Sarens takes pride in helping our clients achieve great things, and as part of this vision, we recently installed two 220-tonne furnaces and will be assisting with another 220-tonne furnace and a 196-tonne steam dryer at the Kamoa Copper Mining Complex in the Democratic Republic of Congo.

Phase 3 of the Kamoa Copper Smelter Project includes the commissioning of a 500.000-tonne per annum on-site, direct-to-blister copper smelter that will increase Kamoa-Kakula’s annual copper production to a ten-year average of 650,000 tonnes. It is expected to positively influence the local economy and job creation in the region.

Sarens first became involved in the project in 2022, providing Kamoa Copper with valuable assistance during preliminary FEED studies. From site planning to budgeting support for our client, it has been rewarding to see the culmination of our hard work over the past two years. We have so far successfully positioned the two furnaces, staying on track to complete the full project scope by the end of April 2024: an achievement that truly feels like a moment of success!

Sarens planned for the use of a Terex Demag CC2800-1 crane to lift the furnaces and steam dryer into place. However, transporting the crane and equipment to the job site, from Angola to Kolwezi in the DRC, proved to be a challenging task: travel along the chosen route took two months and over 25 different truck and trailer configurations, with some items arriving by rail.

The operation then commenced with meticulous site preparation, including the construction of a concrete slab as recommended by Sarens. This slab was crucial for distributing the high ground-bearing forces (up to 300kN/m²), protecting the subsoil layers from sinking or displacement under the weight of the crane and 220-tonne anode drums.

Sarens’ rigging solution utilised a six-metre S406 modular spreader beam to evenly distribute the load and minimise stress on the anode drums during lifting. This setup, including high-capacity slings and shackles, was designed to securely attach the heavy loads to the crane, adhering to stringent safety standards.

The CC2800-1 crane has been pivotal to this operation, with its selected configuration (SSL 36m) and 250-tonne SL ballast accommodating the heavy load while taking into account the precise location, lift radius (24m), and hook height (23m) for optimal safety and efficiency.

The crane operated seamlessly under the skilled guidance of our on-site crew: it carefully lifted and then crawled forward approximately 15 metres with the load to reach the installation points. The anode drums were then meticulously placed in their predetermined positions, marking the successful completion of a high-priority lifting operation at the mine site.

We are proud to have completed the two furnace lifts safely and securely, with the Kamoa project manager commending the exceptional performance of the Sarens team!

Watch the video here!