Ucore
Reports Robust Economics for
Bokan PEA Study
November 28, 2012 –
Halifax, Nova Scotia – Ucore Rare Metals Inc (TSX-V:UCU)
(OTCQX:UURAF)
(“Ucore” or “the Company”) is pleased to report very strong
results of the Preliminary Economic Assessment (PEA)
completed by Tetra Tech of Vancouver, BC, regarding the Dotson
Ridge Zone of
the Company’s Bokan Mountain heavy rare earth property in Southeast
Alaska.
Highlights
of the PEA Include:
·
Net
Present Value (NPV):
$577M at a 10% discount rate, pre-tax.
·
Internal
Rate of Return (IRR):
43%.
·
Payback
Period:
2.3 years.
· Capital
Cost:
$221M, including a complete on-site rare earth oxide (REO)
separation plant, and a contingency provision in the amount of
$25M. Among the
lowest capital outlays in the rare earth mining sector.
·
Mining
Rate:
1,500 tonnes
per day (TPD), 75% of mill feed is eliminated via the use of Dual
Energy X-Ray
Transmission (DEXRT) sorting and magnetic separation, netting
approximately 375 TPD to feed the leach
circuit.
·
Average
Total Rare Earth Recoveries:
81.6%
·
Production
of REOs at site:
Deployment of Solid Phase Extraction (SPE)
technology to generate high purity individual rare earth oxides at
the site.
· REO
Production:
Averaging 2,250 tonnes per year (TPY) during
the first five years at full production, including 95
tonnes
of
dysprosium oxide, 14 tonnes of terbium oxide, and 515 tonnes of
yttrium oxide.
·
Mine
Life:
11 years, based on existing Inferred Mineral Resource
Estimate (April 21, 2011), excluding highly prospective expansion
at depth,
along strike, and other exploration targets at the I&L Zone and
beyond.
·
Direct
Employment:
170 employees.
· Ease
of Shipping Access:
Only rare earth project with immediate deep
water shipping facilities, resulting in prospective mine-mouth
shipping rates
among the lowest in the industry.
· Elimination
of Tailings on Surface at Closure:
Only known mine to eliminate
tailings on surface at closure. All tailings will be placed
underground via
cemented paste backfill. The processing plant will generate
approximately 735
TPD of tailings, significantly less than the mine requirement of
approximately
1,030 TPD backfill.
· Recycling
of Nitric Acid:
Nitric acid that is not consumed in the leach
circuit will be recycled through the use of diffusion dialysis,
greatly
reducing acid consumption by more than 75%, resulting in
significant financial
and environmental benefits.
·
Near
Term, High Value Production:
Relative high percentage of rare earth
metals strategically critical to the US defence, clean energy,
aerospace,
supercomputing and transportation sectors: including Tb, Dy and
Y.
·
Excellent
Geopolitical Support:
Offset of completion risk through strong
legislative and financial support at state and federal
levels.
“The completion of this PEA
is a key milestone in Ucore’s march to near term HREE production,”
said Jim
McKenzie, President & CEO of Ucore. “Bokan’s unique features
have generated
a CAPEX that is among the absolute lowest in the industry,
remarkably including
full downstream separation facilities that promise to render high
purity oxides
both economically and on-site. In turn, the Bokan PEA has delivered
highly
robust IRR and NPV calculations. Beyond all of this, the Bokan
facility will have
little in the way of direct domestic competition. The facility will
generate critical
technology metals that are indispensable and increasingly difficult
to obtain
for applications that are the lifeblood of US competitiveness,
including defense
sector, clean technology, supercomputing, transportation and
advanced aerospace.
Our thanks to the many researchers, scientists, engineering
specialists and
contractors who made this document possible.”
Overview
of Bokan Project and PEA
Ucore’s Bokan Mountain
project is located on Prince of Wales Island, Alaska, approximately
60 km
southwest of Ketchikan, Alaska and 140 km northwest of Prince
Rupert, British
Columbia, with direct ocean access to the western seaboard and the
Pacific Rim. The project is situated in the Tongass
National Forest, within an area set aside for natural resource
development.
The PEA has been completed
based on the Inferred Resource Estimate Technical Report filed on
April 21st,
2011 by Ucore, with the exclusion of the I&L Zone. The
resource was estimated by R. J. Robinson
of Aurora Geosciences. The resource incorporated into the current
mine plan
totals 5.3 million tonnes, with an average grade of 0.65% total
rare earth
oxides (TREO), at a cut-off grade of 0.4% TREO. Of the TREO,
approximately 40%
are comprised of heavy rare earth oxides. A summary of the
operating
assumptions and financial model for the project is as
follows:
Item
|
Units
|
Year
1
|
Year
2
|
Annual for
balance of mine life
|
Tonnes
Mined
|
Mt
|
198,000
|
470,900
|
540,000
|
Tonnes
Processed
|
Mt
|
198,000
|
470,900
|
540,000
|
Mined
Grade TREO
|
|
0.416%
|
0.511%
|
0.473%
|
Recovery
|
|
81.6%
|
81.6%
|
81.6%
|
|
(million
$US)
|
Total
Revenue
|
$2,546
|
Initial
Capital Expenditure
|
$221
|
Sustaining
Capital
|
$145
|
Total
Before-Tax Cash Flow (undiscounted)
|
$1,516
|
Before-tax
NPV @ 8%
|
$697
|
Before-tax
NPV @ 10%
|
$577
|
Before-tax
NPV @ 12%
|
$478
|
Before
tax IRR (%)
|
43%
|
Geology
The Dotson Ridge deposit is
a well delineated rare earth element (REE) mineralized vein-dike
system related
to the Mesozoic Bokan peralkaline granitic complex. The mineralized
system is a
tabular body exposed at the surface for a strike length of 3.5
km. The deposit was drilled to a depth of 450 m, and
remains open both along strike and at depth. The system outcrops
along the
ridge so that it is readily accessible for drilling and bulk
sampling. The REE-bearing veins can be visually
identified
from the surrounding host rock and the material is amenable to
DEXRT sorting,
as noted below. An existing road network
provides access to all main target areas. There are a number of
other
occurrences of REE mineralization located within, or at the margins
of the
Bokan complex which remain highly prospective exploration
targets.
Proposed
Mining Plan
The underground mine design
was completed by Stantec of Tempe, AZ.
The design contemplates trackless mining with adit access and
blasthole
stoping with paste backfill as the preferred mining method for
the
project. This mining approach will
result in a production rate of 1,500 tonnes per day, at a 0.4% TREO
cut-off
grade.
The mine plan proposes the
use of mill tailings as cemented paste backfill to fill the mined
out areas of
the underground workings. At full production, the mill will
produce
approximately 735 TPD of tailings and the mine will require 1,030
TPD of
backfill. This will result in all
tailings being placed underground as backfill, thereby eliminating
the need for
a tailings facility at surface upon mine closure. Waste rock
will be utilized for the remainder
of the backfill.
Proposed
Beneficiation and Processing Plan
The proposed processing flow
sheet consists of three areas: physical beneficiation, leaching and
downstream
REO separation.
i)
Physical
Beneficiation
The mine will produce 1,500
TPD of mineralized material which will be crushed and split into
four size
ranges. The fines will by-pass the sorters and each of the other
size ranges
will feed one of three sorters utilizing dual energy x-ray
transmission. This
circuit will reject approximately 50% of the feed as waste. The
concentrated mineralized
material will then be further crushed and ground in a rod mill. The
resultant material
will be processed by magnetic separators, which will reject a
further 50% of
their feed as waste.
In total, approximately 75%
of non-REE bearing material will be discarded through the physical
beneficiation
process. The remaining 375 TPD of
concentrated mineralized material is further ground to -40 um and
then fed to
the leaching circuit.
The physical beneficiation
circuit results in significant savings in terms of initial capital
expenditure and
ongoing operating costs, due to reduced power and acid consumption
during the leaching
and separation process.
ii)
Leaching
Circuit
The leaching circuit consists
of a nitric acid leach process. The concentrated mineralized
material is
leached utilizing nitric acid heated to a temperature of 90°
C. The resultant slurry is filtered, with solids
then submitted to the backfill plant to be placed underground as
cemented paste
backfill. Prior to the pregnant solution continuing on to the
separation circuit
it is treated by diffusion dialysis in order to recover the
unconsumed nitric
acid. The recovered acid is then recycled into the leach circuit,
resulting in significant
operating cost savings.
iii)
REO
Separation Circuit
The separation of individual
rare earth oxides is achieved through the use of Solid Phase
Extraction (SPE),
a technology developed by IntelliMet LLC of Montana, in conjunction
with Ucore. The pregnant leach solution generated by the
nitric
acid leach is introduced into a series of purpose-built SPE
columns. The first stage of this process removes nuisance
materials such as thorium, uranium, and iron from the
solution. A subsequent series of columns then separates
the rare earths into the following lanthanide sub-classes, Ce-La;
Pr-Nd; Y; Sm-Eu-Gd;
Tb-Dy; and Ho-Er-Tm-Yb-Lu. The final
circuit of columns then separates the subclasses into individual
rare earth chlorides,
which can then be precipitated to generate individual purified rare
earth
oxides.
The SPE process produces
chemical transfers of selective elements from the pregnant solution
to a solid
phase within a matter of seconds, giving the columns the capacity
to process a
large volume of solution in relatively small flow-through
extraction units. The result is a relatively low initial
capital
cost for the SPE circuits. Waste products from the separation
process will be
returned underground as part of the cemented backfill.
Capital
Cost Estimate
Initial capital cost
estimates for the project are as follows:
Item
|
Total Cost
(million $US)
|
Direct Capital Cost
|
Site development
|
6.1
|
Mine underground
|
18.9
|
Mine surface facilities
|
23.8
|
Process
|
62.9
|
Tailings and waste rock
management
|
10.1
|
Utilities
|
3.4
|
Buildings
|
3.0
|
Temporary facilities
|
5.2
|
Plant mobile equipment
& misc.
|
1.4
|
Subtotal
|
134.7
|
Indirect Capital Cost
|
Indirect construction costs
|
51.1
|
Owner's costs
|
10.9
|
Contingency
|
24.5
|
Subtotal
|
86.5
|
Total Capital Cost
|
221.3
|
Initial
capital costs include all costs required to bring the facility to
production. The
ongoing sustaining capital costs are estimated to be $145M over the
11 year
mine life.
Operating Cost Estimate
Item
|
Average
Unit Cost
($US/t mined)
|
Mining
|
41.69
|
Processing
|
54.83
|
G&A
|
13.56
|
Power
|
11.78
|
Misc.
|
0.93
|
Total Operating Cost
|
122.78
|
REE
Pricing Considerations
In developing rare earth
pricing assumptions, a number of sources were considered by both
Ucore and Tetra
Tech. Price forecasts generated by
analysts and Ucore’s rare earth peer group vary widely. In
selecting pricing assumptions, efforts
were made to incorporate assumptions that were independent,
supportable, and
conservative. As a result, Tetra Tech
has used a three-year trailing average of China FOB prices from
October, 2009
to October, 2012 to establish prices for the rare earth oxides,
except Ho, Lu, Yb
& Er oxides, where two-year trailing averages were used due to
limited
Chinese market data. These prices are displayed in
“Scenario 1”
below. The Company also considered the
impact of pricing REO’s based on a 6-month trailing average and a
3-month
trailing average. These results are
displayed in “Scenario 2” and “Scenario 3” below,
respectively.
|
Pricing Scenario 1
3-Year trailing
average
|
Pricing Scenario 2
6-Month trailing
average
|
Pricing Scenario 3
3-Month trailing
average
|
REO
|
$US/kg
|
$US/kg
|
$US/kg
|
La2O3
|
48.69
|
20.85
|
18.42
|
Ce2O3
|
47.21
|
21.38
|
19.23
|
Pr2O3
|
113.10
|
110.00
|
103.08
|
Nd2O3
|
126.70
|
108.96
|
101.58
|
Sm2O3
|
57.74
|
71.79
|
61.42
|
Eu2O3
|
1,834.94
|
2,185.00
|
2010.00
|
Gd2O3
|
81.70
|
99.42
|
96.35
|
Tb2O3
|
1,520.83
|
1,907.12
|
1,840.38
|
Dy2O3
|
845.80
|
1,009.42
|
948.08
|
Ho2O3
|
211.39
|
107.25
|
107.05
|
Er2O3
|
88.20
|
153.61
|
140.08
|
Tm2O3
|
N/A
|
N/A
|
N/A
|
Yb2O3
|
102.79
|
124.07
|
110.51
|
Lu2O3
|
1,036.40
|
1,420.79
|
1,427.56
|
Y2O3
|
80.41
|
100.75
|
85.12
|
|
|
|
|
NPV @ 10%
Discount
|
$577M
|
$620M
|
$513M
|
Economic
Analysis and Sensitivity Analysis
The economic analysis was
based on the mineral resource estimate filed by Ucore in April of
2011, totalling
5.3 million tonnes at an average grade
of 0.65% TREO in the Inferred category.
This resource is adequate to allow for an 11 year mine life, based
on
current mining assumptions including a mining rate of 1,500
TPD. TREO recoveries are expected to average
81.6%.
These assumptions, together
with capital cost and operating cost estimates noted above, result
in a before
tax NPV, at a 10% discount rate, of $577 million. The payback
period for the project is 2.3
years from the start of production. The
project generates a pre-tax IRR of 43%.
A sensitivity analysis was
performed, to test the impact of changes to several key assumptions
included in
the economic model, with the following results:
Changes
to selling price of REOs
|
NPV at 10%, $US
million
|
IRR, %
|
|
|
|
Increase of 20%
|
802
|
52%
|
Increase of 10%
|
690
|
47%
|
Base Case
|
577
|
43%
|
Decrease of 10%
|
464
|
38%
|
Decrease of 20%
|
352
|
33%
|
Changes in
operating costs
|
NPV at 10%,
$ US million
|
IRR, %
|
|
|
|
Increase
of 20%
|
519
|
40%
|
Increase
of 10%
|
548
|
42%
|
Base
Case
|
577
|
43%
|
Decrease
of 10%
|
606
|
44%
|
Decrease
of 20%
|
635
|
45%
|
Change in initial capital
expenditure
|
NPV at 10%, $ US million
|
IRR, %
|
|
|
|
Increase
of 20%
|
526
|
37%
|
Increase
of 10%
|
552
|
40%
|
Base
Case
|
577
|
43%
|
Decrease
of 10%
|
602
|
46%
|
Decrease
of 20%
|
627
|
51%
|
Environmental
Assessment
Ucore is currently
conducting environmental baseline studies to prepare for the
forthcoming
permitting process at the Dotson Ridge Project.
The project plan is being developed in consultation with local
stakeholders as well as state and federal regulators. A Plan
of Operations, which will be based upon
engineered facility designs advanced from the concepts presented in
the PEA,
will be submitted to the US Forest Service (USFS) to initiate a
National
Environmental Policy Act (NEPA) review.
Permitting advantages for the project include the elimination of
a
permanent surface tailings storage facility, due to the use of
x-ray sorting
technology, which will allow for 100% of the mill tailings to be
placed in
mined out areas underground as cemented paste backfill. The study
includes cost
estimates for site water management and treatment.
Qualified
Persons
The technical disclosures in
this press release have been reviewed and approved by Kenneth W.
Collison, P.
Eng. a consultant to and COO of Ucore together with the following
independent qualified
persons;
·
R.
J. Robinson, consultant, Aurora
Geosciences Inc. for geology and mineral
resource
·
S.
Annavarapu, consultant, AMEC (formerly
Stantec) for mine planning.
·
E.
Bentzen, consultant, Lyntek for physical
benefication processes.
·
R.
Hammen, consultant, IntelliMet for leaching
and SPE processes.
·
H.
Ghaffari, consultant, Tetra Tech for cost
estimating.
·
S.
Hafez, consultant, Tetra Tech for economic
analysis.
Cautionary
Notes
Please note that the PEA is
preliminary in nature, that it includes inferred mineral resources
that are
considered too speculative geologically to have the economic
considerations applied
to them that would enable them to be categorized as mineral
reserves, and there
is no certainty that the PEA will be realized.
Mineral resources that are not mineral reserves do not have
demonstrated
economic viability.
Neither the TSX Venture
Exchange nor its Regulation Services Provider (as that term is
defined in
policies of the TSX Venture Exchange) accepts responsibility for
the adequacy
or accuracy of this press release.
About Ucore Rare Metals Inc.
Ucore Rare Metals Inc. is a
development-phase mining company focused on establishing rare metal
resources
with near term production potential. With multiple projects across
North
America, Ucore’s primary focus is the 100% owned Bokan - Dotson
Ridge REE property
in Alaska. The Bokan - Dotson Ridge REE
project is located 60 km southwest of Ketchikan, Alaska and 140 km
northwest of
Prince Rupert, British Columbia and has direct ocean access to the
western
seaboard and the Pacific Rim, a significant advantage in developing
near term
production facilities and limiting the capital costs associated
with mine
construction.
The Bokan property is
particularly enriched with heavy rare earth elements, including the
critical
elements dysprosium, terbium and yttrium. Approximately 40% (by
weight) of the
rare earth elements contained on the Dotson Ridge property are
heavy rare earth
elements, as disclosed in the Company’s NI43-101 resource estimate
technical
report, filed on April 21st, 2011. The resource was
completed by R.
J. Robinson, a consultant from Aurora Geosciences.
For further information,
please contact Mr. Jim McKenzie, President and Chief Executive
Officer of Ucore
Rare Metals Inc. at: (902) 482-5214 or visit
http://www.ucore.com
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