Reliable level measurement is essential in copper and cobalt processing, and at KCC, VEGA Controls (Pty) Ltd is helping ensure uninterrupted operations with robust vibrating level switch technology.
In Kolwezi, in the heart of the Democratic Republic of the Congo, Kamoto Copper Company (KCC) stands as a leading producer of copper and cobalt. The name “Kamoto,” drawn from the Swahili word for “small fire,” aptly reflects the company’s role in fuelling modern industry. KCC’s mineral zones sit at the western end of the Congolese Copperbelt — a region renowned for exceptionally rich copper, cobalt, and uranium deposits that are central to the global energy transition. Copper underpins electrification and grid expansion, while cobalt remains a critical component in many battery chemistries powering mobility and energy storage.
A region of extraordinary resource
The Copperbelt is remarkable in both scale and grade. It hosts the world’s second-largest copper reserve, with deposits that can exceed 5% copper in ore grade — well above the global average. The DRC also holds a significant share of the world’s cobalt resources, and despite long mining histories, parts of the belt remain underexplored, leaving room for new discoveries as exploration methods and processing technologies continue to advance.
From ore to refined metal
Copper occurs widely in the Earth’s crust, typically as copper-bearing minerals within mixed ores. At KCC, copper-cobalt sulphide ores are extracted primarily through opencast mining, then processed through a sequence of mechanical and chemical steps to produce refined metals for global industrial use.
After extraction, ore is crushed to liberate copper minerals and treated through froth flotation. Reagents render copper particles hydrophobic, and injected air carries mineral-rich bubbles to the surface, forming a concentrate. This concentrate is smelted and cast into anodes, which are then electrolytically refined to produce high-purity copper cathodes, typically around 99.99% Cu.
Cobalt recovery follows a hydrometallurgical route. Smelting residues, which still contain valuable cobalt, are treated with acids to dissolve the metal into solution. A series of chemical separation processes isolate the cobalt, which is then refined through electrolysis — passing electrical current through a cobalt-ion solution to plate pure cobalt onto a cathode. The result is a high-purity cobalt product ready for global markets.
Precision instrumentation in a demanding environment
Throughout this intricate production process, maintaining precise control of liquid levels, pressure, and density is critical. This is where VEGA sensors play an essential role. At KCC, VEGA vibrating level switches are deployed to regulate water levels within columns containing acidic scrub water at a pH of 11, a challenging, corrosive environment where reliable measurement is non-negotiable.
The instrument of choice is the VEGASWING 63, a tuning fork level switch with a tube extension designed for point level detection in demanding process conditions. Mounted to the side of the tank with its vibrating fork extending into the liquid, the sensor responds in real time to changes in fluid level. Pre-determined high and low setpoints dictate when the instrument triggers protective actions.
When liquid reaches the high-level setpoint, the VEGASWING 63 activates an alarm and signals pumps to halt filling, preventing costly overfill incidents. When the level drops to the low setpoint, it prompts tank refilling or shuts down equipment to protect against dry-run damage. This dual protection ensures uninterrupted flow of process liquid to downstream production stages.
The VEGASWING 63’s resistance to harsh, corrosive conditions makes it particularly well suited to the acidic environments common in mining operations. Seamlessly integrated into KCC’s broader control system, it enables reliable automation and consistent operational performance.
A partnership built on trust
When asked what differentiates VEGA from competing solutions, KCC’s Plant Instrumentation Coordinator (who wished to remain anonymous in accordance with company policy) was clear: “What sets VEGA sensors apart is their robustness and reliability. Despite challenging conditions involving steam and aggressive mediums, VEGA sensors have consistently delivered precise and trustworthy measurements. Having always achieved positive results with VEGA instruments, we knew they were the right choice.”
That confidence is grounded in more than two decades of successful collaboration. VEGA sensors form an integral part of KCC’s continuous monitoring and control infrastructure, working alongside pumps and ancillary equipment to maintain a smooth, efficient production flow while minimising the risk of costly disruptions or operational hazards.
In copper and cobalt production, precision and reliability are everything. VEGA’s proven performance backed by responsive aftersales support wherever operations are located has made them an indispensable partner in KCC’s mission to supply the metals the world’s energy transition depends on.
