As the Democratic Republic of the Congo (DRC) continues to expand copper and cobalt production to meet rising global demand for battery minerals, mining companies are harnessing BME Metallurgy’s expertise to improve efficiency while reducing environmental impact and operating costs.
Lefa Masiuana, General Manager at BME Metallurgy, said that the DRC currently accounts for more than 70% of global cobalt production and is Africa’s largest copper producer.
“Output is expected to continue growing as investment in the Central African Copperbelt accelerates. However, expanding production is also bringing new processing challenges that require innovative mining chemical solutions,” he said.
Daniel Verwey, Business Development Manager at BME Metallurgy, explained that orebodies are becoming more challenging to process. “This often requires finer grinding and more selective metallurgical processes to liberate valuable minerals efficiently,” he said.
Across the DRC Copperbelt, many operations are processing increasingly complex ores characterised by lower grades, variable mineralogy and higher impurity levels. “This is particularly evident in oxide-sulphide transition zones, where impurity management, acid consumption and recovery optimisation are becoming increasingly important,” he said.
At the same time, global battery and automotive supply chains are placing greater pressure on producers to align with stricter environmental, social and governance (ESG) standards.
Selective chemistries for complex ores
Verwey said that as ore complexity increases, greater emphasis is being placed on reagent optimisation to improve flotation performance, hydrometallurgical efficiency and overall plant recovery.
“Advanced collectors, depressants and modifiers are becoming increasingly important in improving selectivity in difficult ore environments,” he said.
“Variable mineralogy and finer particle sizes require more customised reagent strategies supported by ongoing test work and process optimisation.”
BME Metallurgy has helped operations reduce frother consumption by up to 50% while also improving recovery performance, reducing both operating costs and logistical pressure.
In hydrometallurgical circuits widely used across the Copperbelt, the company’s reagent technologies have also improved solvent extraction efficiency, reduced organic losses and increased plant throughput by up to 20% through better impurity management.
“These improvements are particularly important in solvent extraction-electrowinning operations where acid efficiency and extraction stability have a major impact on profitability,” he explained.
Water and tailings management under pressure
Verwey said that as processing capacity expands across mining regions such as Kolwezi and Lualaba, water management is becoming a critical operational concern for DRC miners.
“The focus is on improving water recovery, reducing freshwater consumption and strengthening tailings management practices as ESG scrutiny intensifies,” he said.
He explained that expanding copper-cobalt production places greater pressure on water infrastructure and raises expectations from international investors and downstream supply chains around responsible mining practices.
“Advanced thickening technologies using polyacrylamide flocculants and synergistic coagulants can improve settling rates and overflow clarity while supporting more efficient water recycling,” he said. This helps operations reduce pressure on local water resources while improving process performance.
Masiuana noted that as producers seek safer and more sustainable storage solutions following increased global scrutiny of tailings failures in the mining industry, tailings management will continue to receive greater attention.
“BME Metallurgy works with mines to optimise reagent dosing, improve slurry rheology and support more effective dewatering strategies,” he said.
“In tailings applications, improving dewatering can reduce storage risks and lower environmental footprint.”
Cleaner processing and reagent recovery
According to Masiuana, global demand for responsibly sourced battery minerals will increasingly shape processing decisions in the DRC mining sector.
“Producers supplying international markets will face growing pressure to demonstrate responsible extraction practices, emissions management and safer chemical handling procedures,” he said.
BME Metallurgy is responding by expanding its portfolio of biodegradable and lower-toxicity reagent alternatives.
“Recent innovations include acid mist suppressants for copper electrowinning operations as well as technologies that support cyanide detoxification and emissions control,” he said.
One of BME Metallurgy’s emerging technologies is membrane-based reagent recovery, which enables the reuse of chemicals such as sulphuric acid and caustic soda.
“Early test work indicates reagent recovery potential of up to 70%,” Verwey said. “This can significantly reduce chemical consumption while improving the economics of processing lower-grade deposits.”
Supply chain reliability
Masiuana said that reliable reagent supply remains a major operational consideration for mining companies operating in remote parts of the DRC, where logistical disruptions and border delays can quickly affect production continuity.
“To mitigate these risks, BME Metallurgy maintains strategic stocking and diversified sourcing supported by regional infrastructure and supplier networks,” he said.
With copper and cobalt demand expected to remain strong as the global energy transition accelerates, he said DRC mining companies are expected to continue investing in technologies that improve recovery, operational efficiency and sustainability performance.
“Our focus, therefore, remains on delivering site-specific metallurgical solutions that improve recovery, support sustainability objectives and enhance operational performance over the long term,” he concluded.
