Innovative low-impact supply of critical raw materials from the Copperbelt (HE INSOKA)

Introduction

The INSOKA consortium unites leading European and Zambian partners across research, industry, and civil society to establish a new paradigm for responsible critical raw material supply. Rather than relying solely on new primary mining, INSOKA pioneers competitive and responsible reprocessing of legacy and production tailings. The project focuses on Mopani Copper Mines (MCM) operation, in particular its Nkana–Mindola historical tailings site as its main case study, with replication across the wider Copperbelt.

At its core is a low-cost Pond Bioleaching process (Low-Duty Bioreactor; LDB), using lined ponds and floating agitators to achieve microbial leaching of Cu–Co sulfides at far lower CAPEX/OPEX than conventional stirred tanks (STR) bioleaching. Residues are rendered inert and/or valorised as construction materials, supporting a near-zero-waste approach. Downstream, INSOKA validates sustainable solvent extraction (SX) routes for the separation and refining of Cu and Co, producing high-purity refined products for European end-users, including cobalt sulfate for the electric vehicles market through Kobaloni Energies. The combined benefits vs incumbent practices include >30% lower CO₂ footprint, >20% energy savings, and significant reductions in water use and long-term liabilities.

Demonstrated in Zambia, INSOKA supports both the EU Critical Raw Materials Act targets (diversification, sustainability, resilience) and Zambia’s “Three Million Tonnes” copper initiative, transforming a growing national two-billion-tonne tailings stockpile into a scalable resource recovery opportunity with measurable ESG gains.

Partners: BRGM – French Geological Survey, Copperbelt University (Zambia), Katholieke Universiteit Leuven, Technical University of Crete, Caspeo, Tecnalia Research Centre, Maelfwyn Mineral Services, Milton Roy Mixing, Kobaloni Energy, Mopani Copper Mines, Shell, Aurubis

The coordinator of the project: BRGM – French Geological Survey

Funding authority: Horizon Europe

Contact persons: Sonja Lavikko and Quentin Dehaine

 

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