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KAMOTO COPPER COMPANY – FEASIBILITY STUDY EXECUTIVE SUMMARY
Rev. 1.0
KAMOTO COPPER COMPANY
EXECUTIVE SUMMARY REPORT
for
KAMOTO REDEVELOPMENT PROJECT
April 2006
,
ISO 9001
KAMOTO COPPER COMPANY – FEASIBILITY STUDY EXECUTIVE SUMMARY
Page i of 38
Table of Contents
1. Introduction ...........................................................................................................................5
2. Study Methodology...............................................................................................................5
2.1 Study Results............................................................................................................................... 6
3. Resources.............................................................................................................................7
4. Overview ...............................................................................................................................7
5. resource development..........................................................................................................9
6. Kamoto Mine..........................................................................................................................9
6.1 Mining Method .............................................................................................................................. 9
6.1.1 Room and Pillar Mining Method. .....................................................................................................9
6.1.2 Long Hole Retreat Stoping .............................................................................................................11
6.1.3 Cut and fill mining with secondary pillar extraction.......................................................................12
6.1.4 Kamoto Development Schedule......................................................................................................12
6.1.5 Kamoto Production Profile .............................................................................................................12
7. Open Pits .............................................................................................................................13
7.1 Dewatering................................................................................................................................. 13
7.2 Operations ................................................................................................................................. 13
7.3 Consolidated Open Pit Production Schedule ............................................................................. 13
8. Kamoto Concentrator .........................................................................................................14
8.1 Summary.................................................................................................................................... 14
9. Luilu
9.1 Summary.................................................................................................................................... 16
9.2 Basis of Design.......................................................................................................................... 17
9.2.1 Process Objective...........................................................................................................................17
9.3 Control Philosophy..................................................................................................................... 17
10. Infrastructure......................................................................................................................18
10.1 Power......................................................................................................................................... 18
10.2 Water ......................................................................................................................................... 18
10.3 Tailings Sites.............................................................................................................................. 18
10.3.1 Kamoto Concentrator.....................................................................................................................18
10.3.2 Luilu...............................................................................................................................................19
11. Human and Social Issues...................................................................................................19
11.1 Project Benefits.......................................................................................................................... 19
11.2 Staffing Levels ............................................................................................................................ 20
12. Environmental .....................................................................................................................20
13. Cost Estimate ......................................................................................................................20
13.1 Capital Costs.............................................................................................................................. 20
13.1.1 Capital Cost Estimate......................................................................................................................20
13.2 Operating Costs .......................................................................................................................... 22
14. Economic Analysis .............................................................................................................23
14.1 Introduction ................................................................................................................................ 23
14.2 Summary.................................................................................................................................... 24
14.3 Sensitivity Analysis ..................................................................................................................... 26
14.3.1 Metal Prices ...................................................................................................................................27
KAMOTO COPPER COMPANY – FEASIBILITY STUDY EXECUTIVE SUMMARY
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14.3.2 Recovery ........................................................................................................................................27
14.3.3 Costs...............................................................................................................................................27
15. Expansion scenario ............................................................................................................29
15.1 Summary.................................................................................................................................... 29
15.1.1 Operating Plan ...............................................................................................................................29
15.2 Capital and Operating Costs....................................................................................................... 30
15.2.1 Capital Cost Estimate......................................................................................................................30
15.3 Operating Costs .......................................................................................................................... 31
16. Economic Analysis .............................................................................................................32
16.1 Summary.................................................................................................................................... 32
KAMOTO COPPER COMPANY – FEASIBILITY STUDY EXECUTIVE SUMMARY
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Table of Contents – Tables
Table 1 - Operating and Capital Costs (per pound of Copper) .....................................................6
Table 2 - Mineral Reserve Summary ............................................................................................7
Table 3 - Mineral Resource Summary ..........................................................................................7
Table 4 - Room and Pillar Extractable Tonnes ...........................................................................10
Table 5 - Input Parameters .........................................................................................................11
Table 6 - Long Hole Retreat Stoping Extractable Tonnes ..........................................................11
Table 7 - Input Parameters .........................................................................................................12
Table 8 - Concentrator Performance ..........................................................................................16
Table 9 - Key Plant Design Parameters......................................................................................17
Table 10 - Total Recoveries........................................................................................................17
Table 11 - Power Consumption (MVA) .......................................................................................18
Table 12 - Economic Benefits .....................................................................................................20
Table 13 - Capital Costs .............................................................................................................21
Table 14 - Replacement and Ongoing Capital Costs..................................................................21
Table 15 - Capital Cost Summary...............................................................................................22
Table 16 – Site Operating Cost by Phase...................................................................................23
Table 17 - Operating Cost Summary ..........................................................................................23
Table 18 - Metal Price Sensitivity................................................................................................27
Table 19 - Recovery Sensitivity ..................................................................................................27
Table 20 - Capital and Operating Cost Sensitivity ......................................................................28
Table 21 – Expansion Scenario Capital Cost .............................................................................30
Table 22 – Expansion Scenario Operating Cost by Phase.........................................................31
Table 23 – Expansion Scenario Operating Cost Summary ........................................................31
Table 24 – Expansion Scenario Economic Benefits ...................................................................32
Table 25 – Expansion Scenario Economic Summary.................................................................32
KAMOTO COPPER COMPANY – FEASIBILITY STUDY EXECUTIVE SUMMARY
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Table of Contents – Figures
Figure 1 - Production Phases .......................................................................................................6
Figure 2 - Plan section – Room and Pillar Common Block .........................................................10
Figure 3 - Plan view – LHRS Common Block .............................................................................11
Figure 4 - Development Schedule ..............................................................................................12
Figure 5 - Production Profile .......................................................................................................13
Figure 6 - Consolidated Open Pit Production Schedule .............................................................14
Figure 7 - LoM Metal Production.................................................................................................25
Figure 8 - LoM Cash Flow...........................................................................................................26
Figure 9 – Expansion Scenario Mine Consolidated Mine Production .........................................30
Figure 10 – Expansion Scenario Mine LoM Metal Production ....................................................33
Figure 11 – Expansion Scenario LoM Cash Flow.......................................................................33
Appendices
Financial Models
A.1.1 Amortized Debt Base Case
A.1.1.1 150,000 tonnes copper per year scenario
KAMOTO COPPER COMPANY – FEASIBILITY STUDY EXECUTIVE SUMMARY
Executive Summary Page 5 of 38
1. INTRODUCTION
The Kamoto Copper Company feasibility study has been commissioned by Kinross Forrest
Limited (KFL) the owner of a 75% interest in the Kamoto Joint venture. The other 25% of the
Kamoto Joint venture is owned by La Générale des Carrières et des Mines (Gécamines). The
feasibility study was commissioned to develop a comprehensive plan for the rehabilitation and
redevelopment of the Kamoto mine and related infrastructure located near Kolwezi in the
Democratic Republic of the Congo (DRC). Katanga Mining Limited (KML) holds an option to
purchase one-hundred percent of Kinross Forrest Limited in the Joint Venture.
This Report was prepared for KFL by a team of companies. HATCH was responsible for
developing the metallurgical /plant engineering studies including mechanical/electrical
engineering; surface infrastructure and financial modelling studies. McIntosh RSV LLC, in
association with Caracle Creek International Consulting Inc. were responsible for the resource
and reserve studies, including mine planning, and SRK Consulting Engineers and Scientists
developed the environmental, tailings and groundwater studies.
The feasibility study premise was based in part on a Pre-Feasibility study that was completed by
Hatch in 2003. The feasibility study has confirmed the general concepts of a phased
redevelopment, restoration of economically viable operations within a very short time and low
capital costs relative to the restored production capacity.
The objectives of the feasibility study were defined as follows:
•
Complete a mineral resource and reserve evaluation in compliance with internationalstandards;
•
Complete a mine design and mine plan to support the mineral reserve estimate;•
Develop and define the production ramp up for the plant facilities in line with the mineplan;
•
Complete an Environmental Impact Assessment;•
Define in detail the Scope of Work for the plant areas, underground and open pit minesand infrastructure, necessary to achieve the ramp up plan;
•
Carry out sufficient engineering to enable the project capital and operating costs to bedefined;
•
Update and Refine the financial model developed in the Pre-Feasibility Study based onthe results of the Feasibility Study.
Because of the extensive use of used equipment and the inherent issues surrounding
refurbishment and replacement issues in the existing plants a slightly lower estimation accuracy
is introduced when compared to a typical feasibility study. However, significant effort has gone
into the study to identify and account for critical pieces of equipment in order to restore and
maintain reliable operations.
2. STUDY METHODOLOGY
The re-establishment of operations is based on a phased approach over a four year period. This
was based on an assessment of the condition of the plant sections, the capacity constraints of
the facilities and the condition of the mines. From this, logical and cost effective incremental
throughput steps were established.
KAMOTO COPPER COMPANY – FEASIBILITY STUDY EXECUTIVE SUMMARY
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Figure 1 - Production Phases
The production rates of phase 4 were maintained for the 20-year analysis period.
2.1 Study Results
The study demonstrates that economically viable operations can be restored within a relatively
short time frame. Capital costs, on a comparative basis for the restored production capacity,
are very low. On an annual basis the operation becomes cash neutral in year four and cash
positive in year eight.
Operating and capital costs, per pound of copper, during the project are summarized as follows:
Phases 1-3 Phase 4 Onward Life of Project
Site Operating cost $1.08 $0.70 $0.74
Cobalt Credit ($0.53)
Total After Cobalt Credit $0.21
Transportation and Marketing Expenses $0.16
Royalty & Lease $0.05
Initial Capital $0.09
Sustaining Capital $0.05
Total Production Costs $0.57
Note: Columns may not add due to rounding
Table 1 - Operating and Capital Costs (per pound of Copper)
The amortised debt discounted cash flow evaluation of the KCC redevelopment project shows
an IRR of 25.5% and a NPV 649 million USD using a 6% discount rate and an 8.5% debt rate
(Appendix A.1.1).
The financial base case carries the following assumptions:
0
50
100
150
200
250
300
0 6 12 18 24 30 36 42 48 54
Project Month
Ore Processed (000s) TPM
Sulfide Ore
Oxide Ore
Phase 1
Phase 4
Phase 3
Phase 2
KAMOTO COPPER COMPANY – FEASIBILITY STUDY EXECUTIVE SUMMARY
Executive Summary Page 7 of 38
•
Execution capital cost USD 426.7 million:•
Sustaining capital costs USD 231.3 million:•
Evaluation Period (LOM) 20 years:•
Copper revenue USD 1.10/lb:•
Cobalt revenue USD 10/lb:•
Total production of copper throughout LOM 2.16 millions tonnes (4 758 million lb);•
Total production of cobalt throughout LOM 0.109 millions tonnes (250 million lb).The project is most sensitive to a change in copper recovery and operating costs.
Appendix A.1 shows the KCC financial base case based on 50% third party debt.
3. RESOURCES
The Property’s mineral reserves and resources as of March 27, 2006 are as follows:
Kamoto Mineral Reserve Estimate, March 28, 2006
Classification Ore Tonnes Copper
Grade %
Copper
Tonnes
Cobalt
Grade %
Cobalt
Tonnes
Proven Mineral Reserves 74,634,497 3.16% 2,359,367 0.33% 244,601
Probable Mineral Reserves 18,531,297 3.07% 569,070 0.32% 58,798
Proven + Probable Reserves 93,165,794 3.14% 2,928,437 0.33% 303,399
Notes: Mineral reserves are separate from mineral resources.
Table 2 - Mineral Reserve Summary
Kamoto Mineral Resource Estimate, March 28, 2006
Classification
Ore Tonnes Copper
Grade %
Copper
Tonnes
Cobalt
Grade %
Cobalt
Tonnes
Measured Mineral Resources 53,124,976 3.37% 1,789,165 0.43% 229,386
Indicated Mineral Resources 19,479,801 3.59% 699,676 0.34% 66,716
Measured + Indicated Resources 72,604,777 3.43% 2,488,841 0.41% 296,102
Inferred Mineral Resources - Kamoto 14,778,192 4.95% 731,521 0.16% 23,645
Inferred Mineral Resources – Open Pits 17,493,384 3.41% 596,169 0.32% 55,723
Total Inferred Mineral Resources 32,271,576 4.12% 1,327,690 0.25% 79,368
Notes: Mineral resources are exclusive to mineral reserves.
Table 3 - Mineral Resource Summary
4. OVERVIEW
Corporate mining activity in Katanga began in 1906 with the formation of Union Miniere du Haut
Katanga (UMHK). In 1967, following national independence the operations of UMHK were
nationalized and incorporated as La Générale des Carrières et des Mines (Gécamines). At its
peak, Gécamines produced about 7 percent of global copper mine production and 62 percent of
global cobalt production. In 1986, Gécamines produced 476,000 tonnes of copper and 14,500
tonnes of cobalt, 63,900 tonnes of zinc, 34.3 tons of silver plus cadmium and other minor
metals. The majority of this production came from the Kolwezi district. By 1995, production had
KAMOTO COPPER COMPANY – FEASIBILITY STUDY EXECUTIVE SUMMARY
Executive Summary Page 8 of 38
fallen to 32,500 tons of copper 3,950 tons of cobalt, 4,500 tons of zinc. The decline in metal
production has continued to the point that primary production in the Kolwezi area has now
virtually stopped with much of the current production coming from site cleanup activities. This
has been due to a number of factors including:
•
The political isolation of what was then Zaire in 1991•
The loss of financial credit lines•
The lack of sustaining capital and maintenance improvements•
Social and political environment within the country during this period•
The collapse of the central portion of the Kamoto underground mineThe Kamoto underground mine is accessed by twin declines, two primary shafts and three
secondary shafts. Primary access is through the declines and ore handling is through the main
shaft where crushed ore is transferred directly onto a conveyor to the Kamoto concentrator.
Exploration and development in the Kamoto underground area began in 1959. Underground
production, which began in 1969, used a variety of large-scale techniques including cut and fill,
room and pillar and sub-level caving. Production steadily increased to reach the rate of
3,000,000 tonnes per year by mid-1970. Production reached a peak in 1989 when the mine
produced 3.29 million tonnes of ore. From the mines start-up in 1969 through 2005, the mine
has produced a total of 59.3 million tonnes of ore at an average grade of 4.21% Copper and
0.37% Cobalt. In 1990, a major collapse in the central portion of the deposit resulted in the loss
of approximately 15 million tonnes of resource. Since that time, due to the issues noted above,
production from Kamoto steadily decreased to the point that production has essentially stopped.
The DIMA open pit group consists of the pits Dikuluwe, Mashamba West and Mashamba East.
These pits primarily provided oxide ore to the Kamoto Concentrator (DIMA sections). The DIMA
pit group operated from 1975 through 1998 during which time a total of 57.7 million tonnes of
ore grading 4.96% Cu and 0.16% Co was mined. By 1998, due to the lack of funds and
increasing costs, these pits were allowed to flood. No significant production has come from
Musonoie-T17.
Dikuluwe
– Began operations in 1975 and ended in 1993. The pit produced a total of 26 milliontonnes of ore at an average grade of 5.47% Copper and 0.10% Cobalt.
Mashamba West
– Mining operations began in 1978 and ended in 1995. The pit produced atotal of 21.8 million tonnes of ore at an average grade of 4.35% Copper and 0.14% Cobalt.
Mashamba East
– Operated from 1985 through 1988, the pit produced a total of 9.8 milliontonnes of ore at an average grade of 4.96% Copper and 0.35% Cobalt.
The Kamoto concentrator consists of four sections, Kamoto 1 and 2 built in 1968 and 1972
respectively and DIMA 1 and 2 built in 1981 and 1982. The Kamoto 1 and DIMA circuits were
designed to process mixed ore types and Kamoto 2 was designed for sulphide ore. From 1969
through 2000, the Kamoto Concentrator processed over 126 million tonnes of ore at an average
grade of 4.33% Copper and 0.28% Cobalt. In its current configuration, the Kamoto concentrator
is capable of processing 7.5 million tons of ore per annum. This throughput was exceeded from
1983 through 1987 with the peak production year being 1985 when production exceeded 7.6
million tons of ore.
The Luilu metallurgical plant is located approximately 6 km north of the Kamoto Concentrator. It
was originally constructed in 1960. In 1972 it was expanded to its present annual capacity of
175,000 tonnes of copper and 8,000 tonnes of cobalt. The site consists of three roasters,
leaching circuit and electrolytic cells for copper and cobalt production. From 1984 through
1989, production at Luilu averaged 173,000 tonnes of copper and 5,900 tonnes of cobalt. The
highest production year was 1986 with 177,500 tonnes of copper and 7,800 tonnes of cobalt.
KAMOTO COPPER COMPANY – FEASIBILITY STUDY EXECUTIVE SUMMARY
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By 1996, production had fallen to an estimated 27,000 tonnes of copper and 1,200 tonnes of
cobalt and has continued to decline.
5. RESOURCE DEVELOPMENT
A substantial resource exists within the Kamoto mine that will be the initial target of a focused
drilling program once operations restart. The first identified target in this resource development
program will be the southern region of Kamoto. A ten hole program has been outlined to confirm
and convert the high grade Inferred Resources in this area into Measured and Indicated
categories. Other under-explored areas within the mine will also be targeted for additional
exploration and development in the early years with the expectation that beneficial modifications
to the current mine plan will be developed as more information is gained. Finally, outside of the
current mine plan area, Kamoto resource potential is still open in most directions.
A district exploration program is also planned once operations are restarted. Recognizing that
no systematic exploration of the project area has been carried out since the 1980’s there are
several highly prospective areas that will provide high quality exploration targets. The DIMA
area currently holds over 20-years of reserves therefore exploration in this area will initially be
focused on enhancing and evaluating the logical expansion of the planned pits.
6. KAMOTO MINE
6.1 Mining Method
The remaining resource areas to be mined consist largely of flat dipping areas, with some
steeply dipping areas mainly concentrated on the western and southern edges of the ore body.
Most of the near vertical or vertical ore body has been mined out, and most of the development
access required is pre-existing to enable extraction of the remainder of the ore body with long
hole drilling.
Three mining methods will be used:
•
Flat dipping areas:1. Footwall benching of all areas pre-developed on the Room and Pillar mining
method;
2. Long Hole Retreat Stoping with top pillar drives.
•
Steeply dipping areas:1. Long Hole Retreat Stoping with top pillar drives;
2. Long Hole Retreat Stoping without top pillar drives.
•
Near vertical or vertical areas:1. Cut and fill mining with secondary pillar extraction.
6.1.1 Room and Pillar Mining Method.
The application of the Room and Pillar method will be limited to areas of the ore body which
have been developed according to this lay out, and where the footwall benching has not yet
commenced. The room and pillar mining zones are as follows:
•
Portions of zone 8 on the Ore Body Supérieur or Upper Ore Body (OBS).KAMOTO COPPER COMPANY – FEASIBILITY STUDY EXECUTIVE SUMMARY
Executive Summary Page 10 of 38
•
Portions of zone 5 on the OBS.•
Portions of zone 1 on the OBS.The key mining activities for this method are the same as previously applied. The only change
between the two methods is the application of backfill in the benched out area. Geotechnical
analysis of the pillars revealed unfavourable safety factors in the slender pillar configuration
after completion of the benching operation.
The backfill is required to:
•
Provide confinement to slender pillars to assist in retaining their load bearing capabilityand preventing premature collapse;
•
Reduce the volume of open stope in mined areas to minimize the probability andconsequences of any pillar collapse and hanging wall caving that may occur.
Ramp
Regional pillars
Areas not benched (5m height)
Areas benched
Benched pillars
X (m)
Z (m) Y (m)
U (m)
W (m)
V (m)
Length (m)
Width (m)
T (m)
U 5.0
V 2.5
W 15.0
X 20.0
Y 15.0
Z 12.0
T 2.5
Dimensions (m)
Figure 2 - Plan section – Room and Pillar Common Block
Figure 2 shows a plan view of a common block (smallest independent block which can be
duplicated to form the mining lay out for the entire ore body). The key mining parameters are
summarized as follows:
Total Area
Geological loss
Initial extraction
Secondary extraction
Backfill required
16375
1638
m2
47%
%
10%
22%
238,680
86,063
Undiluted Ore Flow
Tonnes
510,900
51,090
8798 114,368
7128
Table 4 - Room and Pillar Extractable Tonnes
Room and Pillar Benching Over break
Development over break (h/wall & s/wall) 5%
Benching 5%
Ore loss in stopes 3%
KAMOTO COPPER COMPANY – FEASIBILITY STUDY EXECUTIVE SUMMARY
Executive Summary Page 11 of 38
Table 5 - Input Parameters
6.1.2 Long Hole Retreat Stoping
The Long Hole Retreat Stoping method (LHRS) is the preferred mining method for the
remainder of the Kamoto ore body. The mining method is easily adaptable to either flat dipping,
steeply dipping or near vertical inclinations of the ore body, and is gaining popularity among
other mines in the Copper belt region. The main advantages of the method are:
•
High ratio long hole drilled metres compared to more costly short hole drilled metres, toextract a given tonnage profile per month.
•
Increased utilization of ore body through improved total extraction rate.•
High extraction rates possible due to concentration of mining activities.The main disadvantages of the method are:
•
The need for backfill placement in mined out stopes and the associated binder cost.•
Stopes are no-entry areas, remote controlled load, haul dumpers (LHDs) required.•
Potential for excessive over break on hanging wall contact, thus resulting in increaseddilution.
Figure 3 - Plan view – LHRS Common Block
m2 % Tonnes
Total Area 28,500 889,200
Geological loss 2,850 10% 88,920
Initial extraction 10,125 36% 315,900
Secondary extrac. 20,250 71% 631,800
Final extraction 22,950 81% 716,040
Area filled 20,250 71% 437,400
Cement required 21,870
Undiluted Ore Flow
Table 6 - Long Hole Retreat Stoping Extractable Tonnes
KAMOTO COPPER COMPANY – FEASIBILITY STUDY EXECUTIVE SUMMARY
Executive Summary Page 12 of 38
Long Hole Retreat Stoping Meter Over break
Sidewall over break (initial) - either side 0.5 7%
Sidewall over break (secondary) – 0.75m either side 0.75 11%
Hanging wall over break @ hanging wall value 1 8%
Development over break (h/wall & s/wall) 5%
Ore loss in stopes 3%
Mine Call Factor 100%
Geologic Loss 10%
Table 7 - Input Parameters
6.1.3 Cut and fill mining with secondary pillar extraction.
The key mining activities for this method is the same as historical mining methods. Only a
relatively small portion of the remaining ore body has a vertical or near vertical inclination. The
areas concerned are portions of zone 9 and division 5, which is largely pre-developed and
mainly long hole drilling is required to extract the ore body.
6.1.4 Kamoto Development Schedule
Figure 4 shows the development requirements for the evaluation period. Development is a
combination of 5-meter and 4-meter drifting and production and ventilation raises.
-
2,000
4,000
6,000
8,000
10,000
12,000
14,000
16,000
2007
2008
2009
2010
2011
2012
2013
2014
2015
2016
2017
2018
2019
2020
2021
2022
2023
2024
2025
2026
Development Metres
Figure 4 - Development Schedule
6.1.5 Kamoto Production Profile
Figure 5 shows the total ore production profile for the evaluation period. This is based on the
current proven and probable reserve. As noted in the exploration section of this summary, it is
expected that a focused exploration program will result in the expansion of reserves beyond that
indicated by the current plan.
KAMOTO COPPER COMPANY – FEASIBILITY STUDY EXECUTIVE SUMMARY
Executive Summary Page 13 of 38
-
50,000.00
100,000.00
150,000.00
200,000.00
250,000.00
300,000.00
350,000.00
2007
2008
2009
2010
2011
2012
2013
2014
2015
2016
2017
2018
2019
2020
2021
2022
2023
2024
2025
2026
Average Ore Tonnes per Month
Figure 5 - Production Profile
7. OPEN PITS
7.1 Dewatering
Dewatering of the DIMA pits will require the use of barge mounted pumps and the drilling and
commissioning of a new groundwater pumping wells.
It will require approximately three years to dewater Mashamba East. The Dikuluwe and
Mashamba West pits will be drained over an extended period of approximately 12 years.
It is assumed that six wells will be required to bring the Mashamba East pit into production. The
locations of the wells will need to be finalized at the commencement of mining in accordance
with the planned pit configurations.
7.2 Operations
The open pits will be mined to provide oxide ore. Production will begin in the T17 pit and will
continue there for approximately three years while Mashamba East pit is being dewatered and
prepared for mining. Open pit mining will also be carried out in both Mashamba West and
Dikuluwe in later years. Open pit mining will be done by a contractor.
7.3 Consolidated Open Pit Production Schedule
Figure 6 shows the consolidated production schedule for all the pits. It shows the increased
production at end of mine life to compensate for the drop-off in underground tonnage
KAMOTO COPPER COMPANY – FEASIBILITY STUDY EXECUTIVE SUMMARY
Executive Summary Page 14 of 38
-
1,000,000
2,000,000
3,000,000
4,000,000
5,000,000
6,000,000
7,000,000
2007
2008
2009
2010
2011
2012
2013
2014
2015
2016
2017
2018
2019
2020
2021
2022
2023
2024
2025
2026
Total Ore Tonnes
T17 Mashamba East Mashamba West Dikuluwe
Figure 6 - Consolidated Open Pit Production Schedule
8. KAMOTO CONCENTRATOR
8.1 Summary
Gécamines have historically treated four types of ores at the Kamoto / DIMA concentrator using
different process schemes.
Kamoto – DIMA process performance was reviewed over the life of the plant. Data was
weighted from the actual data given for years 1990 and 1991 based on a Concentrator
production report (for 1991) that was made available. The copper recovery for the concentration
capacity averaged around 86% in the 1980’s rising to around 90% during the 1990’s when the
plant was operating at lower throughputs.
Metallurgical research was undertaken as part of the Feasibility Study aimed at identifying areas
where the performance of the existing operating plant could be improved. This was considered
to be potentially achievable by optimizing the process flow sheet and applying new reagents.
Due to the size of the sample composites, the preliminary nature of the testwork and project
timing constraints there was not a lot of scope for the implementation of results of the
preliminary test work within the process design. However, testwork outcomes have validated
historical production performance data such as concentrate recoveries and grades, identified
recovery limits and highlighted potential for operating cost reductions in the areas of reagent
consumptions. Observations were made with regard to the potential that exists to improve
recoveries in the area of cobalt. Further work is recommended on some of the ores.
Tests indicated that the potential exists to achieve more recovery through finer grinding taking
into account traditional mineralogical constraints such as the tendency to over-slime chalcocite
in the plant autogenous grinding circuit. Copper recoveries of up to 92% were achieved at
rougher concentrate grades above 21%. Additional recovery was achieved as a result of a
tailings regrind, with results consistent with historical plant modifications, indicating that this
circuit should be further investigated if the required regrind capital and power costs were found
to be low enough to be feasible. The cleaner and re-cleaner results indicated that the target Cu
grades of 31% to 44% are easily achievable.
The target copper grade specifications were met for all composites at recoveries ranging
between 70% to 90% Cu for the oxide ores Testwork has indicated that the copper and cobalt
recoveries are sensitive to the over dosage of sulphidiser and there are indications that the
dosage of this reagent can be reduced provided that the cheaper emulsion dosage was
marginally increased from the low levels quoted in the tests, which were significantly lower than
KAMOTO COPPER COMPANY – FEASIBILITY STUDY EXECUTIVE SUMMARY
Executive Summary Page 15 of 38
the consumptions quoted in production records. Gravity separation of a copper rich concentrate
was shown to reduce the reagent consumption significantly on one specific mass fraction, but
more work would be required to confirm that the copper and cobalt recoveries to the combined
gravity/flotation concentrate would not be affected and that the balance of oxide remaining to be
floated would not consume the same mass of reagent per unit volume of slurry generated. It
must be borne in mind that test work sample head grades are 32% higher than forecast for
sulphide and ranging from 56% to 123% higher than forecast in the testwork.
The rehabilitation project consists essentially of equipment replacement and rehabilitation
aiming at improved maintenance, productivity and reduction of operation costs. The
specification for the concentrator was based on a number of documents released from site
personnel. Historical Equipment Lists, Engineers inspection lists, pump schedules and HATCH
questionnaires answered by the client were consolidated to generate a number of phase
specific project Mechanical Equipment Lists. The primary drivers of the overall mining schedule
were sulphide mining production constraints and metallurgical oxide:sulphide balance
constraints. Sulphide throughput has been prescribed with oxide feed levels subsequently
determined by the neutral acid balancing of the refinery solution streams. ‘Mixed’ oxide /
sulphide ore has been assumed to only be mined in Phase III based on the limited mining
planning completed in the early part of this study. This will still require some validation. It is also
assumed for the purposes of scope definition that dolomitic / mixed ore will be campaigned
through the oxide circuit on a regular basis.
Oxide Mill circuit utilization will be very low in phase I and II (there will be a change to a larger
250 tph mill from a 100 tph mill in Phase III). Daily production will continue but on a single shift
basis to facilitate optimum exploitation of the tailings for underground backfill purposes.
Flotation residence time was not prescribed but was calculated from the operation of two 28’
Cascade Mills in parallel. Mineralogical investigations were undertaken to determine the
necessity of the regrinding of concentrate and whether the practice should be re-introduced.
Based on the prescribed design criteria the application of dewatering thickeners to the
concentrate products was not deemed to be necessary. The decision to replace or refurbish the
existing flotation capacity was made on the basis of a capital cost comparison
Some additional recovery benefit is expected to arise from the transition from smaller cells to
larger cells in the later phase of the project. Significant maintenance cost benefits are also
expected. An increase in Cu recovery had been measured to around 1% on similar plants that
have been retrofitted with larger cells. Significant reductions in reagent consumptions have also
been indicated when larger cells were introduced in previous projects.
Preliminary results would appear to indicate that the project could benefit from further detailed
conclusive test work on representative (particularly T-17) composite material before concluding
the level of recovery that can be expected from this ore. It is recommended that oxide tests
should be considered in the future to further evaluate different emulsion component ratios and
the effect of this on Rinkalore Booster to reduce NaSH, NaSiO2, Diesel and lime consumptions.
Table 8 incorporates the best estimates of the concentrator performance based on
historical production data, nominal plant specification and scout test work.
Concentrator Phase 1 Phase 2 Phase 3 Phases 4
Key Data
% Cu %Co % Cu %Co % Cu %Co % Cu %CoFeed
Sulphide Ore 3.51 0.30 4.19 0.31 3.47 0.34 3.14 0.34
Siliceous Oxide 2.73 0.31 2.88 0.30 2.69 0.62 3.03 0.34
Dolomitic Oxide 2.63 0.41 3.41 0.46 2.68 0.27
Concentrates
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Executive Summary Page 16 of 38
Sulphide Concentrate 42.67 3.10 45.82 2.89 45.82 3.75 45.82 4.15
Siliceous Concentrate 22.82 1.80 22.82 1.60 22.82 3.60 22.82 1.77
Dolomitic Concentrate 16.13 0.76 16.13 0.66 16.13 0.49
Tailings
Sulphide Tails 0.39 0.08 0.43 0.08 0.35 0.08 0.32 0.08
Siliceous Tails 0.74 0.16 0.71 0.15 0.66 0.32 0.75 0.18
Dolomitic Tails 0.89 0.37 1.20 0.43 0.91 0.24
Recoveries
Sulphide Ore 89.70 75.5 90.5 76.6 90.5 76.6 90.5 76.6
Siliceous Oxide 75.50 53.1 77.9 53.1 77.9 53.1 77.9 53.1
Dolomitic Oxide 70.0 21.0 70.0 21.0 70.0 21.0
Concentrate Mass Fractions
Sulphide Conc. (%) 7.4 8.3 6.8 6.2
Siliceous Oxide Conc. (%) 9.0 9.8 9.2 10.3
Dolomitic Oxide Conc. (%) 11.4 14.8 11.6
Table 8 - Concentrator Performance
9. LUILU
9.1 Summary
The Luilu Plant is designed to recover copper and cobalt from sulphide, oxide and dolomitic
concentrates produced at the Kamoto concentrator. The operation uses roasting, leaching, and
precipitation circuits to produce copper and cobalt via electrowinning.
The principle of operation of the Luilu Plant is to use the acid generated by the roasting,
leaching and electrowinning of copper from the sulphide concentrates to leach the oxide
concentrates. Balancing the amounts of sulphide and oxide concentrates minimises the
amounts of neutralizing agents or sulphuric acid needed to control the acidity of the process
solutions and reduces the plant operating costs. Consequently, the proportion in which sulphide
and oxide ores are mined, concentrated and presented to the refinery is a key process
parameter.
Process flowsheets, process design criteria and mass balances were developed for the plant,
based on available historical information and in-house knowledge. The major change compared
to historical operation is the implementation of a process control system which constantly
monitors the process conditions in the plant. It is expected that this change, if correctly
implemented, will positively impact overall metal recovery and product quality. Therefore, it is
strongly recommended that after the Luilu Plant has reached stable operation after phase 1
plant start-up, a detailed process review is performed to verify plant operation based on the
developed process design criteria and mass balance and update the design if required.
The process environmental issues are limited to the roaster off gas system and tailings removal.
The existing roasters are equipped with tail gas scrubbers, however it is unlikely that the sulphur
removal efficiency of these scrubbers meets the applicable environmental legislative
requirements. A dual-alkali off-gas scrubbing system is included for the newly installed roasters
(during Phase 2 and 3). The off gas handling problem is therefore limited to Phase 1, when the
existing roaster with tail gas scrubbers is in operation.
The current Luilu plant design assumes that all waste streams generated in the process are
disposed off in the tailings dam with no water recycle to the plant. Incorrect handling and
monitoring of the tailings disposal area could result in downstream handling problems.
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Due to the need to balance the ratio between the oxide and the sulphide concentrate feeds, it is
important that the roaster operation is reliable and the mine is able to produce the required ore
ratio’s. The reliability of the existing roaster poses the main process risk for the refinery in
Phase 1 due to its poor condition. A new roasters cannot be installed prior to Phase 2 due to
the long lead time required.
9.2 Basis of Design
9.2.1 Process Objective
Table 9 identifies the key design parameters for the plant. Copper and cobalt will be recovered
by electrowinning and sold in the form of copper cathode and cobalt broken cathodes (chips).
Upon completion of the simulations, the mass balance was frozen to allow engineering to
commence. This mine plan was adjusted later in the project, resulting in altered production
numbers for the operating cost estimate.
Design Value
Unit
Phase 1 Phase 2 Phase 3 Phase 4
Source
Plant Operating Schedule h/d 24 24 24 24 Kamoto
d/wk 7 7 7 7 Kamoto
d/y 365 365 365 365 Kamoto
Plant Availability % 90 90 90 90 Kamoto
Sulphide Concentrate Feed t/h 6.4 16.2 27.6 37.3 Kamoto
Oxide Concentrate Feed t/h 2.3 7.1 15.2 20.5 Calculated
Dolomitic Concentrate Feed t/h 0.6 1.9 4.2 6.4 Calculated
Overall Copper Recovery % 90.5 90.4 90.3 90.2 Calculated
Overall Cobalt Recovery % 65.1 58.6 57.1 56.4 Calculated
Table 9 - Key Plant Design Parameters
9.3 Control Philosophy
The control philosophy is designed to provide the safe and effective control of the process and
equipment. It provides a simple integrated display of the process operating status and provides
for safe interlocking of processes.
Total Recovery
The feasibility study utilized the following total recoveries:
Phase 1 Phase 2 - 4
Copper Cobalt Copper Cobalt
Sulphide Ore 81.2% 44.2% 81.6% 43.2%
Oxide Ore 68.3% 31.1% 70.3% 29.9%
Dolomitic Ore 63.4% 12.3% 63.1% 11.8%
Table 10 - Total Recoveries
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10. INFRASTRUCTURE
10.1 Power
A total of 303MVA is available to the Kolwezi area. Current consumption is in the region of
80MVA as measured at Substation West, the main transmission substation near Kolwezi.
Power transmission around the mine site is via 110kV lines while distribution is via both 15kV
and 6.6kV power lines.
The maximum demand for the final phase of the KCC project, mining and process included, is
145MVA. Ramp ups are shown in the following figures. This is lower than the installed capacity
of 240MVA. With the installed equipment a firm supply of 120MVA is available at the
concentrator and Luilu.
Table 41 shows the installed power for the different phases. A diversity factor of 80% was used
based on inputs from the various other disciplines and on equipment lists.
For the concentrator and Luilu the majority of equipment will be installed in the first two phases.
This is because most auxiliaries need to run irrespective of production throughput. The figure
also includes small power and lighting, ventilation and compressed air.
Power Consumption
Phase 1 Phase 2 Phase 3 Phase 4
Kamoto DIMA Concentrator 41.6 44.9 48.6 52.1
Luilu 21.1 38.1 54.4 69.1
Underground Consumption 8.0 14.0 19.0 24.0
Total Power Consumption (MVA) 70.7 97.0 122.0 145.2
Table 11 - Power Consumption (MVA)
10.2 Water
Water required for diamond drilling and other exploration and mining activities for the Project
comes from two sites. The Kamoto mine receives an estimated inflow of approximately 60,000
cubic meters per day. From this, a total of 4,000 cubic meters per day is pumped out as potable
water and 19,000 cubic meters is pumped to the Kamoto concentrator for use in the
metallurgical process. Historically, the Luilu metallurgical plant drew up to 620 cubic meters per
hour from the Luilu River. Future operations are based on recycling process water which will
reduce the fresh water demand to approximately 160 cubic meters per hour.
10.3 Tailings Sites
Seven candidate sites were identified for the impoundment of tailings from the Kamoto
Concentrator and two additional sites were located for the disposal of tailings and solid waste
from the Luilu Metallurgical Plant.
Field tests on both the Kamoto and Potopoto Tailings Dams have shown an average density of
1.4 t/m3 for the Kamoto Concentrator tailings at near surface and 0.950 t/m3 for the Luilu
Tailings.
10.3.1 Kamoto Concentrator
After evaluating seven potential tailings sites, the existing Kamoto Tailings Dam was selected
for use by the Kamoto Concentrator. By extending the dam footprint downstream the site can
impound the entire study tonnage.
The preliminary design concepts involve the construction of two closure walls, the first across a
tributary of the Luilu River. The second closure wall will be on the alignment of the current
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Executive Summary Page 19 of 38
Kamoto Tailings Dam embankment. The construction of the closure walls will not only allow
additional storage capacity on the Kamoto Tailings Dam area but it would enable the area
downstream of the existing wall to be integrated into a larger dam footprint.
The return water dam will be located downstream of the closure wall from where the penstock
and under-drainage discharge can be returned back to the Plant.
The entire Kamoto Tailings Dam area will be isolated from the influence of storm events above
the dam footprint area by the construction of storm water diversion structures.
The introduction of the diversion facilities will redirect current stream water crossing the dam. It
will also to reduce the volume of water on the dam that has to be dealt with in the event of a
storm until such time as the tailings dam rises by about another 5m in elevation at the eastern
end of the dam.
10.3.2 Luilu
The new tailings impoundments at Luilu will consist of individual ponds with internal floor
dimensions of 250m by 300m. The floor and perimeter walls will be constructed of compacted
clay to a height of 3 metres above natural ground level. Each impoundment will have an inner
basin area excavated to a depth of 3 metres. The ponds will be built with a dual synthetic liner
with an internal leak detection and drain system installed. Each basin will hold approximately
one year of tailings production. Once filled, the basin will be capped with a local material to shed
water.
Water reuse from the tailings ponds will be maximized with the return water being pumped back
to plant storage for reuse.
11. HUMAN AND SOCIAL ISSUES
11.1 Project Benefits
Katanga Mining Limited (KML) and Kamoto Operating Limited (KOL) will collectively design and
drive social initiatives within the communities in the region, and specifically in the city of Kolwezi
to ensure that the local and regional social infrastructure is benefiting from the project.
These sustainable development programs will be developed in an effort to increase the social
services baseline in the community and will specifically address areas of general education,
advanced technical training, general medical services, local social services, agricultural
education programs and economic opportunities, and other micro-enterprises. These programs
will be reviewed and managed by a collective interest group consisting of corporate / mine
management and community stakeholders.
These programs will provide general guidance to assist in the local and regional economic
rehabilitation resulting from the project’s significant tax contribution, and the many tertiary
economic opportunities that will develop.
During the course of the project the communities and the DRC will recognize the following
economic benefits (000’s USD):
DRC Royalty $139,282
Tax on income $752,445
Dividend tax $151,270
Capital Equipment Duties $15,657
Import Duties Consumables $16,859
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Payroll & Social Support $411,773
Total
$1,487,286Purchased Power Cost $391,256
Table 12 - Economic Benefits
Part of the rehabilitation from a human capital perspective will be to reconstruct the workforce
with experienced, capable workers, as well as skilled educated management and professional
staff. These semi-skilled, skilled, management and professional people will most likely have
gained their work experience with Gécamines.
11.2 Staffing Levels
The proposed staffing levels are based on the phased ramp up schedule.
The total workforce by phase is scheduled to be:
•
Phase 1 : 1,466•
Phase 2 : 1,883•
Phase 3 : 2,154•
Phase 4 : 2,404By utilizing contractors and other available skilled personnel, the company expatriate workforce
will total 32.
12. ENVIRONMENTAL
The project has been planned to confine the entire project to the use of existing mining and
processing infrastructure and footprint areas which have already been disturbed. In this way
Kamoto intends to minimize cumulative impacts and set in motion a process whereby
biophysical conditions in the area will gradually improve, along with a significant socio-economic
improvement in the area.
As required by the Mining Regulations, an Environmental Impact Statement (EIS) and an
Environmental Management Plan of the project (EMPP) have been prepared by SRK
Consulting. They are currently being translated and will be submitted immediately thereafter.
Final closure requirements and associated costs will be developed in consultation with
Gécamines. Upon termination of the operating lease all properties and facilities will revert back
to Gécamines. KCC will reclaim those facilities and operating sites that have been developed by
KCC but which Gécamines does not wish to preserve.
13. COST ESTIMATE
13.1 Capital Costs
13.1.1 Capital Cost Estimate
The initial capital cost of rehabilitating the Kamoto assets have been estimated by the individual
consultancy companies and compiled by Hatch. The ongoing capital cost for replacement of
mining equipment was estimated using a zero-based model. The cost of replacing capital
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equipment in the process plants was estimated based on unit rates. The project calls for two
distinct phases of capital infusion. The first phase relates to the four-year build to a sustainable
production capacity. The second phase consists of ongoing capital replacement costs and lasts
through year 16.
The capital costs for the initial production build up are summarized as follows:
Area Total Phase 1 Phase 2 Phase 3 Phase 4
KTO Mine $ 80,377 $31,683 $20,158 $16,338 $12,158
Open Pits $14,611 $13,161 $1,150 $150 $150
Kamoto Concentrator $55,216 $23,492 $9,835 $14,703 $7,185
Luilu $150,098 $38,772 $44,322 $50,368 $16,635
Infrastructure $23,634 $18,018 $1,662 $3,201 $754
Indirect Costs $54,318 $30,928 $8,421 $7,334 $7,635
Contingency $48,572 $19,504 $10,972 $12,486 $5,611
Total $426,786 $175,558 $96,522 $104,579 $50,128
Note: Columns may not add due to rounding
Costs in 000’s USD
Table 13 - Capital Costs
Replacement and ongoing capital requirements for the life-of-mine analysis period are as
follows:
Area Total
U/G Mine $103,017
Concentrator $30,486
Hydro-Metallurgical $79,310
General & Administration $2,450
Dewatering $16,000
Total $231,263
Costs in 000’s USD
Table 14 - Replacement and Ongoing Capital Costs
•
The estimate is expressed in US Dollars (USD) with a base date of March 2006;•
The estimate consists of four distinct and separate phases in accordance with therequirements of the production ramp-up and is structured according to the Work
Breakdown Structure (WBS);
•
As far as possible, local costs and construction rates were used in the preparation of thecost estimate.
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Capital Costs over the evaluation period life of the project are summarized as follows:
Total(‘000s USD) USD/t ore USD/lb. Cu USD/t Cu
Initial Capex - Phase 1 175,558 1.96 0.04 81
Initial Capex - Phase 2 96,522 1.08 0.02 45
Initial Capex – Phase 3 104,579 1.17 0.02 48
Initial Capex – Phase 4 50,128 0.56 0.01 23
Sub-Total Initial Capex
426,786 4.77 0.09 198U/G Mine Replacement 103,017 1.15 0.02 48
Concentrator Replacement 30,486 0.34 0.01 14
Luilu Replacement 36,750 0.41 0.01 17
Dikuluwe dewatering 16,000 0.18 0.00 7
Additional tailings pond capacity 42,560 0.48 0.01 20
G & A Replacements 2,450 0.03 0.00 1
Sub-Total Replacement
231,263 2.58 0.05 107TOTAL CAPITAL
658,049 7.35 0.14 305Note: Columns may not add due to rounding
Table 15 - Capital Cost Summary
13.2 Operating Costs
The operating cost estimate is based on the phased mining and processing operations.
Underground mining costs were developed by activity. Open pit costs are based on a rate per
tonne on a contract-mining basis. Process costs were similarly developed based on first
principles incorporating energy, reagent and manpower costs.
The usage of individual consumables was calculated in proportion to their major drivers:
sulphide ore milled, oxide ore milled, copper production, cobalt production and operating hours.
The initial estimated operating costs are impacted by the plant throughput ramp-up and by the
metals recovery ramp-up.
Operating costs were estimated for the Luilu plant for four levels of production corresponding to
the four phases of the project. The Metsim mass balance was developed for these four discrete
phases, and from this mass balance reagent and consumable consumption rates were
generated per unit copper or cobalt production. The four sets of consumption rates relationships
developed by the Metsim mass were applied to the relevant phases.
Staffing estimates were developed for each section of the operation. These were done using the
Patterson band grading system. An additional dimension was added to cater for both local and
expatriate labour.
The annual power consumption is based on the connected load of all operating equipment.
Maintenance costs are estimated based, where possible, on comparable operations, and also
as a percentage of the capital costs required to establish a greenfields operation of similar
capacity.
Transport costs were estimated based on the mass of consumables being sourced multiplied by
a relevant quote obtained from a transport operator.
Import duties at three per cent for the duration of the project for all fuels, lubricants, reagents
and consumables as per the DRC mining code.
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Executive Summary Page 23 of 38
Site operating costs by phase are as follows:
Phase 1 Phase 2 Phase 3 Phase 4 Average
Tonnes (t) Copper 23,592 66,510 114,590 1,953,404
Tonnes (t) Cobalt 890 2,757 6,725 102,964
Underground Mining 29,106 37,542 55,362 716,122
Open Pit Mining 20,747 70,591 73,734 841,872
Kamoto DIMA Concentrator 8,415 13,696 22,752 425,791
Luilu Plant 22,762 30,524 50,801 836,989
General & Administration 19,596 15,579 17,392 202,528
Total (‘000s USD) 100,626 167,931 220,041 3,023,302
Cost per lb. (USD/lb. Cu) 1.91 1.15 0.87 0.70 0.74
Cost per lb. Cu (with Co credit) 1.53 0.73 0.28 0.17 0.21
Cost per tonne Cu 4,201 2,525 1,920 1,548 1,627
Cost per tonne Cu (with Co Credit) 3,382 1,611 626 386 469
Note: Columns may not add due to rounding
Table 16 – Site Operating Cost by Phase
Over the analyzed 20-year period, total production costs are as follows:
Total (‘000s USD) USD/t ore USD/lb. Cu USD/t Cu
Underground Mining 838,132 9.36 0.18 388
Open Pit Mining 1,006,945 11.24 0.21 467
Kamoto DIMA Concentrator 470,654 5.26 0.10 218
Luilu Plant 941,075 10.51 0.20 436
General & Administration 255,095 2.85 0.05 118
Site Operating Cost Sub Total 3,511,900 39.21 0.74 1,627
Cobalt Credit (2,498,660) (0.53) (1,158)
Site Operating Cost Total After Cobalt Credit 0.21 469
Transport and Marketing Expenses 769,002 0.16 356
Royalty and Lease Obligations 250,234 0.05 116
Capital Costs 658,049 0.14 305
Total Production Costs 2,690,525 0.57 1,247
Note: Columns may not add due to rounding
Table 17 - Operating Cost Summary
14. ECONOMIC ANALYSIS
14.1 Introduction
The financial model used in the Pre Feasibility study has been updated and expanded in the
feasibility study in consultation with KML.
The model has been developed in real terms i.e. no escalation in revenues or costs.
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The model takes monthly capital, operating costs and revenue into account. These values are
than annualised before the income statement from which the project returns are calculated.
The mine will be run by the Kamoto Operating Company, an independent company contracted
to Kamoto Copper Company.
The financial model allows the returns to the different entities (KCC, KFL and GMC) to be
calculated depending on the level of debt financing. The GMC valuation was based on Artlcle 6
of the agreement between GMC and KCC. According to Article 6 of the agreement between
Gécamines and KCC, ownership of the assets would continue to reside with GMC with any
equipment and facilities acquired outside of the leased assets being ceded to GMC at an
agreed upon rate at termination of the agreement. Consequently, no attempt was made to
establish a value for the assets and any liabilities that may accrue with ownership. Rather, the
focus of financial modeling was on estimating the costs and revenues that would be produced
for the specified production schedule.
The production schedule was driven by the capacity of the concentrator and hydro-metallurgical
plants as well as the underground mine’s sulphide ore production rate. The sulphide to oxide
concentrate balance in the hydro-metallurgical plant then effectively created an oxide and
dolomitic ore demand which the surface mine plan strove to achieve.
Revenue was estimated based on the grade of ore mined and the recovery achieved for the
different ore types by the various plants. The shipping costs required to get the product to
market were then subtracted to determine the net revenue.
Capital cost comprised of both the cost of rehabilitating the Kamoto assets in four phases as
well as the ongoing sustaining capital cost for replacement of mining equipment and maintaining
the plants.
Operating costs for the underground mine, concentrator, metallurgical plant and G&A were
derived using a zero-based model and the mining plan. Operating costs for the open pit mine
were based on contract mining rates.
14.2 Summary
The Kamoto Copper Company – Kamoto Redevelopment Project has been modeled with
financial returns estimated for the following cases:
•
The initial capital investment required to rehabilitate KCC funded by debt (8.5% interestrate) in four tranches, each amortized over 60 months. This is the base case (NPV
based on a 6% discount rate). This evaluation does not attempt to finance any
operational losses occurring in the first years. They are simply treated as negative cash
flows in the first years of the project;
•
KCC funded on a 100% equity basis (NPV based on a 15% discount rate);•
KCC funded on a 100% debt basis (8.5% interest rate), with principal repaid beforedividends are declared to the partners (NPV based on a 6% discount rate).
•
GCM 25% stake in KCC and a royalty with no equity contribution (NPV based on a 6%discount rate).
The financial base case carries the following assumptions:
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Executive Summary Page 25 of 38
•
Execution capital cost USD 426.7 million;•
Sustaining capital costs USD 231.3 million;•
Evaluation Period (LOM) 20 years;•
Copper revenue USD 1.10/lb;•
Cobalt revenue USD 10/lb;•
Total production of copper throughout LOM 2.16 millions tonnes (4 758 million lb);•
Total production of cobalt throughout LOM 0.109 millions tonnes (250 million lb).The amortised debt discounted cash flow evaluation of the KCC redevelopment project shows
an IRR of 25.5% and a NPV 649 million USD using a 6% discount rate and an 8.5% debt rate.
Annual refined copper output peaks at 145,900 tonnes (321 million lbs), while a maximum of
10,000 tonnes (22 million lbs) cobalt is produced (not in the same year due to grade variations).
Average annual production over the 20 year project life is 109,000 tonnes of copper (240 million
lbs) and 5,680 tonnes of cobalt (12.5 million lbs).
Annual Copper and Cobalt production
-
20
40
60
80
100
120
140
160
180
1 3 5 7 9 11 13 15 17 19 21
Year
Tonnes Cu (000
0.0
5.0
10.0
15.0
20.0
25.0
Tonnes C
Copper Cobalt
Figure 7 - LoM Metal Production
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Cash flow for Amortised Debt Scenario (Base Case)
($120)
($80)
($40)
$0
$40
$80
$120
$160
$200
1 2 3 4 5 6 7 8 9101112131415161718192021
Year
US$ million (annu
($1,200)
($800)
($400)
$0
$400
$800
$1,200
$1,600
$2,000
US$ million (cumula
Annual Net Cash Flow Cumulative Net Cash Flow
Figure 8 - LoM Cash Flow
Figure 8 illustrates the net cash flow received by KCC over the 20-year project analysis period
under the base case (amortised debt scenario). The project cash flow can be divided into three
main phases:
1. During the ramp up in years 1-3, KCC is cash negative due to the amortisation schedule
and higher unit operating costs.
2. For years 4-7, KCC is repaying debt and generating an average of USD 61-million free
cash annually.
3. From years 8 onward, the debt is retired and average free cash is driven by the grade
profile of the mine.
14.3 Sensitivity Analysis
Sensitivity analysis considered the impact on the Base Case returns (USD 1.10 Cu and USD
10.00 Co) of variance in the following parameters:
•
Metal Price;•
Process Recovery;•
Capital and Operating Costs.For each, three cases were considered:
•
The project returns to KCC;•
The project returns, assuming 100% equity finance / 100% debt finance;•
The returns to GCM.KAMOTO COPPER COMPANY – FEASIBILITY STUDY EXECUTIVE SUMMARY
Executive Summary Page 27 of 38
14.3.1 Metal Prices
As seen in Table 18, the impact of a $0.10/lb increase in the copper price is roughly equivalent
to a $2.00/lb increase in the cobalt price.
KCC Amortized Debt KCC 100% equity Debt GCM
Copper Cobalt NPV6 IRR NPV15 IRR NPV6 NPV6
$1.00 $9.00 $409 18.4% $32 16.5% $370 $163
$10.00 $494 20.9% $74 18.3% $457 $184
$11.00 $579 23.4% $116 20.2% $549 $206
$12.00 $663 25.9% $157 21.9% $639 $228
$1.10 $9.00 $564 23.0% $108 19.8% $534 $202
$10.00 $649 25.5% $149 21.6% $624 $224
$11.00 $733 28.0% $190 23.3% $714 $247
$12.00 $818 30.5% $231 24.9% $802 $269
$1.20 $9.00 $718 27.7% $182 23.0% $699 $243
$10.00 $803 30.2% $223 24.7% $787 $265
$11.00 $888 32.7% $263 26.3% $874 $287
$12.00 $971 35.1% $304 27.8% $961 $310
Table 18 - Metal Price Sensitivity
14.3.2 Recovery
Table 19 indicates that returns are more sensitive to the recovery of copper than cobalt, with a
4% reduction in cobalt recovery being approximately equivalent to a 2% reduction in copper
recovery:
KCC Amortized Debt KCC 100% equity Debt GCM
Copper Cobalt NPV6 IRR NPV15 IRR NPV6 NPV6
-4% 0% $593 23.8% $122 20.4% $565 $210
-2% 0% $621 24.7% $135 21.0% $595 $217
0% 0% $649 25.5% $149 21.6% $624 $224
+2% 0% $676 26.3% $162 22.1% $654 $232
+4% 0% $704 27.2% $175 22.7% $684 $239
0% -4% $619 24.6% $134 21.0% $593 $216
0% -2% $634 25.1% $142 21.3% $608 $220
0% 0% $649 25.5% $149 21.6% $624 $224
0% +2% $663 25.9% $156 21.9% $640 $228
0% +4% $678 26.4% $163 22.2% $656 $232
Table 19 - Recovery Sensitivity
14.3.3 Costs
Table 20 indicates that project returns are most sensitive to an increase or decrease in
operating costs, and relatively insensitive to variation in the capital costs.
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KCC Amortized Debt KCC 100% equity Debt GCM
Capex Opex NPV6 IRR NPV15 IRR NPV6 NPV6
+10% 0% $611 23.3% $119 19.9% $579 $216
+5% 0% $630 24.4% $134 20.7% $602 $220
0% 0% $649 25.5% $149 21.6% $624 $224
-5% 0% $668 26.7% $164 22.5% $647 $229
-10% 0% $686 28.0% $179 23.4% $669 $233
0% +10% $521 21.1% $81 18.5% $484 $196
0% +5% $585 23.2% $115 20.1% $555 $210
0% 0% $649 25.5% $149 21.6% $624 $224
0% -5% $712 27.9% $182 23.1% $693 $239
0% -10% $776 30.4% $214 24.6% $760 $254
Table 20 - Capital and Operating Cost Sensitivity
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15. EXPANSION SCENARIO
15.1 Summary
Expansion of the Kamoto reserve base will be an immediate priority after operations resume. A
substantial resource exists within the Kamoto mine that will be the initial target of a focused
exploration program once operations restart. The first resource development target will be the
southern region of Kamoto. Other under-explored areas within the mine will also be targeted for
additional exploration and development in the early years with the expectation that beneficial
modifications to the current mine plan will be developed as more information is gained. Finally,
outside of the current mine plan area, Kamoto resource potential is still open in most directions.
The southern region of Kamoto contains substantial measured, indicated and inferred resources
with an average weighted copper grade of 4.58%. A ten hole program has been outlined for this
area with the goal of confirming and converting the high grade Inferred Resources in this area
into Measured and Indicated categories. It is expected that with this drilling and detailed mine
planning this area can be added into the mine schedule.
The scenario is based on these southern resources being converted to reserves and integrated
into the mine plan starting in year nine. Planning accounts for the location and timing relative to
the other mining activities as well as the base operating costs required for mining and
processing. Some additional capital may be required if Kamoto production needs to expand
significantly, however it is expected that ultimately the mining of this or any other higher grade
area would ultimately displace or delay the mining of other lower grade areas.
The same criteria used in the financial base case are used in this scenario. The discounted
cash flow evaluation of this scenario yields a full debt amortized financial base case IRR of
28.6% and a NPV 909 million USD using a 6% discount rate and an 8.5% debt rate (Appendix
A.1.1).
Annual refined copper output peaks at 196,000 tonnes (433 million lbs), while a maximum of
11,200 tonnes (25 million lbs) cobalt is produced (not in the same year due to grade variations).
Total copper production over the analysis period of 20-years is 2,572,000 tonnes while total
cobalt production is 127,300 tonnes.
15.1.1 Operating Plan
Development and operation of the Kamoto mine would be identical to the base case up through
year eight. By then the ventilation and development infrastructure will be sufficient to allow for
the expansion of operations, if required. Open pit production may also have to be expanded to
provide sufficient oxide ore to balance the sulphide production depending upon the final
production profile from Kamoto.
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-
1,000
2,000
3,000
4,000
5,000
6,000
7,000
8,000
2007 2011 2015 2019 2023
'000 tonne
Kamoto T17 Mashamba East Mashamba West Dikuluwe
Figure 9 – Expansion Scenario Mine Consolidated Mine Production
15.2 Capital and Operating Costs
15.2.1 Capital Cost Estimate
Capital costs over the life of the project are summarized as follows:
Total (‘000s USD) USD/t ore USD/lb. Cu USD/t Cu
Initial Capex - Phase 1 175,558 1.75 0.03 68
Initial Capex - Phase 2 96,522 0.96 0.02 38
Initial Capex – Phase 3 104,579 1.04 0.02 41
Initial Capex – Phase 4 50,128 0.50 0.01 19
Sub-Total Initial Capex
426,786 4.24 0.08 166U/G Mine Replacement 103,017 1.02 0.02 40
Concentrator Replacement 30,486 0.30 0.01 12
Luilu Replacement 36,750 0.37 0.01 14
Dikuluwe dewatering 16,000 0.16 0.00 6
Additional tailings pond capacity 42,560 0.42 0.01 17
G&A Replacements 2,450 0.02 0.00 1
Sub-Total Replacement
231,263 2.30 0.04 90TOTAL CAPITAL
658,049 6.54 0.12 256Table 21 – Expansion Scenario Capital Cost
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15.3 Operating Costs
The unit operating costs use the same methodology as the base case. They are based on the
same unit rates for mining and processing by ore tonne and ore type.
Site operating costs by phase are as follows:
Phase 1 Phase 2 Phase 3 Phase 4 Average
Tonnes (t) Copper 23,952 66,510 114,590 2,366,715
Tonnes (t) Cobalt 890 2,757 6,725 116,934
Underground Mining 29,106 37,542 55,362 834,876
Open Pit Mining 20,747 70,591 73,734 841,872
Kamoto DIMA Concentrator 8,415 13,696 22,752 456,897
Luilu Plant 22,762 30,524 50,801 911,935
General & Administration 19,596 15,579 17,392 210,052
Total (000s USD) 100,626 167,931 220,041 3,255,632
Cost per lb. (USD/lb. Cu) 1.91 1.15 0.87 0.62 0.66
Cost per lb. Cu (with Co credit) 1.53 0.73 0.28 0.13 0.17
Cost per tonne Cu 4,201 2,525 1,920 1,376 1,456
Cost per tonne Cu (with Co Credit) 3,382 1,611 626 286 365
Table 22 – Expansion Scenario Operating Cost by Phase
Over the analyzed 20-year life of the project, total production costs are as follows:
Total (‘000s USD) USD/t ore USD/lb. Cu USD/t Cu
Underground Mining 956,885 16.91 0.17 372
Open Pit Mining 1,006,945 22.89 0.18 392
Kamoto DIMA Concentrator 501,760 4.99 0.09 195
Luilu Plant 1,016,021 10.10 0.18 395
General & Administration 262,619 2.61 0.05 102
Site Operating Cost Sub Total 3,744,230 57.49 0.66 1,456
Cobalt Credit (2,806,654) (0.50) (1,091)
Site Operating Cost Total After Cobalt Credit 0.17 365
Transport and Marketing Expenses 913,637 0.16 355
Royalty and Lease Obligations 293,934 0.05 114
Capital Costs 658,049 0.12 256
Total Production Costs 2,803,195 0.49 1,090
Table 23 – Expansion Scenario Operating Cost Summary
Under this scenario, the communities and the DRC would recognize the following economic
benefits (000’s USD):
DRC Royalty $162,596
Tax on income $1,022,409
Dividend tax $201,794
Capital Equipment Duties $15,657
Import Duties Consumables $18,620
Payroll & Social Support $411,773
KAMOTO COPPER COMPANY – FEASIBILITY STUDY EXECUTIVE SUMMARY
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Total
$1,832,849Purchased Power Cost $405,530
Table 24 – Expansion Scenario Economic Benefits
16. ECONOMIC ANALYSIS
16.1 Summary
The alternative scenario has been modeled with financial returns estimated for the following
cases:
•
The initial capital investment required to rehabilitate KCC funded by debt (8.5% interestrate) in four tranches, each amortized over 60 months. This is the base case (NPV
based on a 6% discount rate). This evaluation does not attempt to finance any
operational losses occurring in the first years. They are simply treated as negative cash
flows in the first years of the project;
•
KCC funded on a 100% equity basis (NPV based on a 15% discount rate);•
KCC funded on a 100% debt basis (8.5% interest rate), with principal repaid beforedividends are declared to the partners (NPV based on a 6% discount rate).
•
GCM 25% stake in KCC and a royalty with no equity contribution (NPV based on a 6%discount rate).
This financial case uses the same financial assumptions carried in the Feasibility Study financial
analysis.
KCC Base case KCC 100% equity Debt GCM
Copper Cobalt NPV6 IRR NPV15 IRR NPV6 NPV6
$1.10 $10.00 $909 28.6% $241 24.2% $885 $298
Table 25 – Expansion Scenario Economic Summary
Annual refined copper output peaks at 196,000 tonnes (433 million lbs), while a maximum of
11,200 tonnes (25 million lbs) cobalt is produced (not in the same year due to grade variations).
Total copper production over the analysis period of 20-years is 2,572,000 tonnes while total
cobalt production is 127,300 tonnes.
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Annual Copper and Cobalt production
-
50
100
150
200
250
1 3 5 7 9 11 13 15 17 19 21
Year
Tonnes Cu (000
0.0
5.0
10.0
15.0
20.0
25.0
Tonnes C
Copper Cobalt
Figure 10 – Expansion Scenario Mine LoM Metal Production
Cash flow for Amortised Debt scenario
($120)
($80)
($40)
$0
$40
$80
$120
$160
$200
1 2 3 4 5 6 7 8 9101112131415161718192021
Year
US$ million (ann
($1,200)
($800)
($400)
$0
$400
$800
$1,200
$1,600
$2,000
US$ million (cumula
Annual Net Cash Flow Cumulative Net Cash Flow
Figure 11 – Expansion Scenario LoM Cash Flow
Figure 8 illustrates the net cash flow received by KCC over the 20-year project life under the
base case (amortised debt scenario). The project cash flow can be divided into three main
phases:
1 During the ramp up in years 1-3, KCC is cash negative due to the amortisation schedule
and higher unit operating costs.
2 For years 4-7, KCC is repaying debt and generating an average of USD 60-million free
cash annually.
3 From years 8 onward, the debt is retired and average free cash is driven by the grade
profile of the mine.
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Financial Models
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A.1.1 Amortized Debt Base Case
KCC 100% Amortized Debt Description TOTALS 1 2 3 4 5 6 7 8 9 10
Profit After Tax USD '000s $1,561,863 ($58,775) ($22,508) ($17,374) ($3,451) $46,063 $83,612 $101,539 $126,222 $137,228 $142,545
Depreciation USD '000s $760,157 $0 $0 $0 $106,684 $108,840 $61,966 $50,454 $42,867 $34,011 $27,212
Interest USD '000s $98,584 $13,793 $18,776 $21,466 $18,539 $13,737 $7,388 $3,522 $1,164 $200 $0
Sub-Total Cash Generated By Operations USD '000s $2,420,604 ($44,982) ($3,732) $4,091 $121,772 $168,639 $152,965 $155,516 $170,253 $171,439 $169,757
Amortized Capital USD '000s ($525,370) ($43,222) ($66,986) ($88,442) ($97,875) ($105,074) ($61,852) ($38,088) ($16,633) ($7,199) $0
Replacement Capital USD '000s ($231,263) $0 $0 $0 ($814) ($4,254) ($24,723) ($21,901) ($20,594) ($19,914) ($9,434)
Witholding Taxes USD '000s ($151,270) $0 $0 $0 $0 $0 $0 ($94) ($12,093) ($13,121) ($14,575)
Project Negative Cash Position USD '000s $0
Net Cash Flow USD '000s $1,512,701 ($88,204) ($70,717) ($84,350) $23,083 $59,311 $66,390 $95,432 $120,933 $131,205 $145,748
Discount Factor
6% 94.34% 89.00% 83.96% 79.21% 74.73% 70.50% 66.51% 62.74% 59.19% 55.84%NPV USD '000s
$648,586 ($83,211) ($62,938) ($70,822) $18,284 $44,321 $46,802 $63,468 $75,875 $77,660 $81,385IRR
25.50%KCC 100% Amortized Debt
11 12 13 14 15 16 17 18 19 20 21
Profit After Tax $116,922 $145,727 $142,736 $105,710 $66,206 $61,443 $51,065 $93,200 $95,969 $112,624 $35,160
Depreciation $34,619 $33,924 $34,332 $32,540 $24,556 $31,220 $32,950 $32,817 $32,865 $38,174 $124
Interest $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0
Sub-Total Cash Generated By
Operations
$151,542 $179,652 $177,067 $138,250 $90,763 $92,662 $84,015 $126,017 $128,834 $150,799 $35,284
Amortized Capital $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0
Replacement Capital ($26,733) ($23,904) ($23,842) ($17,797) ($8,260) ($15,271) ($7,740) ($3,040) ($3,040) $0 $0
Witholding Taxes ($11,346) ($14,159) ($13,930) ($10,950) ($7,500) ($7,036) ($6,934) ($11,180) ($11,436) ($13,709) ($3,208)
Project Negative Cash Position
Net Cash Flow $113,463 $141,589 $139,296 $109,503 $75,003 $70,356 $69,341 $111,797 $114,358 $137,090 $32,076
Discount Factor 52.68% 49.70% 46.88% 44.23% 41.73% 39.36% 37.14% 35.03% 33.05% 31.18% 29.42%
NPV $59,771 $70,365 $65,307 $48,433 $31,296 $27,695 $25,751 $39,168 $37,797 $42,745 $9,435
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Project amortization cash flow based on the following schedules:
Start Month Term
(months)
USD ‘000
Tranche 1 1 60
175,558Tranche 2 13 60
96,522