Vision, turned
into plants.
At Rotehügels we don’t just advise — we execute. From a greenfield copper plant on the Zambian Copperbelt to a zero-discharge zinc recycling facility in Chennai, every project is built on the same foundation: rigorous research, safe execution, and sustainable outcomes.
Swarna Metals Zambia Limited — A Greenfield Copper Project
In Zambia’s Copperbelt, Rotehügels supported process engineering and commissioning for Swarna Metals Zambia Limited — a greenfield hydrometallurgical copper extraction facility operated by PLR Zambia Limited (part of the PLR Projects group). Construction began in April 2024; first commercial production was achieved in October 2025.
Scope
Commissioned a facility processing 1,200 MT/day of ore across two circuits.
Concentrator (crush → grind → flotation) for sulphide ore; leach + SX–EW for oxide and mixed ores.
Innovation
Flexible design for mixed sulphide–oxide ores, adaptive reagent schemes to handle impurities (As, Pb, Sb), and by-product recovery opportunities (Ag, Ni, Co).
Sustainability
Onsite reservoir for water security and a thickener–clarifier system recycling >50% process water.
Circular economy built into design from day one.
Output
- ~1,000 MT/month copper concentrate
- ~200 MT/month of 99.99% copper cathode
- 200+ direct jobs, 2,000+ indirect beneficiaries
- Construction to first copper: 18 months (Apr 2024 → Oct 2025)
Source: swarnametals.com — public company disclosure.
Zinc Dross Recycling Plant — Chennai, India
Rotehügels is currently delivering a complete turnkey Zinc Dross Recycling facility for a confidential industrial client in Chennai, India — covering full layout design, civil construction, CAPEX equipment procurement, and the supply of custom-manufactured electrodes. Client identity will be disclosed upon successful commissioning.
300 kg/day
Processing Capacity
Zinc dross feed
≥ 60%
Zinc Feed Grade
Zn content in feed
₹2.5 Cr
Project CAPEX
End-to-end EPC
6 months
Timeline
Oct 2025 → Apr 2026
EPC Scope
- • Complete plant layout design
- • Civil construction management
- • CAPEX equipment procurement
- • Process flowsheet: dross processing → electrowinning → casting
- • Commissioning, ramp-up & production stabilisation
Custom Electrode Supply
Rotehügels is manufacturing and supplying bespoke electrodes engineered to the customer's exact electrowinning process requirements:
- • Pb-Ca / Pb-Ca-Ag alloy lead anodes — custom dimensions
- • High-purity aluminium cathodes — custom dimensions
- • Designed for high-efficiency zinc electrowinning
Output Products
- • Zinc cathodes — high-purity electrodeposited zinc
- • Zinc ingots — cast for direct market sale
- • Value recovery from a previously wasted industrial by-product
Sustainability & Compliance
- • Zero liquid discharge — all process water treated and recycled
- • All waste streams handled per PCB guidelines
- • ~109 tonnes/year of zinc dross diverted from landfill
- • Circular economy model — industrial waste to saleable metal
Social & Economic Impact
30–40
Direct jobs created
10×
Indirect beneficiaries per direct job
₹2.5 Cr
Local industrial investment
Digital Integration — Complimentary
Rotehügels is implementing AutoREX™ — our intelligent process automation platform — at this facility at no additional cost. AutoREX will provide real-time parameter monitoring, AI-powered anomaly detection, and predictive maintenance from day one of commissioning.
Looking Ahead
From a $30M greenfield copper plant in Zambia to a zero-discharge zinc recycling facility in Chennai — Rotehügels delivers across geographies, scales, and metals. Every project is built on the same foundation: rigorous research, safe execution, and sustainable outcomes.