Mutanda mine
The Mutanda mine is an open-pit copper and cobalt operation situated in the Lualaba Province of the Democratic Republic of the Congo.[1] Owned and operated by Mutanda Mining SARL, a subsidiary of Glencore plc, the mine began commercial production in 2011 following Glencore's acquisition of an initial stake in 2007.[2] It achieved peak output in 2018 with 27,300 tonnes of cobalt, positioning it as the world's largest cobalt mine at that time, alongside significant copper production exceeding 190,000 tonnes annually in high-output years.[3][4] The site's high-grade ore deposits have made it a cornerstone of global cobalt supply for lithium-ion batteries and copper for electrical and industrial applications, though operations were suspended from late 2019 to mid-2021 amid low cobalt prices before restarting.[5] Glencore maintains majority control, having transferred a required 5% equity to the DRC government in 2023 per national mining regulations.[2]Geography and Geology
Location and Accessibility
The Mutanda mine is located in the Lualaba Province of the Democratic Republic of the Congo, within the mineral-rich Katanga Copperbelt. It is situated approximately 40 kilometers east of Kolwezi, a major mining center in the region.[2][1] The site's geographic coordinates are approximately 10°47'14"S latitude and 25°48'34"E longitude.[6] Access to the mine is primarily via road from Kolwezi, which benefits from regional infrastructure including Kolwezi Airport for air transport and rail links to Lubumbashi, the nearest major city about 250 kilometers to the southeast. The operator, Mutanda Mining SARL, has undertaken road rehabilitation efforts in surrounding rural areas to improve connectivity and support operations.[7] Road conditions remain variable, influenced by seasonal rains and the remote terrain typical of the DRC's southeastern provinces.[8]Geological Characteristics and Mineralization
The Mutanda copper-cobalt deposit is situated within the Neoproterozoic Katangan Supergroup of the Central African Copperbelt, specifically in the southern portion of the Lufilian Arc thrust-and-fold belt that extends over 700 km from Zambia into the Democratic Republic of Congo's Katanga region.[9][1] The host rocks primarily comprise metasedimentary sequences of the Roan Group, with mineralization concentrated in the upper Dipeta Subgroup (R-3), including the Kansuki Formation (R-3.4), which consists of silicified dolostones, dolomitic shales, and argillites.[9] These carbonate- and carbon-rich lithologies form a stratabound deposit type, characterized by infilling of fissures, fractures, and breccias.[1] Structurally, the deposit is controlled by the east-west trending Kansuki Fault, a major 75+ km long feature that has facilitated overturned and thrust-displaced rocks dipping 5° to 30° south, bounded by north-dipping faults.[9] Deformation includes D1 thrusting and subsequent D2 strike-slip faulting, contributing to the localization of mineralized corridors up to 30 km in length.[9] The ore bodies exhibit stratiform geometry with associated supergene alteration, where shallow oxide caps overlie hypogene sulfide zones, extending to depths of 60-100 m in enriched zones.[9][1] Mineralization at Mutanda is typical of sediment-hosted stratiform copper-cobalt deposits in the DRC Copperbelt, featuring hypogene assemblages of chalcocite, bornite, carrollite, and minor chalcopyrite disseminated or veinlet-hosted within the dolomitic host rocks.[9] Supergene enrichment has produced significant oxide mineralization, including malachite and pseudomalachite for copper, and heterogenite for cobalt, with gangue minerals such as quartz and chlorite.[1] This enrichment results in elevated grades in the weathered upper portions, while deeper sulfide ores remain largely untapped, presenting potential for future underground development.[1] The deposit comprises multiple ore bodies, including Mutanda East with a 1400 m strike length, up to 150 m thickness, and dips of 0-30° south; Mutanda Central, approximately 500 m strike, 75-100 m thick, dipping 15-20° south; and Mutanda Central Northwest, around 300 m wide and 200 m deep.[9] These bodies align within a broader mineralized trend, with total resources exceeding 1 Gt at average grades of 1.4-2.6% copper.[9] Current open-pit operations target the oxide cap, leveraging the supergene enrichment for high-grade extraction.[1]History
Early Exploration and Development
The Mutanda deposit in the Democratic Republic of the Congo's Lualaba Province was initially explored by the state-owned mining company Gécamines during the 1980s. This early work involved excavating shallow pits, conducting geological mapping of the local stratigraphy, and confirming the presence of copper-cobalt mineralization within the Roan Group 4 (R4) interval, specifically the Mwashya Subgroup. These activities established the basic geological framework but did not advance to large-scale development due to economic and political challenges in the region during that period.[10][9] Exploration resumed in the mid-2000s amid renewed interest in the DRC's Copperbelt resources. In 2004, initial programs included core drilling (diamond drilling or DD), reverse circulation (RC) drilling, soil sampling, and geophysical surveys, which delineated near-surface oxide mineralization extending to depths of approximately 100 meters across the central and eastern zones of the deposit. By 2005, artisanal mining had begun on the northern flank of Mutanda Hill, exploiting high-grade surface ores but was halted due to safety risks from steep pit walls exceeding 70 degrees inclination and depths up to 70 meters. That year, Mutanda Mining contracted Gécamines to undertake 33 DD holes totaling 1,780 meters, targeting the Central and East Zones, with four holes intersecting significant mineralization. Additionally, Groupe Bazano conducted 47 RC holes averaging 80 meters depth over four weeks in November, focusing on the Central Zone to expand the resource outline.[10] Further delineation occurred in 2006, with soil sampling in June identifying geochemical anomalies that guided additional drilling. RC drilling completed infill coverage of the Central Zone by September on a nominal 50-meter by 50-meter grid, while work shifted to the East Zone. In 2007, DD drilling supplemented RC efforts starting in June, providing higher-quality samples for the up-dip portions of both zones on tighter 25-meter by 25-meter grids, enhancing confidence in the near-surface resource estimates. These pre-commercial activities laid the groundwork for feasibility studies, including an interim study in February 2007 that incorporated environmental assessments approved by the DRC Ministry of Mines.[10]Glencore's Involvement and Expansion (2000s–2010s)
Glencore acquired an initial 30% stake in the Mutanda mine in June 2007 from Groupe Bazano, a Congolese entity linked to local interests, thereby assuming operational control of the project.[11][2] This entry marked Glencore's strategic push into high-grade copper-cobalt deposits in the Democratic Republic of the Congo's Katanga region, leveraging its trading expertise to develop untapped oxide ore resources previously explored but underdeveloped by state-owned Gécamines. Under Glencore's management through its subsidiary Mutanda Mining SARL (MUMI), initial development focused on open-pit mining and basic processing infrastructure, with commercial production of high-grade copper and cobalt ore commencing in February 2011.[2] The operation rapidly scaled, producing 24,500 tonnes of copper and 17,000 tonnes of cobalt in its first full year, capitalizing on favorable metal prices and the mine's rich surface mineralization averaging over 6% copper equivalent.[12] Expansion accelerated in 2012 when Glencore secured majority control via deals totaling $480 million, including the purchase of additional stakes from joint venture partners such as High Grade Metals (HGM) and the exercise of options that elevated its ownership to approximately 55%.[12] This consolidation enabled aggressive capital investment, with over $570 million expended by mid-2013 on mine development, haul roads, and a hydrometallurgical plant upgrade to boost oxide ore throughput.[13] A pivotal step in the 2010s came in July 2013 with the merger of Mutanda's operations with the adjacent Kansuki mining project, integrating complementary sulfide ore resources and expanding the site's footprint to over 220 square kilometers.[14] Glencore committed $641 million in total capital expenditure for this phase, completing expansions by late 2013 that added sulfide flotation circuits and increased annual processing capacity to 3.5 million tonnes of ore, positioning Mutanda as one of the world's largest cobalt producers.[13] These enhancements shifted production toward mixed oxide-sulfide feeds, enhancing efficiency amid depleting high-grade surface ores.[1]Operational Shutdown and Phased Restart (2019–2024)
In August 2019, Glencore announced the suspension of operations at the Mutanda mine by the end of the year, citing persistently low cobalt prices, elevated production costs, and increased fiscal pressures from the Democratic Republic of Congo government, including new royalties and taxes.[15][16] Operations were placed on care and maintenance to reassess the deposit's long-term potential, with the shutdown ultimately occurring in November 2019—a month ahead of schedule—due to supply chain disruptions in procuring sulphuric acid essential for processing.[17][2] By mid-2021, Glencore decided to restart the mine amid recovering cobalt market conditions, announcing plans for a phased resumption beginning late that year or early 2022, with recruitment for operations already underway.[5][18] The initial phase commenced in October 2021, focusing on processing ore from existing stockpiles to test systems and gradually rebuild workforce capacity, while targeting a return to full underground mining activities by 2024.[2] This limited restart in late 2021 contributed to Glencore's own-sourced cobalt output rising 14% to 31,300 tonnes for the full year, with approximately 3,900 tonnes attributable to Mutanda's early contributions despite ongoing ramp-up constraints like power outages.[19] Subsequent phases involved scaling up processing lines and mining output, though production faced headwinds from feed plan adjustments and grade variability. In 2023, Mutanda's operations led to a 6% decline in Glencore's overall cobalt production to 41,300 tonnes, reflecting deliberate optimizations to manage ore quality.[20] By 2024, full mining resumption was achieved, but expected lower grades at Mutanda resulted in a further 10% drop in Glencore's cobalt output to 35,100 tonnes, alongside signals of approaching ore depletion that could necessitate guidance reductions.[21][22]Ownership and Corporate Structure
Evolution of Ownership Stakes
Glencore first acquired an initial equity stake in Mutanda Mining S.A.R.L. (MUMI), the entity operating the Mutanda mine, in 2007 through an investment of approximately $200 million, marking its entry into the project as a significant shareholder alongside other partners.[23][2] In March 2011, the state-owned Gécamines sold its 20% stake in MUMI to Rowny Assets Limited, an entity linked to Israeli businessman Dan Gertler, for $137 million, despite independent valuations estimating the stake's worth at over $600 million; this transaction shifted control away from direct state involvement.[24] By May 2012, Glencore increased its holdings through deals totaling $480 million, securing majority control of MUMI and enabling operational expansion.[12] In July 2013, Glencore completed a merger of MUMI with the adjacent Kansuki mining operations, acquiring additional interests and gaining options to purchase up to 50% of partner Rowny Assets' shares in phases, further consolidating its position.[25] On February 13, 2017, Glencore purchased the remaining 31% stake in MUMI from subsidiaries of Fleurette Properties Limited (another Gertler-linked entity) for a gross consideration of $922 million, offset by $556 million in loans and $130 million in shareholder debts, resulting in net cash outflow of $534 million and full 100% ownership of MUMI by Glencore.[4] In 2023, Glencore transferred 5% of its shareholding in MUMI to the Democratic Republic of Congo government, as mandated by revisions to the 2002 Mining Code requiring progressive state participation up to 10% in mining projects without dilution of existing shareholders' economic interests; Glencore thus retains 95% ownership.[2][26]Current Ownership by Glencore
Glencore plc, through its subsidiary Mutanda Mining SARL (MUMI), holds a 95% ownership stake in the Mutanda mine as of 2024, with the remaining 5% owned by the Democratic Republic of Congo (DRC) state, typically represented by the state-owned mining company Gécamines.[27][1] This structure resulted from Glencore's compliance with the DRC's 2018 Mining Code revisions, which mandated the transfer of a 5% free carried interest to the state upon finalization of certain operational and legal processes; Glencore completed this transfer in April 2023.[1][2] Prior to this adjustment, Glencore acquired full indirect ownership of Mutanda in 2017 by purchasing the remaining 31% stake from subsidiaries of Fleurette Properties Limited, a group linked to Israeli businessman Dan Gertler, for $534 million, valuing that portion at approximately $922 million including assumed liabilities.[4] This transaction consolidated Glencore's control following its earlier stakes acquired through mergers and investments in the 2000s and 2010s, establishing MUMI as a wholly-owned entity at that time.[2] The 95% stake positions Glencore as the primary operator and beneficiary of Mutanda's production, which focuses on high-grade copper and cobalt ores essential for global battery supply chains.[28] Glencore's operational oversight includes responsibility for exploration, mining, processing, and supply chain due diligence, as outlined in its annual reports and site-specific disclosures.[27] The DRC's 5% holding entitles it to dividends and strategic participation but does not alter Glencore's dominant decision-making authority under the joint venture framework.[29] No further ownership changes have been reported as of October 2025, despite ongoing discussions in the DRC mining sector regarding potential stake adjustments for other Glencore assets like Kamoto Copper Company.[30]Operations and Production
Mining Methods and Facilities
The Mutanda mine utilizes conventional open-pit mining methods to extract oxide copper-cobalt ores from the Katanga sedimentary succession.[1] These methods encompass drilling, blasting for fragmentation, loading, hauling, stockpiling, and dewatering to manage water ingress common in the region's hard rock conditions.[1][31][32] The operation comprises three open pits—East, Central, and Central North-West—which supply raw ore directly to integrated hydrometallurgical processing facilities without reliance on underground extraction.[33][10] Earlier plans outlined consolidation of these pits into a single large open pit by 2018 to optimize efficiency, though current configurations maintain multiple active sites for ore feed.[34] Supporting infrastructure includes ancillary services for reclamation, maintenance, and ore handling, enabling a vertically integrated flow from pit extraction to on-site cathode and hydroxide production.[31] The pits are located approximately 35-36 km east of Kolwezi, with mining activities focused on metasedimentary deposits amenable to surface methods due to their shallow to moderate depths.[1][35]Processing and Output Capacity
The Mutanda mine employs a hydrometallurgical processing route suited to its oxide copper-cobalt ores, involving crushing and grinding of ore from open pits, followed by dense media separation (DMS) to preconcentrate copper minerals, leaching of the concentrate, solvent extraction, and electrowinning to yield high-purity copper cathodes, with cobalt recovered as hydroxide precipitate via purification and precipitation steps.[1] An associated sulfuric acid plant, commissioned in 2012, supports the leaching process with a daily output capacity of 390 metric tons of sulfuric acid and 73 metric tons of liquid sulfur dioxide.[1] The facility's designed output capacity for copper cathodes stands at 200,000 tonnes per annum (tpa), achieved through expansions including a 200 ktpa SAG mill commissioned in late 2013, enabling annualized throughput rates exceeding this level prior to the 2019 shutdown.[34][4] Cobalt hydroxide production capacity is approximately 24,000 tpa of contained cobalt, though actual outputs have varied with ore grades and operational phases post-2021 restart.[4] These capacities reflect the plant's vertical integration for direct metal and intermediate outputs, without reliance on smelting.[36]Historical Production Trends
The Mutanda mine commenced commercial production of copper and cobalt in February 2011 following Glencore's acquisition of stakes starting in 2007.[2] Output rapidly escalated through the mid-2010s, leveraging high-grade oxide ore deposits amenable to open-pit mining and hydrometallurgical processing, with cobalt production rising from 13,700 tonnes in 2013 to a peak of 27,300 tonnes in 2018, accompanied by 199,000 tonnes of copper in the latter year.[3][20] This growth positioned Mutanda as the world's largest cobalt mine by 2018, contributing significantly to Glencore's overall cobalt output exceeding 40% from the DRC asset.[3] In 2019, production declined sharply to 103,200 tonnes of copper and 25,100 tonnes of cobalt before operations suspended in November amid plummeting cobalt prices, escalating costs including sulfuric acid procurement challenges, higher royalties, and ore depletion concerns, rendering the mine uneconomic.[37][38] No industrial-scale output occurred in 2020.[39] A phased restart began in October 2021, initially processing stockpiles to produce copper cathodes, with cobalt hydroxide output limited to 3,900 tonnes that year as priorities focused on copper amid volatile markets.[40] Mining activities remained curtailed until planned resumption in 2024, while processing continued from existing material.[2] By 2022, Glencore's total cobalt production surged 40% year-on-year largely due to Mutanda's contribution post-restart, though site-specific figures reflected moderated volumes.[39] Cobalt output at Mutanda fell to 11,200 tonnes in 2023, attributable to deliberate feed adjustments and declining ore grades from earlier high-grade depletion.[41] Further reductions occurred in 2024, with Glencore citing expected lower grades at Mutanda as a key factor in an 8% drop in group cobalt production to 38,200 tonnes.[42]| Year | Copper Production (tonnes) | Cobalt Production (tonnes) | Notes |
|---|---|---|---|
| 2013 | Not specified | 13,700 | Early ramp-up phase.[3] |
| 2018 | 199,000 | 27,300 | Production peak.[37] |
| 2019 | 103,200 | 25,100 | Partial year before shutdown.[37] |
| 2020 | 0 | 0 | Full suspension.[39] |
| 2021 | From stockpiles (specific volume unspecified) | 3,900 | Phased restart initiated.[40] |
| 2023 | Not specified | 11,200 | Grade and feed adjustments.[41] |
Resources and Reserves
Proven and Probable Reserves
As of 31 December 2024, the Mutanda mine's proven and probable ore reserves totaled 276 million tonnes, grading 1.91% copper and 0.65% cobalt, in accordance with the JORC Code (2012).[43] Proven reserves accounted for 197 million tonnes at 1.94% copper and 0.61% cobalt, while probable reserves comprised 80 million tonnes at 1.83% copper and 0.74% cobalt.[43] These figures yield contained metal of approximately 5.3 million tonnes of copper and 1.8 million tonnes of cobalt across the total reserves.[43] The reserve estimates reflect updates to economic assumptions, including commodity prices and processing recoveries, alongside depletions from mining and stockpile adjustments during 2024.[43] Primarily oxide ores amenable to hydrometallurgical processing, these reserves support an estimated mine life of about 20 years to 2044, contingent on regulatory approval for sulphide ore treatment to extend operations beyond current oxide depletion.[43] Mining permits remain valid through 2037, with ongoing exploration aimed at converting additional resources to reserves.[43] Separate underground potential, with smaller proven reserves of 27.8 million tonnes at 3.0% copper and 0.38% cobalt plus probable reserves of 11.2 million tonnes at 2.8% copper and 0.35% cobalt, indicates supplementary higher-grade opportunities but is not yet integral to primary open-pit operations.[43]Resource Estimates and Exploration Potential
As of 31 December 2024, Glencore reports total measured and indicated mineral resources at Mutanda of 276 million tonnes grading 1.91% copper and 0.65% cobalt, encompassing open-cut, underground, and stockpiles, with Glencore's attributable interest at 95%.[43] Inferred resources add 26 million tonnes at 2.62% copper and 0.76% cobalt.[43] These figures reflect adjustments from economic assumptions, stockpile depletions, and prior mining, with resources constrained by economic pit shells and underground potential evaluated to a depth of approximately 500 meters.[43]| Category | Tonnage (Mt) | Copper (%) | Cobalt (%) |
|---|---|---|---|
| Measured + Indicated (Open Cut) | 240 | 1.97 | 0.67 |
| Measured + Indicated (Underground) | 8.0 | 2.89 | 0.99 |
| Measured + Indicated (Stockpiles) | 28.0 | 1.12 | 0.43 |
| Total Measured + Indicated | 276 | 1.91 | 0.65 |
| Inferred (Total) | 26 | 2.62 | 0.76 |