Preface

The Kamoya Phase II Oxide Ore Capacity Expansion and Copper–Cobalt Sulfide Concentrate Roasting Project is designed to, upon completion of the second-phase oxide ore capacity expansion, achieve an annual production capacity of 4.0 t/a of standard cathode copper and 10,000 t/a of crude cobalt hydroxide (as metallic cobalt). The project also includes the construction of a 284 t/d fluidized‑bed roasting unit for copper–cobalt sulfide concentrates, a 120 kt/a sulfuric acid plant, and all associated auxiliary facilities. With its large overall production scale and stringent requirements for continuous operation, the project imposes rigorous standards on the stability, continuity, and corrosion resistance of the tailings‑water recycling system.

Kamoya Phase II Oxide Ore Capacity Expansion and Copper–Cobalt Sulfide Concentrate Roasting Project Construction Project

Location: Kambove, Haut-Katanga Province, Democratic Republic of the Congo

      Deficiencies in road transport infrastructure pose a persistent challenge to the project’s operational sustainability. Cross-border transshipment procedures are cumbersome, and the roads linking mining sites to townships—often rudimentary gravel or laterite tracks—are narrow and in poor condition, severely restricting the passage of heavy‑haul vehicles. As a result, large equipment frequently encounters difficulties such as being unable to access the site or requiring on‑site reconfiguration.

Acidic tailings water contains flotation reagents, has a pH of 1–3, is highly corrosive, and contains fine suspended solids as well as dissolved metals. In the reservoir area, water level fluctuations are common, leading to issues with conventional fixed‑type intake systems, such as cavitation, elevated sand content in the extracted water, and unstable operation. Moreover, overseas construction sites often face limited assembly conditions and scarce resources, making on‑site installation and commissioning challenging and time‑consuming.

End-to-End Specialized Optimization Technology System

Pre-visit on-site inspection

During the project’s preliminary phase, through on-site surveys and in-depth technical coordination with the developer, a comprehensive assessment was conducted to delineate the core boundary conditions at the Kambove mining site in the Democratic Republic of the Congo. Key parameters—including access road width, pavement load-bearing capacity, grade, turning radius, clearance height, and bridge load limits—were rigorously verified, enabling precise identification of the largest permissible transport vehicle types as well as the dimensional and weight limits for individual pieces of equipment.

Based on field‑measured transportation conditions, a modular optimization design has been implemented, with the pontoon hull, pump units, piping systems, anchoring components, and other equipment systematically disassembled to ensure precise alignment with the transport capacities of overseas mining sites. This approach eliminates at the design stage issues such as oversized or overweight components that cannot be brought on site, on‑site cutting and modification, and misalignment during assembly. Furthermore, taking into account the constraints of on‑site construction spaces and the shortage of large‑capacity lifting equipment, the on‑site assembly process has been streamlined, providing critical assurance for the efficient deployment, rapid installation, and timely commissioning of overseas projects.

Factory Full-Realism Pre-Assembly Simulation

Considering the challenging construction conditions at overseas mining sites, limited local expertise, and the high complexity of after-sales operations and maintenance, all floating pump‑station equipment is manufactured using a fully prefabricated, factory‑integrated production approach, with pre‑assembly conducted under realistic operating‑condition simulations. In the production workshop, the entire workflow—including equipment transportation, lifting, docking, and assembly—is meticulously replicated, enabling completion of all critical steps: splicing the pontoon structure, precisely positioning and installing the pump unit, connecting pipeline flanges, and commissioning the electrical control system.

Through full‑scale workshop simulations, we proactively identify and thoroughly resolve issues such as component loosening and structural deformation caused by transportation vibrations, as well as misalignment of piping, installation interference, and insufficient docking accuracy that often arise during on‑site assembly, thereby completing all corrective measures and optimizations in advance. Prior to shipment, the equipment undergoes comprehensive verification; upon arrival at the project site, it requires only modular connection and fixation, eliminating the need for secondary cutting, rework, or repeated commissioning. This significantly shortens the construction timeline for overseas projects while reducing outdoor operational safety risks and labor costs.

Tailings-specific optimization for acidic conditions

Number of pumps: 2 (one in service, one on standby)

Model: 200DYLW350-60-1.5

Pump performance: 350 m³/h, 60 m

Matching motor: 4P/110 kW/380 V/WF1/F/variable frequency drive

Drawing on extensive, long-term experience in tailings‑pond operations—particularly in the challenging conditions of acidic tailings‑water recirculation—we have undertaken a comprehensive, project‑specific optimization of the pump‑unit’s materials, design, and operating mode to address the harsh service environment of this project: pH 1–3, highly acidic; abrasive due to trace suspended solids; and continuous operation at low temperatures year-round. The pump‑unit’s critical wetted components are fabricated from CD4MCu high‑alloy duplex stainless steel, a material that offers exceptional resistance to strong acid corrosion, erosion‑corrosion, and stress‑corrosion cracking. This grade ensures reliable long‑term performance in dilute sulfuric‑acid environments and in tailings‑water recirculation streams containing trace solid particles, effectively mitigating common failures such as pitting and perforation of conventional stainless‑steel pump casings, impeller wear, and seal degradation.

Meanwhile, by taking into account the water-level fluctuation characteristics of the reservoir area, the floating‑boat anchoring and lifting system has been optimized to ensure that the pump unit’s suction inlet remains consistently within the clear‑water layer, thereby preventing the intake of bottom‑settled sediment and further reducing equipment wear and tear. The system is equipped with a 110 kW variable‑frequency motor that intelligently adjusts its operating load in response to changes in reservoir water level and return‑water flow, accommodating operational fluctuations while effectively lowering energy consumption and mitigating equipment fatigue. The motor features an outdoor corrosion‑resistant protection rating of WF1 and Class F insulation, making it well suited to the harsh outdoor conditions typical of mining areas—exposure to intense sunlight, high humidity, and corrosive environments—thus significantly enhancing the equipment’s continuous‑operation reliability and service life.

Looking forward to working with you.

Our company has developed an end-to-end optimized floating pump station solution that addresses, from the design stage, key operational challenges faced in overseas mining areas—such as difficulties in equipment mobilization, lengthy on-site modifications, high rates of corrosion and wear‑related failures, and unstable operation due to fluctuating tailings‑pond water levels. We offer a one‑stop service covering the entire value chain, from site surveys and production to transportation, installation, and ongoing operations and maintenance. To date, we have successfully implemented several benchmark tailings‑water recycling projects in Katanga, Lualaba Province, and Kolwezi, Democratic Republic of the Congo, backed by proven local delivery expertise. We look forward to deepening our collaboration with your organization and welcome opportunities for technical exchanges, on‑site inspections, and discussions on project proposals and pricing.