TIDMAMI
RNS Number : 2948L
African Minerals Ltd
03 July 2014
03 July 2014
African Minerals Limited
("African Minerals", "AML", or "the Company")
Results of Phase 2 Friable Hematite Concentrator Engineering
Study
African Minerals Limited is a mineral exploration, development
and mining company, and is the developer and operator of the
Tonkolili iron ore mine in Sierra Leone.
The first Phase of operations at Tonkolili has been the
establishment of a sustainable production level of 20Mtpa from the
direct shipping ore ("DSO") portion of the ore body, recently
re-estimated as having a remaining resource of 140Mt, and
representing only 1% of the total Tonkolili resource.
The first part of Phase 2 is the expansion of DSO processing and
infrastructure operations to a capability of 25Mtpa, which is
currently underway. The next stage of Phase 2 is the establishment
of concentrator facilities to treat the large underlying ore
resource, which requires processing to a concentrate. Over time,
the concentrator capacity will increase to fully replace the
depleting DSO resource.
Following receipt of Engineering Studies from Ausenco, the
Company today provides an update regarding this Phase 2
strategy.
Highlights
-- The first friable hematite concentrator will involve a low
capital intensity conversion of the current large Wet Process Plant
1B, including raw water supply, tailings storage, infrastructure
and ancillary services. Commissioning of the first units is
expected to commence within 12 months of project start
-- The estimated capital costs for this brownfield conversion
and associated additional works have been reduced by over $1
billion, to $311 million (+/-25%), prior to final value
engineering
-- The concentrator will target production of c11 million tonnes
per annum ("Mtpa") of a +63% Fe concentrate product, with an
average mass yield of 56%, from head feed sourced from the medium
grade portion of the 1.1 billion tonne ("Bt") friable hematite
resource
-- Based on current reference prices, gross revenue per tonne is
expected to increase by c$30/t for this concentrate tonnage, with
an expected increase in EBITDA margin of $20-25/t as operating
costs for the concentrate product are expected to be slightly
higher in C1 cash cost than for the DSO
-- The Tonkolili Mine will be able to produce 11Mtpa of high
quality concentrate, and over 14Mtpa of DSO product concurrently,
maintaining a +25Mtpa production profile with all-year-round
shippable products
Chief Executive Officer, Bernie Pryor, commented
"I am pleased to confirm that, after six months of intensive
engineering, testwork, analysis and process design, our Phase 2
project could commence production as early as next year.
Our metallurgical expectations have also been surpassed. We had
targeted 35-40% yield to a 62% concentrate, and we are delighted
that the work to date has shown that we can achieve 56% yield to a
63% concentrate, and a lower moisture level of c9%, with associated
significant positive impacts on both cost and revenue.
We have looked at the project with a firm focus on reducing the
capital requirement. Over the course of the design process we have
shaved over $1Bn off our original estimates, and have accelerated
implementation by a year. The innovative brownfield conversion of
our 1B processing plant means that our total capital cost is now
only expected to be $311M (+/-25%), including all ancillary
works.
The commencement of production of a high quality concentrate
will improve our revenue per tonne considerably, thereby expanding
our margin, while maintaining our +25Mtpa production profile.
The replacement of over 45% of our current DSO tonnage by this
high grade high value concentrate product, and the concurrent
running of concentrate alongside DSO, would allow us to defer
further capital expenditure for additional concentrators, which
would now only be required to be in production in 2020 or later,
thus allowing more of the project's near term cash flow to be
returned to the project's shareholders."
Results of Engineering Design for Friable Hematite
Concentrator
AML engaged Ausenco to undertake a study of the various options
of development for the initiation of concentrate production, which
envisaged the construction of a c10Mtpa output of concentrate from
the friable hematite portion of the Tonkolili ore body. Ausenco is
a leading engineering and project management services company
servicing the global resources and energy sectors.
Following the detailed engineering studies and the assessment of
multiple flowsheet options, supporting laboratory and pilot scale
testwork and front end engineering design work, as well as the
receipt of results following the completion of a large (1,000t)
industrial scale bulk sample process test of all proposed headfeed
types through London Mining's Marampa concentrator facilities, the
Company has now frozen its flow sheet for the establishment of its
first friable hematite concentrator.
Quality
The flow sheet incorporates crushing and screening, ball milling
in closed circuit with cyclones to <0.710mm, followed by low
intensity and wet high intensity magnetic separation, and finally
rejection of gangue material including quartz from the iron
minerals using reverse flotation, followed by belt filtration.
Results of laboratory and pilot scale testing indicate production
of a 63% Fe concentrate with indicated silica content of less than
5%, alumina of below 2.5%, and a moisture content of 9%.
Production
The initial output from this concentrator, for at least the
first four years, will be c11Mtpa of high grade concentrate. The
designed head feed for the concentrator will be c8Mtpa from the
friable hematite resource, together with c10Mtpa from the -2mm
fines from plants 1D and 1G (as discussed in our press release of
26 June 2014) and c2Mtpa from tailings recovery, giving a mass
yield of 56% from headfeed to concentrate. 1D and 1G plants will
together continue to produce c14Mtpa of intermediate and lump
product, and generate c10Mtpa of fines feed into the
concentrator.
Mining
Total head feed required from mining across all of the process
plants will be c32Mtpa, generating c11Mtpa of concentrate product
and c14Mtpa of DSO products, with an overall yield of 78%, compared
to the designed DSO only yield of 84%. As such, direct mining and
process volumes will increase marginally by around 8%. The
additional process steps and power requirement will also increase
the unit cost of processing. Friable hematite volumes will
initially be sourced from stockpiles developed from DSO mining
(previously capitalized).
Operating Costs
The total increase in mine and process operating costs across
the full tonnage suite is expected to be in the region of c$4/t,
equivalent to c$10/t for the concentrate tonnage alone. Power will
be provided by a third party on an operating cost only basis. The
current power production capability of the mobile diesel generators
at Tonkolili is 20MW, and the requirement post this conversion is
expected to rise to 42MW. We intend to award a BOOT contract
(build, own, operate, transfer) for the construction of a new c50MW
power station consisting of high efficiency, medium speed
reciprocating engines operating on medium or heavy fuel oil.
Revenue
Revenue per tonne will increase significantly. The current TSI
62% price is $95/t whereas that for the Platts 58% price, off which
the current DSO product is priced, is $73/t. Furthermore, current
deleterious element and physical property discounts that the DSO
attracts are c$8/t. The clean, low silica, low alumina 63% product
is expected to attract a $-3-4 premium over the 62% index, and have
minimal penalties, estimated at $2/t. As a result we expect
improvement in our reference pricing of over $30/t in revenue per
dry tonne for this concentrate tonnage (under current pricing
conditions).The reduction in moisture content from the current
c10.5% to a planned 9% after belt filtration, will reduce
equivalent dry freight rates marginally, and will capture the price
benefit of more dry material delivered at the full CFR China price,
resulting in an additional moisture benefit equivalent to a further
$2/t.
Capital Costs
The capital cost of the conversion of the 1B Wet Process Plant
to produce a concentrate, is estimated at $202M. Tailings storage
facility ($26M), indirect construction costs ($15M), and on site
infrastructure ($7M) bring the total engineered cost to $250M.
Owner's costs ($5M) and Engineering, Procurement and Construction
Management ("EPCM") costs ($32M) bring the total to $288M. With a
contingency of 10% of the direct costs for the conversion of this
existing plant, we estimate that the full capital cost to the
commencement of concentrate processing, including all ancillary
work, will be $311M. The amounts quoted are estimated with a +/-25%
confidence range. We will complete value engineering during
detailed design to reduce this further.
The boards and shareholders of the operating companies, which
include Shandong and Government representation, will now review the
engineering studies prior to approval and implementation. Funds
required to commence this project are available and are held at the
operating companies.
The information in this announcement that relates to the design,
capital and operating cost estimates for the mineral processing and
associated infrastructure is based on information compiled by
Ausenco under the study management of Mr L. Paul Staples, P.Eng. He
is a Member of the Australasian Institute of Mining and Metallurgy
and has sufficient experience, which is relevant to the activity he
is undertaking, to qualify as a Competent Person as defined in the
JORC Code. Mr Staples consents to the inclusion of such information
in this Report in the form and context in which it appears.
The information in this announcement that relates to
Metallurgical Test Results is based on information compiled by Dr
John Clout who is a Fellow of the Australasian Institute of Mining
and Metallurgy. Dr Clout was a consultant to African Minerals
Limited during the study. Dr Clout has sufficient experience, which
is relevant to the style of mineralisation and type of deposit
under consideration and to the activity, which he is undertaking to
qualify as a Competent Person as defined in the JORC Code. Dr Clout
consents to the inclusion in the report of the matters based on his
information in the form and context in which it appears.
Contacts:
African Minerals Limited
+44 20 3435 7600
Mike Jones
Tavistock Communications
+44 20 7920 3150
John West / Jos Simson / Nuala Gallagher
Jefferies
+44 20 7029 8000
Nick Adams / Alex Collins
About African Minerals
African Minerals operates the Tonkolili Iron Ore Project (the
"Project") in Sierra Leone, with a JORC compliant resource of 12.8
Bt. The Project, which currently has a 60+ year mine-life, is being
developed in a number of staged expansions. In 2013, African
Minerals completed sales of 12.1 Mt to its customers. The current
year sales guidance is for 16-18 Mt of exports as the operations
focus on operating at the 20 Mtpa run rate design capacity.
Phase II expansion will see exports increase to 25 Mtpa, and
will incorporate production of a high grade concentrate product.
Concentrate production will begin in 2015 and will eventually
displace current DSO production as concentrate volumes increase and
the DSO resource depletes over time.
The Company has also developed significant port and rail
infrastructure to support the operation of the Project, via its
subsidiary African Rail and Port Services (SL) Limited ("ARPS"), in
which the Government of Sierra Leone ("GoSL") has a 10% free
carried interest.
The Project companies are currently owned 75% by AML, and 25% by
Shandong Iron and Steel Group ("SISG"), except for ARPS, which is
currently owned 75% by AML and 25% by SISG, with the GoSL having
the right to a 10% free carried interest from AML.
www.african-minerals.com
This information is provided by RNS
The company news service from the London Stock Exchange
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