Dubbo polymetallic project
The Dubbo zirconium-rare earth element-niobium-hafnium project is composed of one mining lease (1724), which covers an area of 3,456ha (Exhibit 8), within a larger exploration licence, and is focused on the Toongi deposit. The mining lease was awarded in December 2015 and is valid for an additional 21 years, and can be renewed, which should cover the project’s initial 20-year mine life. The project has all the material state and federal approvals, permits and licences in place and is construction-ready, once the finance required to move the project into production is secured.
Exhibit 8: Location of the Dubbo Project
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Source: Alkane Resources – Dubbo Project: Engineering & Financials Update, 4 June 2018
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Two DFSs have been completed for the project (announced in 2011 and 2013). Since then, the company has completed a number of optimisation studies and engineering reviews to improve project metrics and potential returns, culminating in the Dubbo Project: Engineering & Financials Update (announced on 4 June 2018). This study defined a pre-tax NPV8 of A$909m and a pre-tax IRR of 16.1%.
Our valuation of the Dubbo Project is based on the results of this study, which defines a two-stage development programme for the project. Stage 1 will be a 500ktpa operation due to start construction once funding is secured, which in our model we assume is secured early in FY20, as a scenario to demonstrate the potential value of the company. In reality, market conditions will dictate the pace of the development funding timetable, which is considered to be fairly fluid at present.
Following stage 1, an expansion to 1Mtpa is planned for stage 2. The two-stage development allows Alkane to build the project in a more investor-friendly way. The first stage will de-risk the project and act as a proof of concept, potentially allowing the funding for stage 2 to be secured on more favourable terms. Alkane is also examining the potential for a further expansion to 2Mtpa should demand be high enough and funding available. Once the financing is completed, construction of the project is estimated to take 27 months.
Reserves and resources
The Dubbo Project has a total a total JORC 2012-compliant mineral reserve estimate of 18.9Mt at a grade of 1.85% ZrO2, 0.04% HfO2 and 0.7% TREO (Exhibit 3). It’s JORC 2012-compliant mineral resource estimate is 75.18Mt at a grade of 1.89% ZrO2, 0.04% HfO2 and 0.74% TREO (Exhibit 9), excluding yttrium, including yttrium grade is 0.88%.
Exhibit 9: Reserves and resources for Dubbo polymetallic project
Reserve category |
Tonnes (Mt) |
ZrO2 (%) |
HfO2 (%) |
Nb2O5 (%) |
Ta2O5 (%) |
Y2O3 (%) |
TREO (%) |
Proved |
18.90 |
1.85 |
0.04 |
0.44 |
0.03 |
0.14 |
0.74 |
Resource category |
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Measured |
42.81 |
1.89 |
0.04 |
0.45 |
0.03 |
0.14 |
0.74 |
Inferred |
32.37 |
1.90 |
0.04 |
0.44 |
0.03 |
0.14 |
0.74 |
Total |
75.18 |
1.89 |
0.04 |
0.44 |
0.03 |
0.14 |
0.74 |
Source: Alkane Resources – Dubbo Project Resource and Reserve Statements FY17, 19 September 2017
Infrastructure
The Dubbo Project site will require a significant amount of ancillary infrastructure despite its proximity to the town of Dubbo, largely because of the massive scale of the project. The project will be able to use existing roads to transport goods to and from site, but the exiting road to the site entrance will need to be upgraded to accommodate the project's traffic.
The water required for construction and development will come from the Macquarie River and the Upper Macquarie River Alluvial Aquifer. Alkane has already obtained the required licences to extract c 2gl annually.
Natural gas is required to heat reagents within the processing plant and Alkane is in discussions with the owner of the gas distribution network in NSW to expand the existing network to the Dubbo Project site. However, as a base case, the company has assumed the required gas is trucked to site in its estimate of operating costs.
Grid-based high-voltage power will be installed at the site through a single-circuit 132kV overhead transmission line and a dual-circuit 132kV overhead transmission line to the Geurie Switching Station, around 25km away.
The Dubbo Project will use a residue storage facility made up of a series of cells that are double lined to prevent leakage. Cells can be filled, closed and rehabilitated independently of each other, providing a high standard of safety and rehabilitation.
The Dubbo Project will also require the construction of two facilities to produce two of the process plant’s main reagent consumables: sulphuric acid and limestone. Sulphuric acid will be produced in an on-site sulphur-burning plant with waste heat from the acid plant used to co-generate electricity. Limestone will initially be purchased externally, while a quarry close to Geurie can be developed.
Geology
The Toongi deposit, on which the Dubbo Project is focused, is one of several alkaline volcanic and intrusive bodies in the area that formed during the Jurassic period. Toongi is an elliptical-shaped lava flow or sub-volcanic intrusion with a strike of 850m east-west and a width of 550m, extending to a depth of around 115m below the surface (Exhibit 10).
Exhibit 10: Cross-section through the Toongi deposit
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Source: Alkane Resources – Dubbo Project: Engineering & Financials Update, 4 June 2018
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The orebody is dominantly fine-grained micro-porphyritic trachyte that is composed of 80% feldspar, with potassium feldspar, albite and aegirine in roughly equal amounts. The minerals of economic interest are fine grained (<100µm) and fairly evenly distributed throughout the host rock. The bulk of the ore metals occur within Na-Ca-Zr-Hf-heavy rare earth elements (HREE) silicate phase minerals (similar to eudialyte). The dominant Nb and Ta mineral is close to natroniobite in composition and bastnasite hosts the light rare earth metals. The deposit also contains low levels of uranium and thorium and is therefore a weakly radioactive ore.
Mining method
Ore will be extracted from a single open pit using conventional drill and blast operations in two c 10-year stages. The initial open pit (stage 1) will have an area of c 20ha and be excavated down to a depth of c 32m; the second stage will widen the pit to an area of 40ha.
Processing method
Alkane has been working on the processing flow sheet for the Dubbo project since 1998. The flow sheet is based on sulphuric acid and water leaching, followed by solvent extraction recovery and refining. A pilot plant has been periodically operational since 2008.
The extracted ore from the open pit first undergoes several stages of crushing and grinding before being mixed with sulphuric acid and roasted to form sulphated solids (Exhibit 11). The sulphated solids are then cooled, mixed with water and leached into a solution. The leach slurry is washed and separated into two liquors. The first contains the majority of the light rare earth elements (LREE), the second contains the zirconium, hafnium, niobium and HREE.
The liquor containing the HREE and other minerals passes through a solvent extraction circuit in several stages. The zirconium-hafnium precipitate is extracted in the first stage; some of this precipitate then passes to a hafnium-removal circuit producing zirconium and hafnium-rich products. The liquor then passes to a crude niobium-tantalum precipitate that is further refined to produce the final ferro-niobium product. The remaining liquor (mainly HREE concentrate) is combined with the LREE concentrates and pumped to a REE separation process, which produces final separated REEs as oxides.
Exhibit 11: Dubbo flow sheet
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Source: Alkane Resources – Dubbo Project: Engineering & Financials Update 4 June 2018
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Products
The polymetallic nature of the Toongi deposit combined with the complex processing method means Alkane can produce a variety of products to supply a variety of end users, but the products can broadly be split into four groups. Zirconium accounts for 47% of estimated life of mine (LOM) revenue, REE 33%, ferro-niobium 13% and hafnium oxide 7% (Exhibit 12).
Exhibit 12: Percentage contribution of minerals and metals to LOM revenue at Dubbo
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Source: Edison Investment Research
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The Dubbo Project contains 14 of the 15 REEs, but neodymium, dysprosium and praseodymium account for 84% of the LOM REE revenue (Exhibit 13).
Exhibit 13: Percentage of 'contribution to REE revenue (by REE) from the Dubbo Project
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The 14 products Alkane plans to produce are:
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zirconium oxychloride (ZOC), which is used to make other zirconium chemicals;
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zirconium basic carbonate, derived from ZOC, is used in the manufacture of zirconium salts, as well as in coating, painting, papermaking, leather softeners, cosmetics, catalysts, ceramics and as a lacquer dryer;
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high-purity monoclinic zirconia powders are used in refractory materials and molten metal fillers among other things;
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low-hafnium zirconium oxide used to produce zirconium metal in the nuclear industry and attracts a significant price premium over other grades containing hafnium;
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yttria-stabilised zirconia powders and products are used for a range of applications and markets, including zirconia-milling media to reduce and control particle sizes;
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hafnium oxychloride is used as a source of hafnium to produce other hafnium chemicals or complexes, or converted to high-purity hafnium oxide;
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high-purity hafnium oxide has an increasing range of applications due to its specific ferroelectric and thermoelectric properties;
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ferro-niobium, Alkane will produce crushed ingots with a composition of 65% Nb via a joint venture with Treibacher Industrie; the main market for ferro-niobium is the steel industry;
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praseodymium/neodymium oxide are used in rare earth permanent magnets;
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dysprosium oxide is used in conjunction with other elements in making laser materials, commercial lighting and in neutron-absorbing control rods in nuclear reactors;
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terbium oxide is used as a dopant for materials that are used in solid-state devices, and as a crystal stabilizer of fuel cells which operate at elevated temperatures;
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yttrium oxide is a common material used for materials science and inorganic compounds;
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unseparated lanthanum and cerium concentrates used in glass, and as a catalyst for oil cracking and rubbers; and
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heavy and light rare earth concentrates that contain samarium, europium, gadolinium and lutetium.
Additional information on the most economically significant minerals to be produced at Dubbo can be found in the Edison Explains section of our website:
Funding
The capex for stage 1 at Dubbo is estimated to be A$808m and A$692m in stage 2, giving a total expenditure of A$1.5bn. This is a large amount for a company with a market cap of A$99m to secure. Alkane plans to raise the funds required through:
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securing offtake contracts: Alkane has an agreement with Minchem for zirconium products, a JV with Treibacher Industrie for ferro-niobium, a memorandum of understanding with Siemens for a number of REE products and range of other letters of intent for zirconium products; it is continuing its discussions with other potential offtake counterparties;
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the sale of an interest in the project: Alkane continues to meet with potential strategic partners;
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export credit agencies (ECAs): the company continues to liaise with ECAs from potential offtake partner countries, as well as engineering, equipment supply and construction partners;
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traditional debt and equity: the company appointed Sumitomo Mitsui Banking Corporation to assist with arranging the debt financing for the project; and
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non-traditional funding: the company recognises that it may be necessary to look at prepaid offtake contracts, royalties, product streaming and equipment leasing.