includes basic engineering, technology and equipment deliveries for a new plant with an annual processing capacity of 20,000 tonnes copper and 16,000 tonnes cobalt. The plant will use Outotec’s modular hydrometallurgical solutions, s u c h a s O K TO P ® re a c to r s, V S F ®X s o l v e n t e x t r a c t i o n , and electrowinning. The supply includes grinding mills, thickeners, filters, analysers and a process control system. Deliveries will take place during 2018. Shalina Resources has two operating copper/cobalt plants at Etoile and Usoke. There is a growing demand for copper and cobalt for the electric vehicle market. Outotec has secured a further EUR 33 million order for the delivery of three skid mounted, modular sulphuric acid plants for new Mutoshi coppercobalt plant, it was announced in late January. www.outotec.com

Vedanta copper FY17 report highlights In FY 2016-17 (FY17), Vedanta India copper cathode production achieve d a re cord leve l of 402,000 tonnes through in-house technological upgrades at the Tuticorin refinery that raised the previous design level density of 310 A/m2 to 350 A/m2. This was offset by lower copper grades and a few unplanned outages spread over the year. Plant utilisation touched a record level of 94% with overall equipment effectiveness (OEE) of 86%. Sulphuric acid availability wa s at record levels 10 0% throughout the year.

At the Tuticorin smelter, the cost of production in FY17increased from US cents 3.2 per lb to US cents 5.0 per lb. Scrubber cakes generated at the smelter were transformed from a hazardous to a non-hazardous state through the installation of bag houses before the scrubbers. This led to a significant reduction of ha zardou s c ake gener ation, enhancing secured landfill life. www.vedantalimited.com

New refractories group President elected Ste fa n B o rg a s, C EO of R H I Magnesita, was elected as the second President of the World Refractories Association (WRA) and took up office in early January. The inaugural Presidential role had been fulfilled

by François Wanecq, former CEO of Vesuvius plc, for the previous two years. After the successful merger of RHI and Magnesita in October 2017, the combined group RHI Magnesita set itself the ambition to Stefan Borgas is currently President of the WRA be ‘the driving force of the industry’. held during CERAMITEC, which Borgas aims to increase the number runs from 10 - 13 April 2018 in of WR A members to unite as Munich, Germany. many producers as possible. The www.worldrefractories.org next WRA Board Meeting will be www.rhimagnesita.com

FM North Western Province operations grow US$ 0.09 /kWh, provided that Kansanshi and Sentinel can each import a portion of their total power requirements from alternative suppliers. The Government and ZESCO committed to provide continuous unrestricted supply of power to First Quantum’s operations and to facilitate the power importation. The tariff will be reviewed upon finalisation of a The North Western Province of Zambia Cost of Service Study, due in early Scheduled maintenance on the 2018, which has been commissioned First Quantum Kansanshi smelter by the Energy Regulation Board. began in August 2017 and was 1. Preliminary figures for First Quantum’s 2017 completed within the planned 28 Table production (t Cu in concentrate) day time period, with the staged Kansanshi (mine) 250,801 restar t and ramp-up process Sentinel 190,683 initiated on 12 September. SteadyOther First Quantum operations: state operations were achieved Las Cruces (Spain) cathodes 73,664 the next week. An agreement Guelb Moghrein (Mauritania) 28,791 was reached between ZESCO Çayeli (Turkey) 16,523 (the state-run power company), Pyhäsalmi (Finland) 13,501 the Government of the Republic of Zambia and First Quantum The Sentinel figure showed a rise whereby First Quantum agreed to of over 50 kt on the previous year. a tariff increase, to approximately www.first-quantum.com

Domestic update from Beijing-based body According to a Beijing Antaike 2017 Copper Market Report circulated in January, China’s newly added smelting and refining capacity was estimated to be 100 kt in both cases in 2017, making total smelting and refining capacities 6.60 Mt and 10.92 Mt respectively. Additional plant volumes in 2018 are estimated to be 550 kt and 650 kt, meaning total smelting and refining capacities would reach 7.15 Mt and 11.57 Mt levels. The main projects proposed to be started or in progress include CHALCO Ningde project, Yunnan Copper Chifeng expansion project, and Zijin Copper Qiqihar project, all

being due for full ramp up in 2019.

In 2018, copper concentrate demand growth will still mainly come from China, but most of the new capacity will be put into operation in the second half or even the fourth quarter. Considering that it takes time to reach production capacity, the increase of demand will be more obvious in 2019.

Looking back, in 2016, since global refined copper consumption growth slightly exceeded that of output, the previously accrued surplus began to narrow. This trend continued to be reflected in 2017. www.antaike.com

Copper Worldwide Vol 8 No 1

In brief…

In the Anglo American plc Production Report for the quarter ended 31 December 2017, copper production for 2017 from the Copper Business Unit was 579,300 tonnes. Quarteron-quarter copper output rose marginally to 148,600 tonnes.

Collahuasi achieved record production in the year, driven in part by continued strong plant performance. www.angloamerican.com

Total U.S. recoverable copper mine production to end-November 2017 was 1.16 Mt, a decline of 12% relative to the same period in 2016, according to USGS data released in February.

Refinery production to end-November 2017 was 998 kt, a decline of 12% comparatively, with 510 kt being electrowon copper. Smelter anode output was 434 kt. www.minerals.usgs.gov

A Rio Tinto Kennecott employee has died two days after exposure to sulphur dioxide gas at the company’s smelter on 8 October. The incident took place in the early hours when the employee was removing debris from a boiler. The worker was treated onsite and at a nearby medical centre. An investigation was commenced into the tragedy. www.riotinto.com

Alex Stewart International principal laboratories in Liverpool (UK), AS International Corporation Ltd, has been accredited by the United Kingdom Accreditation Service (UKAS) to ISO 17025 Standards for its copper concentrates analysis. Other ISOcertified Alex Stewart International laboratories include Argentina, Chile, India, Peru and Zambia. www.alexstewartinternational.com

Codelco El Teniente Division has obtained environmental permits relating to the New Mine Level Project (PNNM) for the Environmental Assessment Commission. The structural project is currently 44% progressed. The approval of the Declaration of Environmental Impact (DIA) took six months, and authorises gradually deepening the deposit. www.codelco.com

Experienced Public Affairs practitioner Mike Smith joined the IWCC as its VicePresident in December 2017, and he has been meeting members and other key players in the copper industry in early 2018 before attending his first IWCC meeting, the annual Technical Seminar on Hot and Cold Deformation in Chicago, USA from 4- 8 March 2018. www.coppercouncil.org

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NEWS | 7

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Moves to put rod plants closer to demand

In brief…

The International Copper Study Group has released its 2017 edition of the ‘Directory of Copper and Copper Alloy Fabricators - First Use’, which covers companies and plants involved in the use of refined copper, copper scrap and copper alloy scrap.

For 2016 almost 2.5 million tonnes of new capacity to use refined copper and scrap, mainly in new copper wire rod, was commissioned, but for 2017 the new capacity being commissioned is below 1.3 Mt worldwide, mainly (but not only) in China.

Empresa Nacional de Mineria (Enami) was forced to suspended operations at its Paipote copper smelter in Chile’s Atacama region from 12 December to 8 January due to a strike by Sindicato Nº 2 de Trabajadores union members over contracts. The plant set out to receive concentrates under contracts only until its materials storage capacity was reached.

The cancellation of copper wire rod projects across China is now a reality of the ongoing industrial restructuring that affected almost 1.8 Mt in cancelled, delayed and postponed projects just in the copper wire rod sector, with some new plants idle or producing at low utilisation rates in 2017.

W ith th e s lowdow n of th e fabrication capacity expansion cycle in China expected for 2019, and a peak in overcapacity expected for 2018 for copper wire rod

and for some other products, some American, Japanese and even Chinese corporations have sold plants in China and other countries to local corporations and are re-investing in new plants and capacities in the Gulf, India, Vietnam and the United States.

The 2017 edition of the Directory is available for sale to ICSG member country/non-member country clients at a price of EUR 400 / EUR 600 respectively. www.icsg.org

China caps off its rod capacity The ICSG Market Study on Industrial Use of Refined Copper and Scrap in Fabrication in China 2017 completed in November 2017 covers over 19 million tonnes (Mt) of copper and copper alloy semi-fabrication capacity in China and copper and alloy fabrication output reported in the survey was over 12.4 Mt copper content. The plants included in the survey cover the known capacity to process refined copper and scrap in Chinese fabrication plants. The

study confirmed that China added around 6.2 Mt of copper wire rod capacity in 2013-2017. A reduction in copper wire rod capacity project pipeline in China is reported, with large scale projects cancelled or postponed in 2017 with no date of future commissioning. The study includes new projects in the pipeline for 2018-2020.

Real use of copper in Chinese fabrication increased over 6% in 2016 on strong demand and more

domestic refined copper supply, with high volumes expected to be used in 2017 and beyond. The use of refined copper is over 90% of all copper uses in Chinese fabrication, with copper in scrap directly melted by fabricators still below the 10% level. The China Study is available for sale to ICSG member country/non-member country clients at a price of EUR 400 / EUR 600 respectively. www.icsg.org

Copper backed in transmission studies The suitability of micro-alloyed copper conductors has been looked at for high-voltage overhead lines, the traditional domain of steel-reinforced aluminium (ACSR) or aluminium alloys. Two feasibility studies were conducted by the Dutch consultancy agency DNV GL (KEMA). The first study examined the construction of new lines, whilst the second investigated the refurbishment of

existing lines. The studies concluded that the use of micro-alloyed copper conductors would be competitive (against traditional choices like ACSR) in the following cases: • When life - cycle costs of overhead lines are taken into consideration, the higher conductivity of copper offers a lower cost of losses, reducing the life-cycle costs by more than 10

percent, with payback periods of around six years.

• In challenging weather conditions, specif ically windy, icy or a combination.

• In corrosive atmospheres.

Fo r e x i s ting lin e s , D N V G L concluded that micro-alloyed copper conductors lead to lower losses and simpler installation. www.copperalliance.org

for Daimler, whilst a recent $1.3 bn expansion added a new car body manufacturing shop and upgraded logistics and computer systems at the plant. Mercedes plans to begin construction in 2018. Daimler plans to offer more than 50 vehicles with some form of hybrid or electric powertrain by 2022.

German automakers, including Volkswagen and BMW, are moving

rapidly away from diesel engines amid increasingly rigid global emissions regulations, while electric vehicle sales to date have been slow.

The U.S. market share for electric cars was only 0.5% in the year to September 2017, but electric cars could be the same price as gas vehicles within three years, according to some analysts. www.usatoday.com

Sustainable practices agreement made Nexans and Codelco have signe d a new M e mor a ndum of Understanding which aims to develop and implement e nv iro n m e n t a l, co m m u ni t yfriendly and ethical processes in the copper industry. Among the key

aims of the project are to evaluate mechanisms to trace Codelco’s sustainable production from the company’s mines to Nexans and to the market, and then to develop a plan to produce sustainable cables and cable systems at Nexans plants

A Mettop, PolyMet Solutions and SMS group Ionic Liquid Cooling Technology (ILTEC) workshop took place at SMS group headquarters in Düsseldorf and at Paul Wurth in Luxembourg in November to look at how to implement ILTEC solutions across the SMS group product portfolio. The interest and participation was phenomenal. www.mettop.com

RHI Magnesita has acquired Agellis Group AB as part of its ‘Ladle to Mould’ strategy for steel and non-ferrous plants. Agellis Group’s products help optimise molten metal production processes. The Agellis team and management will continue to operate from Lund, Sweden together as part of RHI Magnesita’s System & Advanced Technologies unit. www.rhimagnesita.com

Outotec has been selected to supply process equipment for a greenfield copper concentrator in Australia.

The scope includes semi-autogenous (SAG) and ball mills, HIGmill® high intensity grinding mill, flotation cells, sampler and automation technology, plus thickeners for concentrate and tailings treatment. The deliveries will take place during 2018. www.outotec.com

German automaker raises stakes in Alabama Mercedes-Benz plans to invest US$ 1 billion in Alabama to produce electric vehicles and compete with Tesla, whose Model 3 Sedan is seen as direct EV competition. The investment will go both to an expansion of the German luxury brand’s existing plant near Tuscaloosa and to build nearby a new 1 million sq ft battery factory, also creating 600 new jobs. It is the fifth such battery facility worldwide

www.enami.cl

with the intention of having a fully traceable final product. A major milestone in 2018 will be the delivery of the first ‘carbon neutral’ shipment of copper cathodes from Codelco to Nexans. www.nexans.com

Copper Worldwide Vol 8 No 1

Outotec is holding a series of webinars on tailings and water management in early 2018. The first webinar will introduce thickening, and followed by sessions on tailings filtration and water treatment. Each webinar will cover the topic from equipment to plant from a holistic standpoint. Registration is available from January per below. www.outotec.com/webinars

Paranapanema CEO Marcos Camara says its recent restructuring will allow the company to resume production, optimise assets and gradually increase profitability. The sales volume in 2017 was 158.8 kt, being 99.2 kt copper products and 59.6 kt primary copper.

The company has secured supply of copper concentrate for 100% of its 2018 production program. www.paranapanema.com.br

Introducing…

The driving force of the refractory industry

8 | KEY WORDS Contd from page 3

year alone. There is a chance that some of these Chinese projects will get delayed or cancelled if operators become concerned about the availability of concentrate. We do not think there has been a significant change in the prospects for smelter projects over the last year, and with the growth in capacity, conditions will remain challenging for those with higher costs. However, there will still be opportunities for those who can source feed at competitive prices.

4 The World Copper Conference always attracts top level executives

To what extent are trade restrictions and disputes affecting the current copper market, and has their prevalence increased over the last two to three years? What is likely to be happening in 2018, and are there any steps which firms can consider taking to mitigate any effects? Where can they get further expert advice?

In terms of downstream products, copper is not seeing the same degree of attention as either aluminium or steel. However, there are some disputes taking place on the mine side. In Indonesia, negotiations over the future of the Grasberg mine have yet to be concluded, while in the Democratic Republic of Congo, the state producer, Gecamines, is lobbying the government to revise its mining code, to gain a greater share of the country’s copper and cobalt revenues.

Scrap has increasingly become a key talking point in the market due to changes in Chinese legislation. In China, so far all the rounds of licences that have been issued for 2018 Category 7 scrap show significant reductions in companies listed as approved importers and far fewer quotas allocated. CRU believes there will be a significant reduction in Category 7 quotas this year, with a full ban coming into effect in 2019.

This will affect metal flows from overseas, and hence smelter production, before processing facilities are relocated and installed in South East Asian countries or elsewhere.

How are the market conditions changing internationally and domestically to allow the reconsideration of, and new proposals for, smelter projects outside of China, for example in India, Uruguay, and Thailand?

There are no risks of a shortage of smelting capacity, and globally smelters are being utilised at just below 75% on average. Smelters in Europe and North America operate at a higher level. On top of this, there are a raft of new smelters due to come online over the next five years, mainly in China, where Chinalco has two 400,000 tpy smelters due this

Unbenannt-1 1

How has CRU’s market offering changed over the past 12 months, and what new initiatives will the company be introducing in 2018?

CRU has spent a lot of time enhancing our Copper Mining Cost Model. The model has improved discounted cash flow capabilities and can easily show the NPV for projects and NAV operating assets, as well as assessing companies’ free cash flow potential. The new mine scenario and planning features enable the user to add new projects to the model, and this has been receiving a lot of positive feedback. We have also overhauled the model’s navigation and introduced asset level summaries, meaning users can access high level details more simply, as well as being able to look closely at all the fine details which our customers have come to expect from us.

Who are the key contacts within CRU for producers and processors wishing to gain market insights, and what are their areas of specialisation? Of these analysts, who will be on hand at the upcoming 17th World Copper Conference in Santiago from 9-11 April?

As usual CRU will be sending a large number of delegates to Santiago from our offices around the world. From CRU’s Beijing Office, Chris Wu (mengjie.wu@crugroup.com) will be on hand to discuss all aspects of the Chinese industry. Also available is Erik Heimlich from our Santiago Office, who heads our concentrates research (erik.heimlich@crugroup.com).

Other specialists in attendance will be Hamish Sampson (hamish. sampson@crugroup.com), who’s focus is African mining, and Robert Edwards (robert.edwards@crugroup.com) whose specialism is demand and semis and sets our long term view. Furthermore there will be Vanessa Davidson (vanessa.davidson@crugroup.com), who is the Director of CRU’s Copper Research, and Charlie Durant (charlie.durant@crugroup.com), who leads our research into refined copper markets and price forecasting. www.crugroup.com/consulting Questions: Chris Holding, Editor, Copper Worldwide Answers: Charlie Durant, Principal Analyst, Copper, CRU Group

20.07.2017 11:05:21

RHI and Magnesita.

A new global leader in refractories.

Find out more at rhimagnesita.com SPOTLIGHT | 9

Smelters rising to DS 28 challenge From small junior mining companies to the large multinationals, tackling environmental issues in mining and metallurgical operations is a major area for each business.

All new projects require an environmental impact statement and permitting is a rigorous process.

The upgrading of older plants to bring them into compliance while holding at the required production capacity can be technically tricky due to space limitations, plant layout issues, and so on. The copper companies in Chile are to be commended for the comprehensive presentations given at the recent smelter seminar held by the IIMCh on 4-5 December 2017 at Copiapo, Region de Atacama, Chile. The Chilean smelters are required to meet certain targets by 2019.

Plans for each of the seven smelters to retrofit in order meet sulphur dioxide targets and other requirements were discussed.

As noted, brownfield projects can represent significant engineering and cost challenges, however careful design work has allowed plants to meet targets set primarily by Regulation DS 28 (2013). A summary of the environmental requirements was presented at Copper 2013 by Contreras et al., ‘New regulation to reduce air emissions from copper smelters in Chile’ (1).

Table 1. Overall data on the seven copper smelters in Chile (order Region II to Region VI)

Smelter Company

Nominal smelter capacity (2016), kt of Cu/year

SO2 limit (DS 28) t SO2/year

Chuquicamata Codelco 420

49,700

Altonorte

Glencore 320

24,000

Potrerillos

Codelco 200

24,400

Hernan Videla Lira (Paipote) ENAMI 100

12,880

Las Ventanas

Codelco 110

14,650

Chagres

Anglo American

185

13,950

365

47,680

Caletones (El Teniente) Codelco

Total 1,700

187,260

Source: Reference 1 and Author data (2017)

Table 2. Summary of main plans for Chilean smelters to meet SO2 regulations (DS 28) (order Region II to Region VI)

Smelter Key components of general plans

to meet SO2 regulations (DS 28)

Nominal smelter capacity (2019

kt of Cu/yr

Chuquicamata

Close CT No. 2, expand flash to 1.17 mill t conc. /yr.

(375 kt of Cu/yr.), new No. 5 PS converter and new PS converter hoods, double contact at acid plants, fugitive gas collection, new steam dryer, anode furnace off-gas treatment, milling of flash furnace slag continues. Target 95.5% S capture.

375

Altonorte

Double absorption at acid plants in place. Target 96.8% S capture

320

Potrerillos

Upgrade PS converter hoods, upgrade acid plants for double absorption, anode furnace off-gas treatment, slag milling plant has been in operation several years.

Target 95% S capture.

180

Hernan Videla Lira (Paipote)

Las Ventanas

Plans based on overall improvements to the gas handling systems, 90 tail gas, anode furnace off-gas treatment. Target 95% S capture. including installation of two new peroxide scrubbers of Chinese design at the two single contact acid plants to continuously treat tail gas, anode furnace off-gas treatment. Target 95% S capture.

Upgrade PS converter hoods, fugitive gas collection, baghouse at dryer, anode furnace off-gas treatment, installation of Hugo Petersen peroxide scrubbers at the acid plant to correct for peaks in tail gas concentration. Target 95.6% S capture.

110

Chagres

New baghouse at dryer. Target 97% S capture.

185

Caletones (El Teniente)

346

Install slag mill for CT slag (pyrometallurgical slag cleaning furnaces to close), add new Sulfacid scrubbers at each acid plant to treat tail gas, anode furnace off-gas treatment.

Target 95% S capture.

Total copper output, kt/yr

1,606

New converter hoods for installation at the Chuquicamata smelter

Source: Author data and 2017 Smelter seminar (IIMCh, Santiago, Chile, December 2017)

There were a total of 25 presentations in an action packed agenda, including presentations on the main smelter plans, supporting technologies and work at the plants. Table 1 summarises overall data for the seven Chilean smelters, while Table 2 provides a summary of the main plans described by the plants at the Seminar. Major retrofit work is underway at the large Chuquicamata and Caletones smelters of Codelco-Chile. As a result of this work, there will be some adjustment to plant capacity.

The photo illustrates the new type of PeirceSmith converter hood to capture primary and secondary gases to be installed at these plants.

Phillip Mackey is due to attend the TMS 2018 meeting in Pheonix, AZ in March References: 1 Contreras, C.G., Ulloa, P and Santic, P, New regulation to reduce air emissions from copper smelters in Chile, paper presented at Cu 2013, Santiago, Chile.

Author: Phillip Mackey Copper Worldwide Vol 8 No 1

CESCO Week 2018

In a February release, Alejandra Wood, Executive Director of Cesco says we are perceiving greater optimism for Chilean and global mining, and opportunities for innovation and sustainable development in the sector. CESCO Week in Santiago, Chile comprises: 9 April - International Explorations Forum 10-11 April - 17th World Copper Conference 11 April - Cesco Dinner 2018 12 April - II International Seminar on Mining and Sustainable Development www.cesco.cl

10 | ELECTROREFINING/ELECTROWINNING

www. c op p e r wor l d w i de. co m

Introducing: The METALEX Corner on Electrowinning It is just over 100 years since the first copper electrowinning plants were established in the Antofagasta Region of Chile and Arizona in the USA.

Alejandro Lillo of Metalex pictured here in Poland in 2014

It is only fitting that some of the excellent innovations to this technology are remembered in this introduction to a Series of in-depth articles on Electrowinning by Alejandro Lillo, founder and President of Santiago-based copper electrowinning and electrorefining consultancy firm Metalex.

Technology history

The main contributions to copper electrowinning organised in historic appearance are summarised here: • 1915 Copper electrowinning commences at Chile Copper Company (Chuquicamata), Inspiration Consolidated Copper Company (Miami), and New Cornelia (Ajo).

• 1967 SX/EW introduced at Ranchers Blue Bird, Arizona.

• 1973 First permanent cathodes (Titanium) introduced at Inco Sudbury operations, now Vale.

• 1974 First large SX/EW commissioned in Nchanga by ZCCM for treating oxides tailings, which incorporated the use of PLS clarification.

• 1975 First relocatable SX/EW facility installed at Johnson Camp, Arizona.

• 1977 First introduction of hoods at Cerro Verde, Peru. Concept abandoned due to operational limitations.

• 1984 First tests with rolled Lead-CalciumTin anodes carried at Tyrone, USA. • 1985 First 316L SS blanks introduced at Port Pirie. Attempt failed due to high levels of chlorides in electrolyte and blanks were substituted by Titanium.

• 1986 First 316L cathodes introduced successfully in copper electrowinning at Gibraltar Mines, McLeese Lake, Canada, including design for subzero conditions for Dump Leach/SX/EW.

• 1988 First polymer concrete cells introduced at Lipesed Plant in Chile.

• 1994 First HL/SX/EW plant commissioned at high altitude (and sub-zero conditions) at Quebrada Blanca, Chile.

• 1995 First plant to use 9 mm thick rolled PbCaSn anodes at Minera Zaldivar, Chile.

• 1997 First plant to incorporate cells arranged in a Back-to-Back configuration at Radomiro Tomic, Chile incorporating some Zn EW technological solutions for equalisation bars and material handlings such as hooks in cathodes and anodes, and straight bars in anodes.

• 1998 Introduction of hoods for acid mist capturing at industrial scale (still in operation at Anglo’s Los Bronces plant in Chile).

• 1998 Introduction of demisting bags for cross flow ventilation at Toquepala, Peru.

• 2003 Introduction of the 1.2 m long wetted length cathode at Kansanshi, Zambia.

• 2005 Plant design for high current density (415 A/m2), long cells, full crane automation, asymmetric anode equalisation, slotted equalising bars, short circuit detection by

infrared scanning in cranes, etc., at Minera Spence, Chile.

• 2007 High current density introduced at San Francisco Plant for operation above 400 A/m2.

• 2012 Cell Top furniture redesign for high current density, up to 600 A/m2. Industrial validation of copper electrowinning at 550 A/ m2 using enhanced hydrodynamics.

Other not-dated contributions to technologies are: • Shorting Frames introduced at Inspiration circa 1973.

• Spring-loaded contacts in shorting frames introduced at Cerro Verde circa 1990.

The first article in the METALEX Corner series immediately follows this introduction and covers electrowinning cells and cell top furniture. www.metalex.cl

Author: Alejandro Lillo, founder and President, Metalex, Chile

State of the art

From the historical contributions shown above, it’s possible to infer that most modern tankhouses could contain some of the following features: Item

Source

Cell Length

Zn EW

Year to industry

Characteristic Up to 11.4 m

Cell Material

Lipesed Plant

1988

Polymer Concrete

Plating Length

Kansanshi

2003

1.2 m

Anode Alloy

Tyrone

PbCaSn Rolled

Anode Hanger Bars

Radomiro Tomic

Straight (for Cu EW)

Anode Thickness

Zaldivar

9 mm Rolled

Cathode Blade Gibraltar 1986

316L ASTM 240 for low chlorides environment

Cathode Hanger Bars with hooks

Radomiro Tomic

Straight

Spacing

Industry Standard

100 or 101.6 mm

Current Density Anglo San Francisco 2012

450 A/m2 (Operational) 600 A/m2 (Design)

Cathode Cycle

4 days

Anglo San Francisco

2012

Harvesting Handling

Boleo

2013

Robotic

Electrodes/Cell

Up to 96

2015

96 (proposed)

Stripping Efficiency Material Handling

2015

Zn Ew

89% (calculated) Full automation

Enhanced Hydrodynamics Anglo San Francisco 2011

Solution jetting from self-aspiration – Demo Cell for Exmajet

Acid Mist Capture

Cell Hoods vs Individual covers with filtration devices

Anglo Los Bronces 2003/2008 or Silver Bell

Copper Worldwide Vol 8 No 1

ELECTROWINNING | 11

w ww.copper worl dw ide. co m

METALEX Corner 1 - The EW cell itself Cell construction

Modern electrowinning (EW) cells include the use of polymer concrete as construction material, which became standard since it was first used in Zambia in the early 1970s. In Chile, Minera Tocopilla introduced it in copper EW at its Lipesed plant in 1988. Since then, most EW plants use polymer concrete cells.

Its development emerged in response to frequent leaks observed at cells made of concrete lined with lead, plastic or FRP, where use of copper starting sheets with frequent corrosion of the loops, or during handling of finished cathodes, damaged the liners due to localised impacts.

Polymer concrete provided plants with an expected long-lasting life product, if not definitive, as many evaluations for substitution considered cells would last beyond the life of projects. It became apparent that the material was very sensitive to thermal shock, even during the first filling and ‘curing’ of cells with electrolyte at process temperature. Many plants have suffered from this effect, for which unexpected maintenance is required. To date, there is evidence of the need to replace polymer concrete cells in copper EW. The original cell construction was very simple. Polymer concrete was poured in batches between and an internal and external mould using vibration to improve distribution and elimination of entrapped air. Both internal and external surfaces developed a ‘metal contact resin reach layer’ which was converted in a ‘veil’ with some glass in the form of mat of different weights and rates, mainly for cosmetic reasons. Some manufacturers introduced pigments, masking the surface and preventing visual detection of voids and similar defects.

In practical terms, the polymer concrete container was made responsible for structural and stagnancy integrity. Cells fabricated using this method leak electrolyte, which produces detrimental effects on the basement and cells supporting structure, besides providing a path for stray currents, loss of plating efficiencies and generating a safety hazard to workers.

In the early 1990s, and to resolve the problem of sensitivity against thermal shock and containment of leaks, a cell manufacturer developed the concept of double containment and manufactured several cells using this technology in Australia and Chile. The technology included an internal cell of FRP which became the inner mould of the cell for the fabrication process. The polymer concrete mortar was then poured between this internal FRP surface and the external metal mould, which also developed the resin reach metal contact surface. The result was a ‘sandwich’ as shown in Figure 1. Since 1995 no cells fabricated using this method have had to have any repair intervention.

The ‘polymer concrete sandwich’ or double containment cell resolved the problem of resistance against thermal shock providing also ‘double containment’, this is an internal

each and spacing between 75 and 104 mm.

Most economical length depends on transportation cost, the preferable length being the one for use of a 20 ft or 40 ft container when considering ocean freight. However, many plants consider 9 m internal length, which is considered uneconomical.

Cell top furniture 1 The ‘polymer concrete sandwich’ or double containment cell

RFP cell and an external Polymer Concrete Container, both providing stagnancy to contain the eletrolyte. It is standard in modern EW cell construction. It consists of polymer concrete mortar poured between internal liner walls and the external mould to improve resistance to thermal shock.

Cell length

EW cells have different lengths depending on the number of electrodes considered in t 2 Today, cells in copper electrowinning average 9 metres in length.

Cell length varies depending on the number of electrodes. The most economical cell length is to suit 20 or 40 ft Full Container Load

3 An arrangement that combines the benefit of slotted machined intercell bars with an auxiliary equalising bar

RFP cell and an external Polymer Concrete Container, both providing stagnancy to contain the eletrolyte. It is standard in modern EW cell construction. It consists of polymer concrete mortar poured between internal liner walls and the external mould to improve resistance to thermal shock.

Cell length

EW cells have different lengths depending on the number of electrodes considered in the design. Longer cells in copper EW can be found at Inspiration (USA) and Luilu (DRC), with more than 100 electrode pairs. Commercial internal cell lengths can range between 1,000 mm and 18,050 mm, with 10 to 195 cathodes Copper Worldwide Vol 8 No 1

This definition applies to the elements installed on top of the cells normally referred as Capping Boards when using symmetric electrode for configurations of asymmetric electrode, but including Electrode Spacers and Insulators.

The incorporation of the copper bar completes the hardware needed to keep electrodes separated at project distance to facilitate harvesting. Together with electrode accessories like insulators and guides, the cell top furniture package aims at generating the correct spacing between electrodes, which is essential for quality, electrical efficiency, reduced power consumption and providing exact coordinates to automated material handling by harvesting cranes, short circuit inspection, and so on.

Today, different designs are in use, from single triangular bars for asymmetric electrodes to more sophisticated systems, all aimed at distributing current evenly. Figure 3 shows an arrangement that combines the benefit of slotted machined intercell bars with an auxiliary equalising bar, both resting on top of highly engineered insulating materials to be compatible with the intercell arrangement - compatible with asymmetric anodes and symmetric cathodes.

The main intercell bar can be a triangle or round bar. However, the use of slots is what improves the electrical contacts, as the electrodes hanger bars rest with their edges touching the inclined planes of the slots, thus generating a double-line contact configuration.

In the case of triangular or round bars, there is only a single-line contact and when the electrode hanger bars have a radius underneath, it is called a single-point contact.

In theory, the single-point contact is better, as the pressure of the weight of the electrodes concentrates on a single point. However, due to plant housekeeping, the impact of solution spillage and splashes, besides normal wearing of the copper bar, usually affect the integrity of the point contact, which becomes flattened or contaminated with electrolyte and therefore loses its ‘perfection’. As a result, the single-line contact faces limitations in current-carrying capacity and frequently generates hot spots associated with short circuits, annealing of electrode hanger bars (commonly copper), and other issues.

Combining the above arguments with other reasons like the convenience to have symmetric electrodes and accurate positioning, for example, an alternative solution has emerged, which uses a more extensive transferring bar with two high-points, as shown in Figure 4.

Contd on page 13

12 | REFINERY TECHNOLOGY

www. c op p e r wor l d w i de. co m

Why CCR Refinery stays on top Table 1. CCR Refinery production capacity (/yr) Copper Gold Silver

Based in Montreal-East, CCR Refinery started operations in 1931 under the name of Canadian Copper Refinery. (INSET: permanent cathodes).

Over the past few years, the CCR Refinery (Affinerie CCR, an integral part of the Glencore group) has been distinguished by remarkable growth in productivity and performance, particularly in terms of financial performance, sustainable development and health and safety.

Based in Montréal-East, Québec, the CCR Refinery started operations in 1931 under the name Canadian Copper Refinery. Today the company has more than 550 employees, of whom 400 are in production and 150 in administration.

The plant is equipped to process anodes that are high in bismuth, antimony, lead and nickel.

It receives 99.1% copper anodes from Glencore’s custom Horne Smelter, which processes e-scrap.

The CCR refinery’s products include copper cathodes, gold, silver and other specialty metals and chemicals, including selenium, tellurium, copper sulphate, nickel sulphate and a concentrate of platinum group metals.

370,000 tonnes Up to 1 million Troy ounces Up to 35 million Troy ounces

Whilst many of its North American competitors have been forced to end their operations, CCR Refinery management team has taken the strategic decisions needed to consolidate its activities and increase its results.

Adding value

Impurities that are not dissolved in the tankhouse electrolyte create anodic sludge.

CCR Refinery has the equipment and expertise to treat both in-house and externally sourced anode sludge, which is put in a rotary converter to separate the remaining impurities and produce golden anodes containing mainly precious metals. These are then processed at the silver refinery. High quality silver ingots (> 99.99% pure) are produced. Through various hydrometallurgical processes, high quality gold bars (> 99.99% pure) and a platinum / palladium concentrate are produced.

Enterprise management

Via two methods, CCR Refinery’s continuous Operational Improvement strategy focusses on goal setting, information gathering and results analysis to reduce process, product and service failures: • DMAAC Operational Improvement -

Define, Measure, Analyse, Improve (Améliorer), Control - aims to improve and control existing processes and products • DFSS (Design for Operational Improvement) - used for the development of new processes or products.

The site’s 5S program is a Japanese working method that builds a functional, efficient and safe working environment. There are three ‘field’ and two ‘sustaining and progress’ elements: • SELECT: Sort, Clear, Clear, Delete Perform a sector-by-sector analysis of the environment, real needs for optimising tasks and optimising space.

• STRUCTURE: Organise, Ranger, Locate, Tidy - Identify and implement best practices for developing space and work processes in a given space.

• SURPOLIR: Clean - Eliminate disruptive elements, unnecessary capital costs and waste.

• STANDARDISE: Create methods and processes to facilitate the execution of tasks, harmonise operations and limit health and safety risks.

• SUPPORT: Follow Up, Progress, Continuous Improvement - Measure results, maintain and continuously improve processes through practice. www.glencorerecycling.com www.affinerieccr.ca

8th ZAMBIA INTERNATIONAL MINING AND ENERGY CONFERENCE & EXHIBITION broNZe SpoNSor

ASSoCIAte SpoNSor

®

Concrete Impregnated Fabric

REGISTER YOUR INTEREST AT: zambia@ametrade.org www.ametrade.org/zimeczambia

21-22 JUNE 2018 LUSAKA | ZAMBIA

Supported by

#ZIMEC Copper Worldwide Vol 8 No 1

StrAteGIC pArtNerS

ELECTROWINNING | 13

w ww.copper worl dw ide. co m Contd from page 11

4 A more extensive transferring bar with two high-points

5 Hardware that incorporates the concept of double equalisation with double-line contacts

Different degrees of sophistication consider only extruded profiles with selected machining, but each design must answer a need. This last bar uses more copper compared with the single triangular bar mentioned above, and there is a trade-off to defining which design to use.

Considering the requirements of highcurrent density incorporated in the modernisation of one of our customer’s facilities, METALEX explored a modification to the existing cell top configuration, which was tested, validated and incorporated to allow the plant to reach operational current densities above 550 A/m2 with parallel electrodes. Figures 4 and 5 show a hardware that incorporates the concept of double equalisation with double-line contacts.

Under this arrangement, each electrode actively ends on slots made on both ‘towers’

of the intercell bars, which are U-shaped.

Meaning, both hanger bars connect the slot with two (2) lines of contacts, produced by the edge of the bar and the slot. To absorb a potential increase of local current, the traditional neutral end of the hanger bars, normally resting on the insulator, now rests on an auxiliary bar which connects all anodes or cathodes of the same wall.

In the event of a sudden increase of electricity, the result is the redistribution of the current through the auxiliary bars and, therefore, the ‘pick’ typically seen for an electrode under short is now compensated or redistributed to adjacent electrodes.

As a result, the current better distributes between electrodes - each cathode receives an equal amount of current, plating is more homogeneous and, consequently, cathode bundles are more even. Another consequence

of the redistribution of current is a reduction of the actual temperature of the bars, preventing the appearance of annealing, which weakens the bars and makes them sag or bend because of their weight or during the stripping operation.

In summary, Cell Top Furniture design is a function of a combination of requirements, from improved contacts to precise positioning of electrodes to allow full automation of harvesting operation. Designs are specific to each application and recommended to be evaluated through trade-off studies. A good CTF design allows intensification of the process being possible to exceed current densities of 550 A/m2. www.metalex.cl

Author: Alejandro Lillo, President, Metalex

IGBT chopper and thyristor rectifiers for electrowinning US-based Dynapower is the world’s largest independent manufacturer of IGBT chopper and thyristor rectifiers for mining and electrowinning applications. With experience in power conversion since the commercialisation of the thyristor, Dynapower has designs that cover all topologies up to 24 pulse. In addition to Dynapower chopper and thyristor rectifiers for mining, it also maintains exclusive rights for manufacturing and service of all products designed and manufactured by Rapid Power Technologies.

Dynapower’s mining chopper and thyristor rectifiers are engineered, designed, manufactured, and tested to internationally recognised standards including ANSI, IEEE, IEC, NEMA, UL, CSA, and JEC. Their design capabilities include the complete High Power Transformer Rectifier System - inclusive of fully integrated operator interfaces and control systems for a single unit or entire multi-unit SCADA network. With over 50

years of experience in high power conversion, Dynapower evaluates the impact of the rectifier system on the incoming power grid and designs power factor correction and harmonic filtering for the application to maximise system efficiency. Using the latest rectifier technologies, application engineers can recommend the optimum rectifier configuration for any mining project.

In situ operational efficiency is assured from the optimum configuration

Dynapower thyristor rectifiers are tested to internationally recognised standards

Copper Worldwide Vol 8 No 1

Dynapower also recognises that maintaining the efficiency of long-lasting rectifiers is crucial to the bottom line. That is why it offers digital control upgrades for any make of aging high power rectifier systems to ensure their safety and reliability and extend the life of their operation. www.dynapower.com

14 | WIRE/TUBE 2018 PREVIEW

www. c op p e r wor l d w i de. co m

New technologies at wire and Tube The next International Wire and Cable Trade Fairs take place from 16 - 20 April 2018 in Düsseldorf, Germany. Join the best.

Think global, act global.

Opening hours: Mon-Thu 9:00 a.m. - 6:00 p.m. and Fri 9:00 a.m. - 4:30 p.m. The great expectation this time is for over 70,000 international trade visitors and over 2,600

exhibitors across 16 Halls and an exhibition space of 110,000 m2. Some of the copper sector technology suppliers are previewed below. www.wire-tradefair.com www.tube-tradefair.com

Fresh casting and rolling innovations

Stand 11G40 – Continuus-Properzi invented and realised continuous casting and direct rolling for main nonferrous rod from 1947 to 1963, and this attitude for innovation has not changed since then.

The Properzi organisation provides technology for the production of aluminium and copper wire rod on a global basis, focusing on high technology machines completed with advanced furnaces for both metals. In particular, ETP copper premium rod can be

produced from copper cathodes, or FRHC rod can be produced by refining, in a proprietary furnace, low quality copper scrap to yield quality copper rod (see CONTENTS page).

The latest innovation is a new process from copper rod to wire with minimum size 1.8 mm based on a sophisticated Properzi mill called Microrolling®. Using the motor power the machine reduces the wire diameter but also anneals the wire, saving half of the energy required by a standard breakdown operation.

The production range is completed with the extrusion Properzi Forming machinery. The first Pro-Form is installed in the factory and available for trials with different materials or end products before delivery.

The famous North Entrance at Messe Duesseldorf

www.properzi.com

Continuous casting technology experts A Holton Crest continuous rotary extruder

Stand 09C06 - Upcast Oy upward continuous casting method - better known simply as the UPCAST® process - was originally developed by the Finnish Outokumpu Group in the late 1960s. This revolutionary technology was the outcome of innovative thinking and solid production experience.

The first UPCAST® production line - still in use - was installed in 1971 at the group’s own facilities in Pori. Since those times about 200 casting lines have been delivered worldwide, making UPCAST® the market leader in its field.

As a result of Outokumpu Group’s decision to

An UPCAST® production line. Photo: Upcast

divest its copper business, a new, independent company called UPCAST OY was established in 2006 to carry the UPCAST® legacy into the future. Central to this legacy has always been an innovative spirit in the R&D work, resulting in consistent high quality and strong commitment to customer support. www.upcast.com

Efficient solutions Hall 07a, Stand B03 / B04 / B15 - SMS group is a group of companies internationally active in plant construction and mechanical engineering for the steel and non-ferrous metals industry.

From pig iron production to metallurgical plant, rolling mills to strip processing lines, tube mills to thermal technology, SMS group covers all sectors, including electrical systems, automation and service. SMS group specialises in new plants and modernisations. It has some 13,500 employees who generate worldwide sales of more than EUR 3 billion annually.

It is listed at wire/Tube 2018 in 23 different Product categories. www.sms-group.com

Heavy-plate mill stand in the production shop. Source: SMS group

Copper Worldwide Vol 8 No 1

Stand 11H39 - Holton Crest designs and manufactures Continuous Rotary Extrusion (CRE) machines and is a global leader within the market, helping international manufacturers to produce copper and aluminium components, cables, wires and profiles.

With over 30 years’ experience, Holton Crest offers the best quality, durable machines with the most advanced technology to drive optimum production performance. Holton Crest has a wealth of experience in both mechanical and process engineering, enabling it to focus on the continuous rotary extrusion process as its key driver, ensuring that its machines are designed around optimising the process for the best possible production output.

Holton Crest is continually investing in R&D, product enhancements and new technological advances to future-proof the machines and provide the upgrades and additional features needed to run production at maximum capacity and efficiency. Its expertise doesn’t stop with the machines - Holton Crest provides a full ‘end to end’ service and focus on maintaining optimum production levels by managing the process effectively and keeping customers’ machines running at all times. Through its process assessment service, design, tooling, upgrades, consumables and maintenance spares and regular servicing, it can provide an individual, long term solution dedicated to its customers’ production needs (see page 22). www.holtoncrest.com

WIRE/TUBE 2018 PREVIEW | 15

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In-process measurement and control Stand 11D68 - Beta LaserMike (an NDC Technologies brand) - The Beta LaserMike products team from NDC Technologies will be debuting several new gauging solutions with modern sleek styling and expanded capabilities in connectivity, communication and control consistent with Industry 4.0.

The new LaserSpeed® Pro non-contact length and speed gauge offers the highest accuracy in the industry (better than ±0.03%) and the widest measurement depth of field for the full velocity range, with over 8,000 units

installed worldwide. The new UltraScan Pro provides high-speed, precision measurement of product wall thickness and concentricity and now includes faster processing and measurement, high-speed tolerance checking, multi-layer measurements (up to 4 layers), enhanced connectivity via built-in web server and other advances.

The new BenchMike Pro now has a larger, higher-resolution display and faster processing.

BenchMike is the industry’s leading off-line diameter and ovality measurement system, with over 15,000 gauges installed worldwide. The Beta LaserMike team will also be exhibiting the latest version of its InControl process controller and data management system - easy to set up,

A LaserSpeed® Pro non-contact length and speed gauge

simple to configure and effortless to use.

Also on display is the AccuScan 6000 Series, the industry’s only four-axis scanning diameter and ovality gauge, providing the highest accuracy to ensure products meet the tightest design and quality specifications. www.betalasermike.com

Progressive copper alloy rod casting Stand 10B52 - Rautomead Limited will be exhibiting its NEW SEALED LID continuous casting RSL technology designed for processing progressive alloy rods such as COPPER CHROME ZIRCONIUM. The single furnace multi-chamber design accurately controls and maintains the target composition by varying the feed rate of each of the constituent elements. The liquid metal is protected from the atmosphere by being enclosed within an argon gas environment.

Rautomead will also be exhibiting its conventional open furnace model continuous

casting machines, which are used for the production of high purity, high quality oxygenfree copper wire rods and also conductor alloy rods such as CuMg, CuAg and CuSn. This high quality, low cost, continuous cast rod material benefits manufacturers of enamelled wires, superfine wires, LAN cables, wiring harnesses, railway wires, shaped, contact wires, CTC and transformer strips. Equipment is available for production of 1,000 - 12,000 tonnes per year in the diameter range 8.0 - 30 mm.

You are invited to visit the Rautomead Stand 10B52

www.rautomead.com

Materials handling in all directions

Stand 6G14 - Combilift Ltd, the Irish specialist forklift manufacturer, now produces a wide range of customised handling solutions, from pedestrian pallet stackers, 4-way forklifts and sideloaders, up to straddle carriers which can transport oversized loads weighing 80 tonnes.

Exhibits this year, all designed for the safe, space-saving and productive handling, include models from Combilift’s core C Series, available with LP Gas, Diesel and electric / battery

power. Mast options offer lift heights up to 9 m and capacities of up to 25,000 kg. The C-Series Combilift can work in guided aisles as narrow as 210 cm. These robust trucks can work inside and out and on uneven terrain in all weathers. Sideways travel with loads resting on the platform also offers greater stability and safer manoeuvring.

Combilift continues to introduce at least one new model a year, so it’s always worth paying a visit to the stand. Pedestrian reach stackers are ideal for handling lighter palletised or long loads and ensure safe working conditions.

The Combi-WR4 multidirectional pedestrian reach stacker is the only truck of its kind to work in an aisle-width of 2.1 m. Its patented

Combilift Combi-WR4 multi-directional pedestrian reach stacker

multi-position tiller allows push button rotation of the rear wheel parallel from the tiller to the chassis and back for enhanced operator safety. www.combilift.com

Integrated extrusion lines provider Stand 13C34 - Presezzi Extrusion was set up in 1994 as a supplier of extrusion presses near Milan, in Northern Italy.

Thanks to constant investment in state of the art machinery and well-targeted acquisitions, today Presezzi Extrusion Group is able to offer customers complete extrusion lines for aluminium, copper, brass, steel and hard alloys.

The group is made up of four entities: Presezzi Extrusion S.p.A., COIM S.r.l., Profile Automation, and Melting Technology (divisions of Presezzi Extrusion). Each member of the

group is a leader in its own market and is able to provide the highest quality equipment for its own stage in the extrusion process.

The close synergies existing within the group allow customers to entrust all their extrusion requirements to a single, consolidated industrial entity. www.presezziextrusiongroup.com

Copper Worldwide Vol 8 No 1

A Presezzi COIM gas-fired billet heater in action

16 | COPPER ROD, TUBE AND WIRE

www. c op p e r wor l d w i de. co m

Recent Italian market developments Italy’s prominence in the European and World Copper Industry is confirmed by its being the sixth most important refined copper consumer in the world, and the second largest in Europe after Germany, writes Jonathan Barnes.

According to the World Bureau of Metal Statistics (WBMS), in 2016 Italy used 596 kt of high grade cathodes, less than half that of its dominant rival Germany (1,234 kt), but a significant magnitude more than its nearest regional competitors such as Poland, Spain, Russia and Turkey (ranging from 285 kt up to 464 kt). With domestic cathode production accounting for merely 1% of local demand, Italy is overwhelmingly dependent on imports for its refined copper needs. Bulgaria (22%), DR Congo (21%), Chile (16%), Peru (7%) and Austria (7%) comprised 73% of its supplies in 2016, with the remaining 27% coming from a wide variety of other trading partners.

Structural economic issues

Economic growth in Italy has struggled in recent years. The economy was in recession from 2011-2013 at the height of the eurozone crisis, and then only grew by 0.1% in 2014, before expanding moderately by 0.8% and 0.9% in 2015 and 2016 respectively. Italy is the third biggest economy in the eurozone with Gross Domestic Product in excess of US$ 2.2 trillion and a population of over 62 million, yielding a GDP per capita of US$ 36,800 in purchasing power parity terms.

Although the economy is fairly diverse with agriculture representing just 2% of GDP, industry 24% and services 74%, growth has been restricted by a number of structural factors. Foremost amongst these is that Italy has the second highest level of public debt in Europe (after Greece) which currently stands at 133% of GDP, resulting in periodic financial scrutiny of its weak banking sector by investors and its EU partners. The country is also characterised by high taxes, a rigid labour market and stagnant productivity. The official unemployment rate currently stands at 11.7%, but the youth unemployment rate is as high as 37.1%. Other long standing problems are the regional imbalance between the richer private sector dominated industrialised north, and the poorer subsidised south. Moreover, the taxevasive black economy is also quite significant, with estimates varying from 15-20% share of total GDP.

Brighter prospects

The most recent set of economic indicators published by the National Statistics Institute (Istat) paints a much more encouraging picture, suggesting that the Italian economy is finally shaking off its lethargy and is now accelerating more rapidly. GDP expanded at 0.4% quarteron-quarter in the third quarter of 2017, slightly faster than the 0.3% rate achieved in Q2. The third quarter growth rate represented a 1.7% year-on-year increase from the corresponding period of 2016. This is quite significant as it equates to the fastest rate of annual growth

1 Italy quarterly semis production (kt, % change)

recorded since the second quarter of 2011.

Domestic demand has remained the main engine of growth with gross fixed investment in construction, capital equipment and transport increasing by 3.0% compared to the prior quarter.

Private consumption is also improving, rising by 0.3% in Q3 of 2017. Consumers are benefitting from low inflation levels and rising consumer confidence, which rose to 116.6 in December from 114.4 in November, the highest level for almost two years. Business confidence is also improving markedly, with the IHS Markit manufacturing Purchasing Managers’ Index coming in at the high level of 57.4 in December 2017, though slightly below November’s multi-year high of 58.3.

The Index is nevertheless considerably above the level of 50 that distinguishes expansion from contraction. Increases in output, new orders and exports were the main contributors to the Index reading in December.

Copper and brass sectors

Italian statistics on the non-ferrous metals sector are compiled by ASSOMET (Associazione Nazionale Industrie Metalli Non Ferrosi) and the production data for recent years are reproduced in the accompanying Figure 2. The statistics reveal that the total annual output of copper and alloy semimanufactures has been high but stable since 2013, with production in a narrow range of 1,045 kt to 1,062 kt (gross weight). Reflecting the improving economic environment, total output rose during the first nine months of 2017, climbing 2.9% year-on-year to 826 kt compared to 803 kt in the prior year period. If this performance is repeated in the final quarter then annual output will reach its highest level in this five-year (2013 - 2017) timeframe, exceeding 1,080 kt.

Copper Worldwide Vol 8 No 1

3 Aerial view of the S.A. Eredi Gnutti Metalli SpA plant in Brescia (taken in 2013)

Copper Alloys 2018 takes place in Milan in April (see page 19)

Major industrial groups

Two product lines comprise almost 90% of the volume of Italian semi-manufactures production. The largest of these is alloy rods, bars and sections, where Italy’s output of 510 kt in 2016 ranks second in the world only behind China. The majority of these products are ultimately destined for the building and construction and industrial machinery and equipment sectors. The four major players in this business are the local companies Trefilerie Carlo Gnutti, Almag, Eredi Gnutti (part of the EGM Group which also includes flat rolled products maker Ilnor), and the European group KME (which also produces a full line of brass mill products). There are also a number of smaller specialist mills, but most of the industry is centred around Brescia in the north of Italy, east of Milan.

The copper wire rod sector in Italy is comprised of two large industrial groups and one minor player. Carlo Colombo has the largest installed capacity with a 240 ktpy

COPPER ROD, TUBE AND WIRE | 17

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2 Italian Production, Consumption and Trade in Semi-Manufactures (KT, % Change)

Year Year Year Year Q1-Q3 Q1-Q3

2013 2014 2015 2016 2016 2017 % Change

Production Copper Wire Rod & Wire

420

431

439

419

316

328

3.7%

Copper Rods, Bars & Sections

13

14

13

12

9

9

-4.3%

Copper Sheet, Strip & Plate

34

29

34

23

18

20

8.2%

Copper Tube

51 49 49 47 37 42 14.7%

Alloy Wire

1 1 1 1 1 1 22.2%

Alloy Rods, Bars & Sections

472

484

485

510

389

397

2.2%

Alloy Sheet, Strip & Plate

50

40

37

36

30

26

-13.2%

Alloy Tube

4 4 4 4 3 3 7.4%

TOTAL

1045 1051 1062 1052 803 826 2.9%

Exports Copper Wire Rod & Wire

84

82

83

79

60

55

-7.8%

Copper Rods, Bars & Sections

5

5

5

5

4

3

-5.3%

Copper Sheet, Strip & Plate

20

22

24

16

12

13

6.3%

Copper Tube

37 39 44 48 36 38 5.2%

Alloy Wire

3 5 6 5 4 4 -2.6%

Alloy Rods, Bars & Sections

83

91

94

102

80

81

0.8%

Alloy Sheet, Strip & Plate

10

11

12

12

9

8

-8.4%

Alloy Tube

8 7 8 7 5 5 -7.1%

TOTAL

250 262 275 272 210 207 -1.3%

Imports Copper Wire Rod & Wire

124

116

128

146

116

90

-22.4%

Copper Rods, Bars & Sections

8

8

9

10

7

10

38.0%

Copper Sheet, Strip & Plate

32

22

29

46

37

28

-24.4%

Copper Tube

28 31 26 28 21 24 10.4%

Alloy Wire

17 18 15 13 10 10 3.7%

Alloy Rods, Bars & Sections

46

48

56

52

40

42

4.2%

Alloy Sheet, Strip & Plate

11

10

11

10

8

8

3.8%

Alloy Tube

11 12 12 14 11 12 4.0%

TOTAL

277 265 287 318 250 223 -10.9%

Net Trade Copper Wire Rod & Wire

-40

-34

-46

-67

-56

-34

-38.0%

Copper Rods, Bars & Sections

-3

-3

-4

-6

-3

-6

84.5%

Copper Sheet, Strip & Plate

-11

0

-6

-31

-25

-15

-39.7%

Copper Tube

9 8 17 20 15 14 -2.4%

Alloy Wire

-14 -14 -9 -8 -6 -7 7.3%

Alloy Rods, Bars & Sections

37

43

39

50

40

39

-2.6%

1

1

2

1

0

-94.1%

Alloy Sheet, Strip & Plate

-1

Alloy Tube

-3 -4 -4 -7 -6 -7 13.6%

TOTAL

-27 -3 -12 -46 -40 -16 -60.8%

Southwire line at its plant in Pizzighettone.

Until mid-2016, the company had also operated a Contirod mill at a separate site near Pisa with a capacity of 150 ktpy. Reduced European demand meant that the company had never managed to operate either line near its rated capacity and the decision was made to close the Pisa plant in 2016 and consolidate all production at Pizzighettone. A bitter strike ensued at Pisa before the decision was ultimately ratified in the autumn of 2016.

The other major producer is Aurubis Italia, a subsidiary of the German Aurubis group, based in Avellino, near Naples in Southern Italy. This operates a 205 ktpy capacity Contirod line with output of 175-180 ktpy. KME Italy also owns a small 30 ktpy wire rod mill, though it is unclear if this is in operation. Total Italian copper wire rod production fell 4.6% to 419 kt in 2016, compared to 439 kt in 2015, due to the impact of the strike at Carlo Colombo. However, output rose by 3.7% in Q1-Q3 of 2017 as this lost ground was made up.

Developments in semis trade

Italy is a major trader in semi-manufactures with traded volumes accounting for between 25-30% of production and consumption. The country is a significant net importer of wire rod and drawn wire, and this increased measurably during 2016 as consumers mitigated their risk during the strike at Carlo Colombo, but has since returned to normal levels in 2017. Official trade data shows a pronounced spike in exports of wire rod in 2016, but this is erroneous as the partner countries do not show this - the data in the table is an estimate of their true level. Italy is a net exporter of alloy rods, bars and sections and copper tube (mainly ACR tube), but a net importer of most other brass mill products.

Improving outlook

The more encouraging economic outlook for Italy and Europe should enable the Italian copper semis industry to continue to expand in 2018. The biggest threat to growth is likely to come from the rapid rise in copper and zinc prices through 2017, which if continued through 2018 may result in a resurgence in substitution pressures in lower added value end use applications.

Consumption Copper Wire Rod & Wire

460

465

485

486

372

362

-2.6%

Copper Rods, Bars & Sections

16

17

17

18

13

15

19.6%

29

39

53

43

35

-19.5%

Copper Sheet, Strip & Plate

45

Copper Tube

42 41 32 27 22 28 26.2%

Alloy Wire

15 15 11 9 7 8 9.2%

Alloy Rods, Bars & Sections

436

441

446

459

349

358

2.7%

Alloy Sheet, Strip & Plate

51

38

36

35

28

26

-10.1%

Alloy Tube

7 8 8 11 9 10 11.7%

TOTAL

1072 1054 1074 1099 843 841 -0.2%

Data: ASSOMET, WBMS, UNCOMTRADE, Estimates.

Copper Worldwide Vol 8 No 1

Jonathan Barnes is now an Independent Analyst

Author: Jonathan Barnes has worked as a principal consultant on copper demand for over 25 years with CRU and Wood Mackenzie. He is now an Independent Analyst on the copper industry, semi-manufactures and wire and cable markets.

E-mail: jpb1.barnes@gmail.com

18 | EVENT REVIEWS

www. c op p e r wor l d w i de. co m

Asia Copper Week roundup Around 2,000 delegates gathered in Shanghai for the 6th Asia Copper Week from 28 November 1 December 2017, which featured the 13th Metal Bulletin Asia Copper Conference.

The conference reports the scales have gradually tipped in favour of sellers for 2018, especially in regard to copper concentrates.

Electrolytically refined cathodes traded at higher premiums compared with SX-EW cathode in 2017. The typical price differential between ER and SX-EW cathode is around US$ 5-10 per tonne, while a wider range of US$ 10-15 per tonne had been prevalent for several months in 2017, and some thought it would widen further in 2018.

Chile

Market participants were unsure about how much tonnage they could secure from Codelco and Enami due to lower exports of cathodes expected from these producers in 2018, while their smelters undergo long periods of maintenance to comply with new environmental regulations. Smelting capacity at Codelco Chuquicamata will fall by 50,000 tonnes in 2018 as it closes down one of the furnaces to undergo an upgrade. Codelco said around 50% of its production volume for next year had already been placed as of 30 November. It sells around 35% of its cathode

Asia Copper Week 2017 in Shanghai

Concentrates will be in demand in 2018

production to China, 15% to the rest of Asia, 15% to Europe, 25% to the United States and 10% to South America.

be introduced in China from the beginning of 2018, with the cost estimated at US$ 3.77 (25 yuan) per tonne.

China intends to adopt thresholds of 1% for impurities allowed in non-ferrous scrap imports to China and 0.5% for ferrous scrap imports, it announced to the World Trade Organisation in November. The changes would cause dislocation and disruption in copper flows because scrap supply generated by mature economies would have to find a new home while Chinese consumers look for alternative options, including importing more concentrates and refined copper.

The 7th Asia Copper Week will take place from 13 - 16 November 2018 in Shanghai.

China

Tongling predicted a net global production increase of near to 800,000 tonnes of copper in concentrates in 2018, including 100,000 t in China (15,000 t for Tongling), 30,000 t in Australia and growth at Chile’s Escondida mine. On the smelting side, Tongling saw globally a net increase in requirements of close to 620,000 t of copper in concentrates. Chinese copper smelters may have to reduce smelting capacity by 30% during the winter months if the government’s pollution index target is not met.

Higher emission costs for smelting slag will

www.asiacopperweek.com www.metalbulletin.com

Copper recovery a focus at ALTA 2018 Organised by ALTA Metallurgical Services, ALTA 2018 takes place from 19-26 May in Perth, Australia This is the 23rd year of one of the world’s premier annual metallurgical events, here comprising three technical conferences, three short courses and an international trade exhibition. The preliminary Conference program includes 88 papers from 24 countries. In a Keynote Address, Dr Kathy Sole (Kathryn C. Sole Consulting), John Parker (Process Ideas), and Peter Cole (Peter Cole Metallurgical Services), all of South Africa, will look at ‘Flowsheet Options for Cobalt Recovery in African Copper-Cobalt Hydrometallurgy Circuits’.

In the main Sessions, Ausenco/Miller Metallurgical International Limited of Australia will go through ‘Design and Material Selection Considerations for Solvent Extraction and Electrowinning Plants’.

Also China Nerin,in their paper entitled ‘The solutions of increasing the copper and cobalt recovery rate for the L-SX-EW plants in D.R. Congo’ (Authors: Wang Wei, Zhang HaiBao, Zhang XiaoBing and Chen YanJie, China Nerin Engineering Co., Ltd, P.R. China), will analyse the technical considerations

COM 2017 metallurgy streams Further papers presented at the 56th Annual Conference of Metallurgists - Part 2 of Phillip Mackey’s report. A suite of seven papers described new advances in the leaching of a number of important copper minerals, including the leaching of chalcopyrite, covellite, chalcocite and enargite: Use of Glycine as an Alternative Lixiviant to Leach Copper from Chalcopyrite D. Shin, J. Ahn and J. Lees, University of Arizona, Arizona, USA Adsorption and Oxidation Properties of Activated Carbon and AF 5 in the Copper Sulfide Minerals Leaching Process F. Jahromi and A. Ghahreman, Queen’s University, Ontario, Canada

Enhancement of Copper Extraction from Covellite by Mechano-chemical Activation M.Matsuoka, J. Chen, K. Horiuchi, G. Granata and C. Tokoro, Kansi and Waseda Universities, Japan Sulfate Leaching of Chalcopyrite: The Use of Potassium Iodide to Enhance the Dissolution of Copper G. Granata and C. Tokoro,A. Fuwa and A.Miura, Waseda University and Nippon Minin, Japan Quantification and Speciation of Copper, Arsenic, and Iron in Atmospheric Leaching of Enargite and Chalcopyrite in the Presence of AF5 F. Jahromi and A. Ghahreman, Queen’s University, Ontario, Canada Hydrochloric Acid in Hydrometallurgy F. Habashi, Laval University, Quebec, Canada A New Perspective on Kinetics of Copper Worldwide Vol 8 No 1

and solutions for copper and cobalt leaching solvent extraction-electrowinning (L-SX-EW) plants in D.R. Congo, such as the selection of the leaching and washing processes, the SX process, and the parameters for the removal of Fe and Mn. At the beginning of ALTA 2018, several Short Courses take place, to include: ‘A-Z of Copper Ore Leaching’ (Saturday 19 May), and ‘SX and its Application to Copper, Uranium & Nickel-Cobalt’ (Sunday 20 May). www.altamet.com.au

Chalcocite Leaching M. Hashemzadeh, V. Concha S., and W. Liu, University of British Columbia.

Mineral Processing On-belt analysis remains an important item in processing all ore types: Faster Analysis: Recent Advances in Geoscan On-Belt Analysis Techniques Allowing for Rapid Real-Time Measurement of Minerals L. Balzan, A. Harris and Z. Bauk, Scantech International, South Australia, Australia Increasingly, ore sorting in mineral processing serves to remove barren ore ahead of crushing: Technical Review and Evaluation of Ore Sorting Technologies on Precious Metals Operations B. Hilscher, P. Nayak and L. Lorio and N. Yoon, Sacre-Davey Engineering, BC, Canada. www.web.cim.org/com2017

EVENT PREVIEWS | 19

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31st International Copper Conference

The 30th MB International Copper Conference in Leipzig in 2017

The 31st Metal Bulletin International Copper Conference takes place from 7-8 March in Madrid, Spain. The Session I Executive Panel on 7 March will include Javier Targhetta, President - Atlantic Copper, Jürgen Schachler, CEO, Aurubis AG, and Marco Calamia, Chief Metal Officer, KME Group. Session II covers Copper Mining, with Humberto Costa Leite, President & Chief Executive Officer, Almina SA, and Jorge Cantallopts, Director of Research and Policy Planning, Chilean Copper Commission.

There follows a World Copper Mine Supply, Recycling and Fabrication presentation by Carlos Risopatron, Director of Economics and Environment, ICSG. The afternoon sees a Copper Scrap Panel and a look at China Scrap Policy. Session III then looks at copper prices.

Session IV on 8 March tackles Refined Copper and Consumers, with Panos Lolos, Commercial Director, Halcor on the consumers Panel. After a look at China Copper Consumption, Bernard Respaut, Chief Executive, European Copper Institute, looks at The Role of Copper in a Greener Economy, before final papers on Electric Vehicles and Copper End Uses close the Conference. For an additional 400 euro fee to registered delegates, is the option of a Field Trip to Atlantic Copper’s Huelva smelter and refinery from 8-9 March. www.metalbulletin.com/events

Copper Alloys 2018 Successor to the Brass Alloy conference in Stockholm in 2016, the Copper Alloys 2018 Conference is being held in Milan, Italy from 11-12 April 2018. Jointly presented by Deutsches Kupferinstitut and Swerea KIMAB, the Conference program is now available to view, and features Keynotes from Deutsches Kupferinstitut and Saarland University, Germany, and KTH Royal Institut of Technology, Sweden. There follow the first pair of Parallel Sessions, on Copper material and corrosion, and Processing, machining and recycling respectively. Day two sees further Parallel Sessions on Material properties and application, and Material development and characterization to conclude.

Registration costs EUR 730 until 11 March. www.copperalloys.org

Copper Cobalt Africa The 2nd Copper Cobalt Africa Conference takes place from 8-11July 2018 in Livingstone, Zambia in association with the 9th Southern African Base Metals Conference. It is jointly hosted by the Mining and Metallurgy Technical Programme Committees of the Southern African Institute of Mining and Metallurgy (SAIMM). The coordinator is Raymond van der Berg, SAIMM Head of Conferencing. The geology and mineralogy of the ores in the African Copper Belt often have very high grades as well as the presence of cobalt. www.saimm.co.za

31st

Conference 7-8 March 2018 | Ayre Gran Hotel Colón, Madrid, Spain Linking up the value chain to foster debate and global industry growth

metalbulletin.com/events/copper

Copper Worldwide Vol 8 No 1

20 | CONTRACTS & PEOPLE

Changes on the SMS group Managing Board Harald Rackel, currently Head of Digitalization at SMS group GmbH, is leaving this post on 31 March 2018 and from 1 April 2018 will join the Managing Board of elexis AG, a subsidiary in the SMS group. On 1 July 2018 he will take over the position of CEO from Siegfried Koepp, who is due to retire on 30 June.

Dr.-Ing. Katja Windt has been appointed Managing Director of SMS group GmbH as from 1 April 2018. As a member of the Managing Board, she will be responsible for the Digital Solutions and Electrical and Automation Systems Divisions.

To take on her new post, the Doctor of Engineering specialising in Production Technology is leaving Jacobs University Bremen. She has been President of the University for several years. Over more than ten years in this function, she has, among other things, successfully implemented digitalisation and logistics projects for customers in the steel industry.

www. c op p e r wor l d w i de. co m

High plant recovery from sulphide concentrates

A quadrupling of gold recovery in Armenia’s GPM was achieved through Albion ProcessTM supply by Glencore Technology

Using Glencore Technolog y’s atmosphe ric le aching A lbion ProcessTM , GeoProMining LLC (GPM) has successfully increased recovery from sulphide concentrates in its Ararat plant in Armenia from 20% to over 95%, beyond all expectations and targets. The

plant was commissioned by Glencore Technology in June 2014 and achieved full capacity after three months. GPM owns and operates the Zod Gold Mine and Ararat Processing Plant in Armenia to produce gold and silver bullion. The Albion ProcessTM plant, installed as part of a facilities

www.sms-group.com

Concentrator technology orders Outotec has been awarded a contract for the delivery of minerals processing technology to a new copper concentrator to be built in Turkey.

Supply scope includes engineering of the concentrator and the delivery of main process equipment including a semi-autogenous and a ball mill, a HIGmill® for regrinding, pumps, thickeners, flotation cells, analysers, and automation. Deliveries will start in the first half of 2018.

The supplier has also been contracted to deliver process equipment for a copper concentrator expansion in Chile. The scope of delivery includes two HIGmill ® high intensity grinding mills and thickeners for concentrate as well as for tailings treatment. In addition, Outotec will provide engineering, spare parts and installation supervision services for the delivered equipment.

The deliveries will take place by the end of 2018. The expansion is expected to increase the life of the mine by more than 50 years. www.outotec.com

CONTIROD ordered by Jiandong Alloy

View from the CONTIROD® line to the shaft furnace

Jiandong Alloy Technology Co. Ltd. based in Nantong City, Jiangsu Province, has placed an order with SMS group to supply a CONTIROD® plant of type CR 3500. Designed for casting and rolling wire rod in one continuous process, the line will have a production capacity of 35 tph copper wire rod. The CONTIROD® CR 3500 will mainly be used to produce ETP (Electrolytic Tough Pitch) copper wire. The scope of supply will

Change in Rhein-Rod brand ownership Aurubis AG and Codelco Kupferhandel GmbH signed a purchase agreement for the acquisition of Codelco’s share in Deutsche Giessdraht

GmbH by Aurubis, subject to antitrust approval. Until now, Aurubis has held 60% and Codelco has held 40% of the joint venture.

include a shaft melting furnace, a twin-belt casting machine with a large cross-sectional area of 6,510 sq. mm, a rolling mill with separate individual drives for all twelve stands, a deoxidation and cooling line as well as a wire coiling station, an automatic strapping unit and a foil packaging plant for the copper wire rod coils.

With its new, energyefficient technologies (lambda control on the shaft furnace, AC motors, deoxidation and cooling lines with separate media circuits) and high performance capability, the CONTIROD® CR 3500 qualifies for the SMS group Ecoplants label for environmentally friendly technologies. Commissioning is scheduled for the first quarter of 2019. CONTIROD® is a registered trademark of Aurubis Belgium.

refurbishment, is used for the oxidation of the sulphide concentrate prior to its treatment in the existing Carbon in Leach (CIL) plant. The flowsheet was configured such that the CIL would treat flotation tailings and oxidised residue from the Albion ProcessTM. The design basis for the Albion ProcessTM at GPM was oxidation of 100,000 tpy of concentrate to give an overall production of 100,000 TOz of gold per annum from concentrate and flotation tailings.

The design recovery of gold from the Albion residue was 92% but the plant frequently achieves over 95% recovery, with an overall plantwide design recovery of 86%, but commonly achieving 88%. The plant has exceeded nameplate production, treating 120,000 tpy concentrate with an overall production of 120,000 TOz annually. GPM is currently evaluating an expansion project comprising a second line of an Albion ProcessTM Plant. www.glencoretechnology.com

Reif becomes CEO of Otto Junker

Mr. Bernward Reif is CEO of Otto Junker GmbH.

Mr. Bernward Reif has joined Otto Junker Group as Chairman of the Managing Board (CEO) of Otto Junker GmbH from 1 November 2017.

Bernward Reif started his career in the metal industry at ABB, with roles including ABB Industrietechnik AG and ABB Automation Systems in Mannheim. In 2006 he joined SMS Siemag and ultimately SMS Group GmbH as a member of the divisional management team. He has gained extensive international experience in sales, project management, www.sms-group.com development of new business fields, strategic planning and corporate governance and possesses in-depth market, industry and product Deutsche Giessdraht produces knowledge. He said the Otto around 240,000 tonnes of copper Junker Group has every potential for successful business development. wire rod per year. www.aurubis.com

Copper Worldwide Vol 8 No 1

www.otto-junker.de

CONTRACTS & PEOPLE | 21

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New President and CEO at Boliden Mikael Staffas has been appointed as new President and CEO of Boliden.

He will assume the position on the 1st of June 2018. Staffas has been at Boliden, and a part of Group Management, since 2011. First he held the position as CFO, and from 2015 he has been the Director of Business Area Mines. The recruitment of a new Director for Business Area Mines is underway. It was announced on 24 October that Lennart Evrell had decided to resign from the position of CEO for Boliden effective half way through 2018.

Thompson to be new Chairman at Rio Tinto

Simon Thompson will become Rio Tinto Chairman in March. Photo: Rio Tinto

Rio Tinto has appointed Simon Thompson as Chairman as at 5 March 2018. He succeeds Jan du Plessis, who will step down from the Rio Tinto board on the same date after serving almost nine years as Chairman. Mr Thompson joined the Rio Tinto board as a

non-executive director in 2014.

He worked for the Anglo American group from 1995 to 2007, including time as Executive Director of Anglo American Plc, and Chief Executive of the Base Metals Division, among other roles. www.riotinto.com

OHL retained at El Teniente for efficiency push

Anglo American selects Jacobs for Los Bronces Jacobs Engineering Group Inc. is to provide engineering services to Anglo American’s Los Bronces copper mine, located approximately 40 miles northeast of Santiago, Chile at an altitude of over 11,000 feet. Under the terms of the three-year Master Services Agreement (MSA), Jacobs will provide engineering services and field technical assistance to support the mine’s sustaining capital program, as well as lead the evaluation and development of environmental permits. In addition, Jacobs will support the preparation of bidding rules for future scopes of work, including studies, engineering services and construction phases. www.jacobs.com

Southeast Copper

Antaike reports CHALCO Southeast Copper Co.’s 400 ktpy copper smelting project using the double flash process is expected to be completed in the second half of 2018.

Southeast Copper Co. is owned by Yunnan Copper Co., Ltd. and Fujian Investment Corporation in the ratio 60% share to 40% share respectively. www.antaike.com

Mr. Gustav Kildén has been appointed Senior Vice President, Strategic Customers and Business Development and member of Outotec’s Executive Board as of 1 September 2017. The change was announced when Adel Hattab, Executive Vice President, Strategic Customers and Business Development, left Outotec to join another company. www.outotec.com

www.boliden.com

Mikael Staffas has been appointed as new President and CEO of Boliden.

In brief…

Spain’s OHL Group has been awarded a US$ 20 million (16 million euro) research and development and innovation (R&D&I) contract by Codelco to boost service efficiencies at the El Teniente underground mine in Chile. The contract includes the support service to be given to the operation and maintenance of the canal for the transport of slurry, tailings and industrial wastewater in the mine. OHL is using drones that will enable observation, monitoring and inspection with detailed information and control of all of the activities of the tailing canal. The scope of the work includes the efficient and timely ongoing maintenance, operational

support and industrial washing of the equipment and installations in the various industrial wastewater, thickening and recirculation units, tailing process, hydrometallurgy process, support to maintenance service and Sewell process.

This project follows several others performed by OHL for Codelco División Ministro Hales in Antofagasta. In early 2017, Codelco awarded OHL a 145 million euro contract for the expansion of the Talabre Dam in Calama, also in Antofagasta. The OHL Group has worked on infrastructure projects in Chile since 1981. www.ohl.es

Cobalt catalyses DR Congo code reform The Democratic Republic of Congo’s new proposed mining code sailed through the Senate without opposition in January. The revised version of the 15 year old mining code sets out taxes of up to five percent on strategic metals, most likely including cobalt, and six percent on precious stones. The price of cobalt has risen by 127% in one year to US$ 75 000 a tonne, due to the global boom in demand for toprange batteries. DRC authorities also want to ensure the repatriation of at least 40% of the revenue of minerals that are sold for export. Minister of Mines Martin Kabwelulu has overseen the industry since February 2007.

Multinational firms including the Congolese subsidiaries of China

Molybdenum, Rangold, Glencore and MMG have said the new mining code would significantly weaken the confidence of investors.

President Joseph Kabila had not yet approved the new code as at 5 February, according to Reuters, but State miner G ecamine s Chairman Albert Yuma told African Mining Indaba delegates in early February that existing deals did not give Gecamines or the State a sufficient share of the nation’s mineral wealth, and that talks on contract revisions should to start in the second quarter and be completed by the end of 2018 or start of 2019. www.reuters.com www.news24.com

Copper Worldwide Vol 8 No 1

Dundee Sustainable Technologies Inc. has received US$ 1.25 M Sustainable Development Technology Canada funding for development of its patented arsenic vitrification process to deliver an 8 tpd capacity plant to an overseas metals processing facility. Construction will be completed in 3Q 2018, with operation after commissioning in late 2018 or early 2019. www.dundeetechnologies.com

The BMW Group and the Chilean copper mining company Codelco have signed an agreement to cooperate on a sustainable and transparent supply of copper. From the mining of the metal to installation in the automobile, Codelco and the BMW Group will form the start and end point in the copper supply chain. www.bmwgroup.com

HBM Test and Measurement (a Spectris plc subsidiary) has launched a new Strain Measurement online guide focusing on the selection, installation, data acquisition, and analysis of electrical as well as optical strain gauges. The new portal contains comprehensive information about measuring strain, including valuable tips from leading experts. www.hbm.com/en/6896/ strain-measurement-basics

The B.C. government in Canada has rejected the proposed US$ 1.5 billion Ajax copper-gold mine project in Kamloops, by declining to issue an environmental certificate. The new government has formally adopted the United Nations Declaration on the Rights of Indigenous People (UNDRIP).

The operator and 80% owner of Ajax is KGHM Polska Miedz. www.kghm.pl

At the 17th CRU World Copper Conference/CESCO Week in Santiago in April, the ICA will host a workshop on important copper demand issues and trends in material substitution, followed by a future-looking panel session on copper demand. At these sessions, ICA will present latest information on the >2 Mt motors market, global substitution, and more. www.copperalliance.org

22 | IN PROFILE

www. c op p e r wor l dw i de. co m

Interview: Malcolm Ladd, Managing Director Holton Crest Ltd Since showcasing its continuous rotary extrusion (CRE) machine design successfully at wire 2016, UK-based Holton Crest Ltd has embarked on an ambitious development programme to drive continuous improvements in extrusion processes and lead the technological revolution to bring next generation CRE applications to market.

We also want to give work experience to the new generation of engineers. We deal with many different areas such as import, export, buying, selling, engineering, subcontracting, free issuing, and more, so can provide a real insight into industry. By investing in young engineers, I feel passionately that we are putting a bit back into society at a technology level, and it is definitely something I want to do more of.

Malcolm Ladd is Managing Director of Holton Crest Ltd

How long has Holton Crest been in existence and how did you come to create the business?

Holton machines have been in existence for over 30 years, a testament to the outstanding build quality in itself, but Holton Crest was established in 2006 due to a restructuring of the parent company and subsequent management buyout under which we bought the rights to the IP from Outokumpu to support and supply CRE machines. Since then, we have focused on developing and growing our core engineering and support team to its current level. By investing in the best technology, talent and engineering skills in partnership with some of the world’s leading producers and institutions, Holton Crest has already seen the fruits of its labours with many different machine configurations being installed all over the world.

What is your management style and how do you recruit and train people for that core team?

We are making a long term investment in the skills of our people, both in mechanical and process engineering, with a strong focus on new technology. As a business, we are dependent upon people coming through with a specific set of engineering skills, but these are not readily available in the UK, so we decided to develop people internally via a graduate training programme that is now coming to fruition. It takes so long, even with someone at degree level, to bring them up to the level of an experienced engineer, on projects that last twelve months at a time, but is well worth the investment to provide the level of expertise that our customers demand.

What are the fundamental tenets of the Holton Crest market strategy and your customer approach?

From the very beginning, we have had a customer focussed philosophy that we will provide the best solution and most appropriate technology that we can apply to any particular application at the time. We never compete solely on price and have always offered the best advice for our solutions and applications. It is an individual customerdriven (not price driven) area, so we always aim for effective solutions that deliver the required results whilst controlling the costs.

We are involved in all areas of the process and have a clear appreciation and understanding of the needs of the client’s team running the process, the machine and the ancillaries. This includes maintenance, production, process technologists, and senior management, as we have skills in all those areas. This makes for strong and lasting customer relationships based on trust.

You presently offer HC1100, HC2200 and HC4000 extruders. How successful have these various models been and where in the world have they been installed?

Geographically our systems are installed in Europe, North and South America, at customers where reliability, efficiency and productivity are extremely important for producing their end products. Around one third run specifically with aluminium, one third are for copper processing, and one third are dual systems capable of transforming both metals. All feature our new digital control software.

The fruits of our labours have been realised over the last two years, during which we have supplied multiples of five different configurations of our dual axis ‘next generation’ HC machines, including two large systems, several small ones, and one with particle feed.

The recent configurations include 1 wire in 1 product out, 1 in 2 out, 2 in 1 out, and 2 in 2 out. The 1 in 2 out machine for aluminium Copper Worldwide Vol 8 No 1

HC4000 with single wire in and 2 products out in operation at site

Holton Crest Twin Coiler

in Europe we believe to be the largest single machine CRE contract to date, which really demonstrates our capacity to deliver at the highest level, with many different applications.

What is your typical scope of supply?

Some of our installations are complete turnkey supply and some are run from a caster. Our core package is a machine, control system, hydraulics, oil and coolant, and product cooling. We don’t get involved with either the casters, or molten metal systems themselves.

Rather than selling specialist coilers and payoffs separately, we will provide a coiler and/or payoff for our machines. Our coilers are designed around our own processes, and can come with auto changeover at full speed.

Payoffs are dependent upon what the customer wants - rotary, automatic, vertical, and so on.

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TAILOR-MADE INNOVATIONS FOR COPPER AND COPPER BASED ALLOYS ROLLER HEARTH FURNACE

my Acade R E K N JU 8 OTTO th pril 201 th - 25 A 24 OTTO JUNKER GMBH Jaegerhausstr. 22 52152 Simmerath Germany

WE

Phone: +49 2473 601-0 | Fax: +49 2473 601-600 E-Mail: info@otto-junker.de

WWW.OTTO-JUNKER.DE

UNDERSTAND METALS

Continuous Process by Design CRE Specialists

Quality Machinery

Advanced Technology

With over 30 years experience, we are experts in Continuous Rotary Extrusion, with machines specifically designed around process needs.

Holton Crest machines are manufactured using the very best materials and tooling expertise to provide robust and reliable extrusion solutions.

With continual investment in R&D, specialist skills and new technology, we are leading the way in technological advances to future-proof our machines.

Holton Crest is a Global leader in designing and manufacturing Continuous Rotary Extrusion machines, helping international manufacturers to produce copper and aluminium components, cables, wires and profiles.

To find out more, contact our experienced team on +44 1202 681 501 or email us at info@holtoncrest.com Holton Crest Limited 10 Cowley Road, Poole, Dorset, BH17 0UJ, UK www.holtoncrest.com

Copper Worldwide Vol 8 No 1

See us at Wire 2018 16-20 April Stand 11H39

24 | IN PROFILE

www. c op p e r wor l d w i de. co m

Product cooling is an extremely undervalued part of the process. If you make a product using CRE, particularly in copper, it comes out 5-600°C. If you don’t cool it quickly and efficiently, then you will end up with oxidised product. With aluminium the heat changes the tensile strength of the product, so cooling and drying is a very important part of the process.

Until the end product comes out the back of the machine dry and cool, the process isn’t finished, so it is unlikely that we would sell a machine without our cooling and drying system, it would compromise our commitment to quality.

The Continuous Rotary Extrusion process was first used in the early 1970s. How has the process technology been developed further in the last five to ten years?

Our philosophy is to always lead with the CRE process, so over the years we have redesigned our machines around the process. With regard to development and new designs, we have built on the original machine specifications that we purchased in 2006 and redesigned it to our own specification. We have designed, built and put into production a new generation of machines with new technology and digital control that have been installed in multiple configurations as highlighted above.

With the new digital controls, we can now change running parameters as we go, whereas we couldn’t before. With full PLC and near real time control we can now introduce adaptive control for a stable process with precise control measures. We can now keep the process stable for long production runs or, with adaptive control, we can now allow it to move process parameters and deliver specific process requirements that we programme into the system.

What initiatives has Holton Crest taken in the application of Industry 4.0, for example in the area of near real time digital process control?

A lot of our research has been put into the software, user interface and control system, which has enabled us to launch a new software and adaptive control system with a response time of 1 ms that will hold the process to within 10 microns of its optimum position.

We are now working on developing artificial intelligence to learn material recipes and running techniques, by running the process so it is inherently unstable. Artificial intelligence will try alternative settings and learn the optimum settings for a particular material, given some input parameters. This makes the process even more efficient, and not just by small margins - we are looking at 20 to 50 percent and more, which could be gamechanging for many of our customers.

In process efficiency terms, how are you addressing scrap levels, and what kind of utilities recycling is now possible?

Special alloys are generally very expensive, so you don’t want any scrap. Most of the machines are running at very low scrap levels. A stable production setup gives typically 3-5 per cent scrap. Beyond this range there is instability and it is harder to control a system for a lower scrap level, so you need some level of adaptive

HC1100 in operation with dual input, single product out

control looking at it. The ultimate goal would be zero scrap in a production environment. Most aluminium operations can be run at near-zero scrap levels with the right control. However, scrap is just one of between 40 and 60 influential process parameters. With any more than four or five parameters, and multiple levels of 1030 parameters, you need to bring some sort of intelligence into the system.

Elsewhere, we address energy efficiency in hydraulics and ancillaries in design and operation. There is significant heat power which can be harnessed, so our machines are heat-recovery ready. We channel everything into heat exchangers, ready for client use. The water system operates as a closed circuit. We look at recyclability of components and look to use recyclable materials wherever possible.

The machine itself has a long life. Any noise environmental impact is also minimised.

We also offer future proofing and modernising of our older machines, for example by digitalising a ten year old line. In the area of instrumentation and electronic controls, we are already looking at some upgrading and modifications of 5-6 year old machines, such is the pace of change. Even some machines over 25 years old are still fundamentally sound, but with modernisation of certain features and components, customers could see significant improvements, by increasing functionality, productivity, efficiencies, coil qualities and running speeds potentially.

You took part of a CRE machine to wire 2016 in Duesseldorf. What was the response to that like, and what do you plan to show at wire 2018 in April?

The 2016 response was quite telling from existing UK and European machine operators and other visitors. The ‘British machine’ was a draw, with many saying that it is an impressive, solid, absolute machine. We received lots of comments on the build quality, with some saying they wanted one there and then.

It demonstrated our ability to construct wellmade machines to withstand the ‘brutal’ (i.e. hot, dusty and dirty) CRE process, and still achieve a product with very low oxide and high quality finish.

The feedback to higher level executives helped us progress several enquiries. In one case, a company that had previously bought cheaper machines elsewhere admitted they were deficient on copper profiles manufacture.

Copper Worldwide Vol 8 No 1

Holton Crest Twin Rising Vertical Payoff with wound coils

Today, a lot of the complex profiles in copper are now made on Holton Crest machines.

Just as this article is an update on what we have been doing over the last two years, at wire 2018 in Duesseldorf we will demonstrate how our range of new generation machines have achieved full commercial operation.

We’ll highlight the different applications using the new technological advances we have introduced, and showcase how the CRE process is expanding its potential, with Holton Crest driving its development and leading the charge.

Lastly, you have one or two competitors based in the UK and Europe. How would you differentiate the Holton Crest offering from others operating in this sector?

Knowledge and experience is our foundation.

We are specialists in the Continuous Rotary Extrusion market, whereas nearly everyone else we know of has simply bought into this area and added the process as part of a portfolio.

Continuous rotary extrusion is what we do, we live and breathe it every day and everything we do is driven by the rotary extrusion process.

We are driving the process forward and are leading the market with technological developments. We have already seen a major step change and we are still pushing our development programme to continue over the next five to ten years, with investments in people, skills, technology and R&D to ensure that we continue to stay at the forefront of this industry. We don’t just want to be known for supplying good quality machinery, we are focused on leading and guiding our customers towards optimum levels of continuous production - by design. www.holtoncrest.com Malcolm Ladd warmly invites wire 2018 attendees to visit the Holton Crest Stand 11H39 in Duesseldorf from 16-20 April.

SUPPLIER DIRECTORY | 25

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MELTING AND CASTING

Optimising your copper process To tackle the challenges of the copper industry, Heraeus Electro-Nite offers some unique solutions specific for the different copper process steps.

EQUIPMENT AND MATERIALS PURCHASING BULK MATERIAL HANDLING Kopar Oy

Sepänkatu 2 FI-39700 Parkano Finland Tel: +358 3 440180 E-mail: sales@kopar.fi Web: www.kopar.fi

CONCENTRATE DRYING Tsukishima Kikai Co Ltd Temperature control is an important area during copper production.

Heraeus Electro-Nite offers a range of measurement instruments, sensors and lances. Customers may chose the disposable Positherm sensor series for batch processes, or prefer the new Contitherm-Cu continuous temperature sensor for continuous copper casting processes like Contirod or Contimelt.

Oxygen content

Celox-Cu and Concelox-Cu are electrochemical sensors for oxygen content measurement in copper melts. Celox-Cu is a disposable sensor for batch processes in copper refining, Concelox-Cu is a continuous sensor for the casting process. Both sensors cover the full technical range of oxygen content in copper from 1 to over 12,000 ppm.

The sensors’ precision is equivalent to combustion analysis, in the low oxygen range even better. CeloxCu is being applied with standard lance hardware and dedicated instrumentation, Multi-Lab III or Celox-Lab Cu. For the continuous Concelox-Cu sensor, a special PC logging and control software Concellog is available. Concelox-Cu

ELECTROLYTIC REFINING Metalex

Hernando de Aguirre 162 Of. 806 Santiago, Chile Tel: 0056 2335 2217 Fax: 0056 2321 8280 E-mail: alillo@metalex.cl Web: www.metalex.cl Contact: Alejandro (Alex) R. Lillo

Mettop GmbH

Sampling products

3-5-1, Harumi, Chuo-Ku Tokyo, 104-0053, Japan Tel: 0081 3 5560 6524 Fax: 0081 3 3536 0575 Email: suwa@tsk-g.co.jp Web: www.tsk-g.co.jp Contact: Satoshi Suwa Oxygen activity control in copper

lifetime may reach up to several days, dependent on application.

CONTINUOUS ROTARY EXTRUSION Holton Crest Limited

Peter-Tunner-Strasse 4 A-8700 Leoben Austria Tel: 0043 (0)3842 81787 Fax: 0043 (0)3842 1787-8 E-mail: cu@mettop.com Web: www.mettop.com Contact: Dr. Andreas Filzwieser

ELECTRONIC SCRAP RECYCLING UrbanGold GmbH

Reliable sampling

Samplers for instant analytical purposes in copper refining and casting are the preferred choice when a reliable chemical sample test must be taken from the melt to be analysed in the chem lab.

The method is much less time consuming than spoon sampling and downstream sample preparation.

The SaF copper samples for optical emission analysers (spectrometers) are free of burr. Heraeus ElectroNite VPT and QSVPT evacuated pin tubes for the combustion analyser show good solid fill. www.heraeus.com

10 Cowley Road, Poole, Dorset BH17 0UJ, UK Tel: +44 1202 681 501 Fax: +44 1202 681 502 Email: info@holtoncrest.com Web: www.holtoncrest.com Contact: Malcolm Ladd

Peter-Tunner-Str. 4 A-8700 Leoben Austria Tel: 0043 (0)664 88364080 E-mail: www.urbangold.at Web: recycling@urbangold.at Contact: Dr. Stefan Konetschnik

ELECTROWINNING

COOLING SOLUTIONS Mettop GmbH

Metalex

Peter-Tunner-Str. 4 A-8700 Leoben Austria Tel: 0043 (0)3842 81787 Fax: 0043 (0)3842 1787-8 E-mail: cu@mettop.com Web: www.mettop.com Contact: Dr. Andreas Filzwieser

Hernando de Aguirre 162 Of. 806 Santiago, Chile Tel: 0056 2335 2217 Fax: 0056 2321 8280 E-mail: alillo@metalex.cl Web: www.metalex.cl Contact: Alejandro (Alex) R. Lillo

ELECTROLYTE PURIFICATION

FURNACES Kumera Corporation

Metalex

Temperature control system

Hernando de Aguirre 162 Of. 806 Santiago, Chile Tel: 0056 2335 2217 Fax: 0056 2321 8280 E-mail: alillo@metalex.cl Web: www.metalex.cl Contact: Alejandro (Alex) R. Lillo

Copper Worldwide Vol 8 No 1

Kumerankatu 2 FI-11100 Riihimäki Finland Tel: 00358 (0)20 755 4200 Fax: 00358 (0)20 755 4320 E-mail: kumera@kumera.com Web: www.kumera.com Contact: Hannu Mansikkaviita

26 | SUPPLIER DIRECTORY FURNACES Contd Küttner GmbH & Co. KG

Alfredstr. 28 D-45130 Essen Germany Tel: 0049 201 7293 0 Fax: 0049 201 7293 134 Email: team-knf@kuettner.com Web: www.kuettner.com Contact: Dr. Farzad Salehi

FURNACES, HEAT TREATMENT EMA Indutec GmbH

www. c op p e r wor l dw i de. co m

MATERIALS HANDLING

PROCESS MODELLING UrbanGold GmbH

Combilift Ltd

Gallinagh Monaghan Town Co. Monaghan Ireland Tel: 00353 (0)47 80500 Fax: 00353 (0)47 80501 E Mail: info@combilift.com Web: www.combilift.com Contact: Sales Office

Peter-Tunner-Str. 4 A-8700 Leoben Austria Tel: 0043 (0)664 88364080 E-mail: www.urbangold.at Web: recycling@urbangold.at Contact: Dr. Stefan Konetschnik

PROCESSING LINES DANIELI FRÖHLING

Kumera Corporation

PROJECT ENGINEERING Contd Mettop GmbH

Peter-Tunner-Strasse 4 A-8700 Leoben Austria Tel: 0043 (0)3842 81787 Fax: 0043 (0)3842 1787-8 E-mail: cu@mettop.com Web: www.mettop.com Contact: Dr. Andreas Filzwieser

RECYCLING TECHNOLOGIES & EQUIPMENT PolyMet Solutions GmbH

Petersbergstrasse 9 D-74909 Meckesheim Germany Tel: 0049 6226 788 0 Fax: 0049 6226 788 100 Email: sales@ema-inductec.de Web: www.ema-indutec.com Contact: Peter Turewicz

FURNACES, MELTING DROSS AND SCRAP PolyMet Solutions GmbH

Peter-Tunner-Str. 4 A-8700 Leoben Austria Tel: 0043 (0)3842 817 87 E-mail: andreas.filzwieser@polymetsolutions.com Web: www.polymet-solutions.com Contact: Dr. Andreas Filzwieser

FURNACE LEVEL MEASUREMENT Agellis Group AB

Kumerankatu 2 FI-11100 Riihimäki Finland Tel: 00358 (0)20 755 4200 Fax: 00358 (0)20 755 4320 E-mail: kumera@kumera.com Web: www.kumera.com Contact: Hannu Mansikkaviita

MINERAL PROCESSING Weir Minerals Europe Limited

Halifax Road Todmorden Lancashire OL14 5RT United Kingdom Tel: 0044 1706 814251 Fax: 0044 1706 815350 Email: europe.minerals@mail.weir Web: www.minerals.weir Contact: Sales

PNEUMATIC CONVEYING/ INJECTION Tellusgatan 15 SE-22457 Lund Sweden Tel: 0046 46 101360 Fax: 0046 46 101361 E-mail: sales@agellis.com Web: www.agellis.com Contact: Magnus Persson

HEAT RECOVERY Küttner GmbH & Co. KG

Josef Fröhling GmbH & Co. KG Scherl 12 D- 58540 Meinerzhagen Germany Tel: 0049 (0)2354 7082 0 Fax: 0049 (0) 2354 7082 200 Email: contact@danieli-froehling.de Web: www.danieli-froehling.de Contact: Detlef Neumann

hpl-Neugnadenfelder Maschinenfabrik GmbH

Spangenbergstr. 20 D-49824 Ringe/Neugnadenfeld Germany Tel: 0049 5944 9301 0 Fax: 0049 5944 9301 44 E-mail: info@hpl-group.de Web: www.hpl-group.de Contact: Mr. Hans-Jaochim Biedermann

Küttner GmbH & Co. KG

Schenck Process

Unit 3, Alpha Court Capitol Park, Thorne Doncaster DN8 5TZ UK Tel: 0044 (0) 1302 321313 Fax: 0044 (0) 1302 554400 E-mail: enquiries@schenckprocess.co.uk Web: www.schenckprocess.com Contact: Richard Sims

Alfredstr. 28 D-45130 Essen Germany Tel: 0049 201 7293 0 Fax: 0049 201 7293 134 Email: team-knf@kuettner.com Web: www.kuettner.com Contact: Dr. Farzad Salehi

Peter-Tunner-Str. 4 A-8700 Leoben Austria Tel: 0043 (0)3842 817 87 E-mail: andreas.filzwieser@polymetsolutions.com Web: www.polymet-solutions.com Contact: Dr. Andreas Filzwieser

REFRACTORIES AND INSULATION HarbisonWalker International

1305 Cherrington Parkway, Suite 100, Moon Township, PA 15108 USA Tel: 001 905 977 7694 E-mail: anthony.rigby@thinkhwi.com Web: www.thinkhwi.com Contact: Joe Rigby

PolyMet Solutions GmbH

Peter-Tunner-Str. 4 A-8700 Leoben Austria Tel: 0043 (0)3842 817 87 E-mail: andreas.filzwieser@polymetsolutions.com Web: www.polymet-solutions.com Contact: Dr. Andreas Filzwieser

RHI MAGNESITA

PROJECT ENGINEERING Küttner GmbH & Co. KG

Alfredstr. 28 D-45130 Essen Germany Tel: 0049 201 7293 0 Fax: 0049 201 7293 134 Email: team-knf@kuettner.com Web: www.kuettner.com Contact: Dr. Farzad Salehi

TO ADVERTISE HERE PHONE CHRIS HOLDING +44 (0) 7731 784798

Alfredstr. 28 D-45130 Essen Germany Tel: 0049 201 7293 0 Fax: 0049 201 7293 134 Email: team-knf@kuettner.com Web: www.kuettner.com Contact: Dr. Farzad Salehi

Copper Worldwide Vol 8 No 1

Wienerbergstraße 9 A-1100 Vienna Austria Tel: 0043 (0) 50 213 – 6200 Fax: 0043 (0) 50 213 – 6391 E-mail: nfm-marketing@rhi-magnesita.com Web: www.rhi-magnesita.com

SUPPLIER DIRECTORY | 27

www.copperwor ldw ide. co m

REFRACTORIES AND INSULATION Contd Saint-Gobain Industrial Ceramics Limited

Mill Lane, Rainford St Helens, Merseyside WA11 8LP, UK Tel: 0044 (0)1744 887939 E-mail: craig.d.brennan@saint-gobain.com Web: www.ceramicmaterials.saint-gobain.com Contact: Craig Brennan

REFRACTORIES ENGINEERING Mettop GmbH

ROLLING MILL TECHNOLOGY Contd Primetals Technologies USA LLC

50 Prescott Street Worcester, Massachusetts, USA 01605 Tel: 001 508 755 6111 Fax: 001 508 849 6573 E-mail: contact@primetals.com Web: www.primetals.com Contact: David Gow

SMELTING – SECONDARY Kumera Corporation

Kumerankatu 2 FI-11100 Riihimäki Finland Tel: 00358 (0)20 755 4200 Fax: 00358 (0)20 755 4320 E-mail: kumera@kumera.com

SAMPLING AND ANALYSIS Alex Stewart (International) Corporation

Alex Stewart International

Web: www.kumera.com Contact: Hannu Mansikkaviita

Küttner GmbH & Co. KG

Alfredstr. 28 D-45130 Essen Germany

Peter-Tunner-Strasse 4 A-8700 Leoben Austria Tel: 0043 (0)3842 81787 Fax: 0043 (0)3842 1787-8 E-mail: cu@mettop.com Web: www.mettop.com Contact: Dr. Andreas Filzwieser

2b Sefton Business Park, Netherton Liverpool, Merseyside L30 1RD, UK Tel: 0044 (0)151 525 1499 Fax: 0044 (0) 151 523 3760 E-mail: analysis@alexstewartinternational.com Web: www.alexstewartinternational.com Contact: Stephen Russell

ROLLING MILL TECHNOLOGY

Tel: 0049 201 7293 0 Fax: 0049 201 7293 134 Email: team-knf@kuettner.com Web: www.kuettner.com Contact: Dr. Farzad Salehi

SOLVENT EXTRACTION Metalex

SCREENING

DANIELI FRÖHLING

Schenck Process Hernando de Aguirre 162 Of. 806

Josef Fröhling GmbH & Co. KG Scherl 12 D- 58540 Meinerzhagen, Germany Tel: 0049 (0)2354 7082 0 Fax: 0049 (0) 2354 7082 200 Email: contact@danieli-froehling.de Web: www.danieli-froehling.de Contact: Detlef Neumann

MINO S.p.A.

Pallaswiesenstraße 100 64293 Darmstadt Germany Tel: 0049 61 51 15 31 0 Fax: 0049 61 51 15 31 66 E-mail: vibrating@schenckprocess.com Web: www.schenckprocess.com Contact: Ingo Fjelsten

SMELTING – PRIMARY Küttner GmbH & Co. KG

Via Torino 1 15122 - San Michele (AL) P.O. Box 362 – 15121 Italy Tel: 0039 0131 363636 Fax: 0039 0131 361611 E-mail: sales@mino.it Web: www.mino.it Contact: Geminiano Chiesa

Alfredstr. 28 D-45130 Essen Germany Tel: 0049 201 7293 0 Fax: 0049 201 7293 134 Email: team-knf@kuettner.com Web: www.kuettner.com Contact: Dr. Farzad Salehi

Santiago Chile Tel: 0056 2335 2217 Fax: 0056 2321 8280 E-mail: alillo@metalex.cl Web: www.metalex.cl Contact: Alejandro (Alex) R. Lillo

WEIGHING AND FEEDING Schenck Process

Pallaswiesenstraße 100 64293 Darmstadt Germany Tel: 0049 61 51 15 31 0 Fax: 0049 61 51 15 31 66 E-mail: sales@schenckprocess.com Web: www.schenckprocess.com Contact: Martin Brauer

ONE ENTRY WITH LOGO FOR FOUR ISSUES (2017) £185 / EUR e265 / USA $320 Copper Worldwide Vol 8 No 1

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28 | ZAMBIA UPDATE

www. c op p e r wor l d w i de. co m

Zambia seeks ethical investment Currently Zambia is keen to attract operators into both the new and old Copperbelt areas. Copper Worldwide met a Zambian delegation in London to discover its latest economic plans.

The Africa Prospect Development Zambia stand at Mines and Money hosted an evening reception for delegates.

Zambia is 50% larger than Germany in land area and is the world’s 7th largest copper producer, the 6th largest cobalt producer, and the 3rd largest emerald producer. The Zambian economy is forecast to grow by just over 50% between 2017 and 2022: How has the productivity and output of the Zambian copper sector since 2012 performed?

Michael Chibonga, Ministry of Mines - Since 2012, productivity has been on the rise. Output, which was 710 thousand tonnes (kt) in 2015, exceeded the 750 kt mark in 2016, with the 2017 expectation being 770 kt, a rise of 8.5 per cent over 2015 levels. We are hoping in 2018 it will be even closer to 800 kt.

There are many factors at work against productivity. How might you overcome these downsides?

Michael Chibonga - Technology is the best way forward. With grades going down, the only hope a mining company would have is to improve its processing and mining technology.

The government’s aim is to create the best enabling environment it can, and we are seriously investing in infrastructure such as roads, rail, and power generation.

What are your future targets in terms of GDP and exports value for mining?

Fredson Yamba, Secretary to the Treasury Around 70 per cent of foreign exchange earnings come from copper exports, and 30 per cent from other sectors. The Government is developing a manufacturing policy and supporting legislation to try to reinforce the approach of value addition across all sectors including agriculture.

What support is available for foreign direct investment in the mining sector?

Fredson Yamba - For anyone who wants to invest in mining there are incentives attached to that. You get a tax rebate on machinery of 100 per cent, and there are a number of tax holidays. For anyone who wants to invest,

it would be prudent to sit down with the Zambian Development Agency.

Are there particular areas of the mining industry that you are focused upon?

Michael Chibonga - Apart from copper there are other minerals being explored, namely coal, gemstones and gold. This is going to be helped by the geological mapping that is being done. Only 60 per cent has been completed, so the exercise is ongoing. It will shed light on the other minerals that are readily available in the country.

Which are the most exciting projects and infrastructure investments over the next five years?

Michael Chibonga - Increased energy output will help increase productivity. Currently our total electricity output is 3,000 MW and this can be ramped up. Zambia is undertaking massive road infrastructure investment. Then there are renovations underway at Kenneth Kaunda International Airport in Lusaka to expand the cargo space. At the new Greenfield Ndola International Airport we are looking at both cargo and passenger services.

The biggest area of prospects at the moment is the Northwestern plateau of Zambia, which has overtaken the Copperbelt in production.

Kansanshi is a gold-copper mine, and the chances are we will find more deposits around there. There are gaps in certain areas of the old Copperbelt, but it is the new (NW) Copperbelt that we see as the future for Zambia presently.

There are huge manganese tracts in Luapula Province and Mkushi District. Manganese prices are going up. The nickel prospect in Munali might be coming into production soon.

Several mines will likely start up. Another area of optimism is in oil prospects in the Lake Tanganyika area.

one of the main pillars of our strategic plan is adding value. We have looked at copper rod manufacturing options, and there are two small companies formed for making cables, Neelkanth Cables Ltd (NCL) and Metal Fabricators of Zambia Plc (ZAMEFA), and we are looking to exploit these avenues.

ZAMEFA recently invested US$ 2 million in a new production plant in Luanshya.

For copper cables of different variants, our biggest market in Zambia is ZESCO for the rural electrification expansion programme.

They need fresh cables for that instead of importing cables. Being land-locked, we are surrounded by neighbours who all need cables. They mostly import from China and the U.S., so we have a big market opportunity there. For manganese, the market is for battery electrodes, paints and chemical additives. There is also the manganese sulphate byproduct from leaching, which can be used in medicine.

Semi-precious and precious minerals such as emeralds in particular are highly valued when from Zambia. The cutting and marketing of gemstones within Zambia would enhance the revenues (to give an idea of scale, Gemfields Kagem mine near Ndola produces 25% of the current world emerald output).

As well as additional hydropower and solar projects, are there other energy initiatives underway?

Dr. Pius C. Kasolo - Yes, we are building a thermal power station, increasing that power source from 300 MW to 600 MW in total. Current electricity generation stands at 3,000 MW, and of this around 2,700 MW is mainly from renewable sources such as hydropower. We are looking at solar scale-up projects too. We are mindful we still have a comparative advantage in generating power using hydro, so we have two projects underway, Batoka Gorge and Kafue Gorge Lower, to generate more than 2,000 MW of power in the near future. (details - added after interview: • Batoka Gorge hydropower project in partnership with Zimbabwe will cost around US$ 6 billion (AfDB estimate, April 2017) and is projected to generate up to 2,400 MW upon final completion.

It is due to begin construction in early 2018.

• Kafue Gorge Lower project (750 kW) is already under construction with Chinese finance, and is due for completion in 2020.)

So clearly, as mining and other activities increase we will also have an increased energy output to support this growth. www.zccm-ih.com.zm

What are the prospects for the development of a downstream added value sector?

Dr. Pius C. Kasolo, Chief Executive Officer, ZCCM Investment Holdings Plc - At ZCCM, Copper Worldwide Vol 8 No 1

www.africapd.com www.mof.gov.zm Thanks to Africa Prospect Development for arranging this interview

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