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The S3 project, first proposed in 2012, includes a new processing plant that nearly doubles Kansanshi’s ore-milling capacity, expands smelter throughput by about 25% and opens a new pit for mining.

Kansanshi is set to produce an average 250,000 t of copper annually through 2044, up from 171,000 t in 2024. The expansion will bolster Zambia’s mining industry as the government seeks to more than triple national copper output by the early 2030s.

For First Quantum Minerals, the Zambian expansion provides much-needed production growth following 2023’s closure of the US$10 billion Cobre Panamá mine.

With Cobre Panamá offline, Zambia now accounts for more than 90% of First Quantum’s output through Kansanshi and its nearby Sentinel mine. These operations contribute more than half of Zambia’s total copper production, reinforcing the country’s reliance on the red metal for over 70% of export earnings.

Timeline: Kansanshi S3 Expansion

May 2022 | Board approval and investment commitment:

First Quantum’s board formally approves the S3 Expansion, comprising a standalone 25 Mtpa processing plant, a new mining fleet, and smelter upgrades. Total capital expenditure is set at approximately US\$1.25 billion with the expectation of first production in 2025.

End of 2023 | Initial progress:

The project achieves delivery milestones, approximately 30% of the fleet commissioned, 80% of engineering complete, with earthworks and civil works ahead of schedule.

End of 2024 / January 2025 | Hallmarks of construction and commissioning:

• Construction completion at 62%
• Early commissioning underway, including gearless mill drive installations, power infrastructure (33 kV line/substation), and process control configuration at 80%
• Operational readiness is 62%, with personnel being trained via simulators

Q1 2025 | Advanced commissioning:

• 83% construction complete
• 20% of systems handed over to commissioning teams
• Commissioning includes energizing substations, lining and starting the SAG mill, and activating water infrastructure
• Operational readiness climbs to 75%

Q2 2025 | First ore processing:

• Construction hits 91% completion
• 50% of systems commissioned
• First ore is fed through the primary crusher, SAG mill, and rougher flotation circuit, ahead of schedule
• Plant control configuration reaches 92%, and operational readiness stands at 93%, with operational teams taking over and controlled plant runs commencing

H1 2025 | Finalization and ramp-up:

• The company targets mid-2025 for project completion and full commissioning of Kansanshi’s S3 Expansion, marking the shift to heightened copper production and an extended mine life into the 2040s

What are stakeholders saying?

“Nobody puts US\$1,250,000,000 in a project located in a country and an environment you have no trust in ... This project symbolizes private sector confidence in this economy.” - President Hakainde Hichilema

“The S3 Expansion Project is a bold US\$1.25 billion investment in Zambia’s mining future… it reflects our unwavering confidence in Zambia’s future, its leadership, its policies and above all in the talent and capability of its people.” - First Quantum CEO, Tristan Pascall

“The immediate fruit… is the direct jobs that this investment will give. When those miners get paid… there is now money circulating in the economy.” - Minister Paul Kabuswe (Mines & Minerals Development)

“The expansion incorporates some of the most advanced technologies available in the mining industry… focused on boosting operational efficiency, minimizing environmental impact, and ensuring long-term sustainability.” - Kelvin Chitambo, optimization manager at Kansanshi Mining