Metso Direct Blister Furnace Enables Large-Scale, Efficient Copper Smelting at Kamoa Kakula
High-capacity single-stage smelting streamlines copper production with improved efficiency and reliability.
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Metso’s Direct Blister Furnace has been successfully brought into operation at the Kamoa Kakula copper smelter in the Democratic Republic of Congo, marking a major milestone in large-scale, energy-efficient copper production. The furnace supports annual copper output of approximately 500,000 tonnes, making it the world’s largest licensed single flash smelting furnace by copper capacity.
The start-up culminated in the successful casting of the first copper anodes, demonstrating the readiness of the smelting line and confirming stable, high-performance operation. The installation plays a central role in Kamoa Kakula’s strategy to combine high production capacity with sustainability, safety, and operational efficiency.
“The successful casting of the first anodes is a significant milestone for us,” says Annebel Oosthuizen, Managing Director of Kamoa Copper S.A. “Collaboration with Metso throughout the project was smooth, from the early stages through commissioning. The Direct Blister Furnace and anode casting technologies are expected to deliver exceptional operational efficiency while supporting our commitment to sustainable copper production.”
Single-Stage Smelting for Higher Efficiency
At the heart of the smelter is Metso’s Direct Blister Furnace, which produces blister copper in a single flash smelting step. By eliminating the need for a separate converting stage, the process simplifies plant layout, reduces energy consumption, and lowers emissions compared to conventional multi-stage smelting flowsheets.
The smelting line is supported by advanced automation and digital solutions, providing high-level process control, improved safety, and continuous monitoring of furnace performance. An intelligent safety automation system enhances operational reliability and protects both personnel and equipment in demanding smelter conditions.
High-Quality Anode Production
Metso also supplied the anode casting shop, ensuring consistent production of high-quality copper anodes with reliable mechanical and metallurgical properties. The integrated approach between smelting and casting enables stable downstream processing and supports the overall efficiency of the copper value chain.
“I would like to congratulate Kamoa Copper and all teams involved in bringing the new smelter into operation,” says Jyrki Makkonen, Vice President, Smelting at Metso. “We are proud to support this project with solutions that emphasize sustainability, safety, and high process performance.”
Proven Technology for Sustainable Copper Production
The Kamoa Kakula installation builds on Metso’s long-standing experience in copper smelting and refining technologies. Metso’s flash smelting and anode casting solutions are widely recognized for their low environmental footprint, high energy efficiency, and strong metal recovery, even when processing challenging raw materials.
With more than 60 flash furnaces and over 100 anode casting plants delivered worldwide, Metso’s smelting technologies continue to set benchmarks for clean, large-scale copper production. At Kamoa Kakula, the Direct Blister Furnace demonstrates how modern smelting solutions can support both rapid capacity growth and long-term sustainability objectives.
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