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You want to build a metal smelter of your own? Andy Home

The race to secure vital minerals has created a wealth of opportunity for countries that have the fortune of having the right metal deposits.

The goal is to extract as much value as you can from the metals in the earth.

The obvious answer is processing. Smelters that convert ore to metal are not only more valuable, but also provide a path to greater industrial and economic growth.

It's a way for Western policymakers to loosen China's grip over midstream capacity in a large part of the critical metals spectrum.

According to a joint study by the consultancy CRU, and the World Bank, there are "vast" barriers to setting up a successful business. (Technical and economic feasibility of smelting and refining in developing countries, June 2026).

In order to be profitable during low-price cycles, power supply, infrastructure and logistics are all important.

CONTROL THE ORE

Of course, it helps if the minerals are available.

Integrating domestic mining with processing helps to build price resilience.

It's hard to be in the zinc or copper smelting industry without a guaranteed source of feed. Spot treatment conditions are not favorable, so non-integrated smelters must rely on revenue streams from by-products to survive.

The ore must be kept at home.

Indonesia is the leader in imposing raw material export restrictions to force miners into building processing plants.

Other people do the same.

Cobalt exports are restricted in the Democratic Republic of Congo, lithium is controlled by Zimbabwe and bauxite is controlled by Guinea.

Angola is an interesting exception. It has no bauxite, but it is building a smelter at the port of Barra do Dande with a first-stage production capacity of 120,00 metric tons annually.

Have the Infrastructure

The Angolan project has a deep sea port that is suitable for raw material handling.

The free-trade area is also strategically located, with shared infrastructure and rates for business, as well as reliable power.

Power at a competitive price is essential for any aluminium smelter. This industry can use as much energy as a city of the size Boston in one year.

According to the report, Angolan electricity costs are comparable to global averages. The same is not true in Mozambique, which is why South32 put its Mozal power plant on care and maintenance.

The infrastructure that is most important for copper and zinc smelters is their ability to store, transport, and place the sulphuric acids generated during the smelting processes.

Co-location of copper smelters with large acid users such as fertilizer factories or, as in Zambia, regional mines that use acid as a leaching agent is the most cost-effective.

GET CHINESE HELP

The project's low-cost construction is another advantage.

The capital expenditure (capex), which is estimated at around $2,084 for every ton of aluminum, is higher than the domestic Chinese smelters, but "remarkably" low compared to the rest the world.

The project uses production equipment that was idled in China.

The Chinese are also leading the massive expansion in Indonesia of aluminium smelting capacities, and it is a similar low capex at under $3,000 per tonne.

Capex?for any type of smelter located outside China has been rising due to the soaring costs for equipment and construction.

The number of equipment providers has decreased as fewer smelters have been built in Western countries in the past decade. Prices have increased accordingly.

The authors of the report point out that "Modular equipment with lower specifications and Chinese technology can provide more affordable options."

Not everyone is a winner

It is not possible to build processing capacity in a universal way.

The success or failure of a project depends on a range of complex economic, technical, and institutional factors that differ by metal and country.

Zambia has successfully built up copper processing capacity, but Peru's mining sector and infrastructure are designed to provide raw materials to overseas metal smelters through ocean ports.

Angola's aluminum project is more feasible that Ghana's hopes to revive its existing Volta Smelter. This project faces high modernisation cost, increased?power prices and a lack vertical integration with an Alumina Refinery.

Zimbabwe's lithium reserves are greater than those of Nigeria, which rely on small-scale artisanal mining.

Turkiye’s Siirt Zinc Smelter Project benefits from a strong demand for zinc from the country’s thriving steel sector and a design which allows it to produce valuable by-products like lead, nickel, cobalt and cadmium.

The economics of a site can make a huge difference in the success or failure of a product.

The report concludes that "developing countries should be careful which metals they use, where they locate them, and what business model they choose."

The World Bank is interested in hearing from you if?you are still interested in building a smelter. The World Bank may be able help.

Andy Home is a columnist at. This column is great! Check out Open Interest, your new essential source for global financial commentary. Follow ROI on LinkedIn and X. Listen to the Morning Bid podcast daily on Apple, Spotify or the app. Subscribe to the Morning Bid podcast and hear journalists discussing the latest news in finance and markets seven days a weeks.

(source: Reuters)