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Sierra Leone
Sierra Rutile Mine (Sembehun Expansion Project)

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 Location:
120km WSW from Kenema, Sierra Leone

  Regional Office:
20 Hill Cot Road Hillstation
Freetown
Sierra Leone
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  • Overview
  • Owners
  • Geology
  • Mining
  • Processing
  • Production
  • Reserves
  • Costs & Financials
  • Personnel
  • Filings & News

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Overview

StageProduction
Mine TypeOpen Pit
Commodities
  • Heavy Minerals
  • Rutile
  • Ilmenite
  • Zircon
Mining Method
  • Truck & Shovel / Loader
Processing
  • Electrostatic separation
  • Desliming
  • Spiral concentrator / separator
  • Flotation
  • Magnetic separation
Mine Life2039
Sierra Rutile’s current mining and mineral processing operations at Area 1 include four wet concentrator plants (WCPs); a mineral separation plant (MSP). Sierra Rutile also includes Sembehun project which is scheduled to stert constraction in 2024.

Sembehun is one of the largest and highest grade natural rutile deposits in the world.


Owners

Source: p. 127
CompanyInterestOwnership
Iluka Resources Ltd. 100 % Indirect
Sierra Rutile Ltd. (operator) 100 % Direct
Sierra Rutile is a wholly owned subsidiary of Iluka Resources (Iluka).

Deposit Type

  • Mineral sands
  • Sedimentary


Summary:

The Sierra Rutile Area 1 (the Gangama and Lanti Deposits and other deposits within SRL’s current operations in Sierra Rutile Area 1) consists of a series of prominent hills and slight undulations with an elevation range of 0.9 meters above sea level (masl) along the mangroves, to 322 masl with the highest point being at Gbangbama Hill. The existing dredge ponds and rutile deposits are situated around the Imperi Hills region on the western and south-western extent, with the Lanti and Gangama expansion situated within the alluvial plains and mangrove swamps to the north west. The hills in the region have relatively steep slope angles and form prominent features in the landscape. The majority of the area adjacent to the hills comprises undulating, broad expansive fluvial plains, becoming increasingly flat towards the mangrove swamp areas.

The local geology is described as Tertiary aged alluvial deposits overlying the Precambrian high-grade quartzo-feldspathic-garnet gneiss (charnockite). The SR Area 1 heavy mineral sands placer deposits are hosted in the Bullom sediments which were deposited following a Tertiary marine regression with seas levels some 100 m below current levels. Mechanical and chemical weathering liberated heavy minerals from the underlying Kasila Group which were deposited in pre-incised channels.

Estuarine and marine unconsolidated sediments are located to the west of the major watershed located within the centre of SR Area 1. In contrast, alluvial and elluvial sediments were deposited subaerially to the north-east of the watershed. Several cyclic sequences comprising poorly sorted clastic gravels overlain by sands and clayey silts are preserved. Hard lateritic inclusions are common but are generally associated with the upper portions of the sequence.

The heavy minerals are generally angular and display little evidence of transport over long distances or extensive reworking. Grades rapidly decrease downstream with sand replacing the argillaceous material within the matrix.


Mining Methods

  • Truck & Shovel / Loader


Summary:

Sierra Rutile’s current mining and mineral processing operations at Area 1 include four wet concentrator plants (WCPs); a mineral separation plant (MSP) and associated infrastructure; residential camps for senior and management staff; and a dedicated port facility (collectively referred to as Area 1). Sierra Rutile also holds one of the world’s largest known natural rutile deposits, the Sembehun Project.

Mineral reserves at Area 1 is represented by Gangama, Gbeni North, Lanti and Taninahun deposits. Mineral resources for Area 1 extension are comprises Pejebu, Ndendemoia East and Ndendemoia West deposits.

GANGAMA
Mining at Gangama involves the excavation of ore using a conventional load and haul method to deliver ore from the Gangama deposits to two adjacent WCPs (known as DM2:1 and DM2:2). Ore is excavated in the pit and delivered to the Run of Mine (ROM) stockpile or direct to the feed hopper.

TANINAHUN
Taninahun deposit is located within Area 1, approximately 6km northeast from the current Gangama operation. Mining is planned to commence in the second half of 2022 with a contractor truck and excavator operation. Ore from the Taninahun deposit will be hauled to the existing Gangama
DM2:1 and DM2:2 plants. The ROM ore will undergo primary mineral processing to produce HMC as is the current process outlined above.

GBENI & LANTI
At Gbeni and Lanti, two separate WCPs are operated (DM1 and DM4). In both cases, ore is delivered to in-pit mining units (mobile mining units or MMUs). Depending on operational constraints the MMUs are fed by an excavator either via stockpile or directly from dozer push.

PEJEBU AND NDENDEMOIA
The Pejebu and Ndendemoia deposits, comprising Indicated Mineral Resources of 18.6Mt at 1.0% rutile grade for 0.18Mt of contained rutile and 18.3Mt at 1.0% rutile grade for 0.18Mt of contained rutile respectively, are located less than 5km south of the MSP within the Mining Lease. Subject to completing the technical and operational planning activities required to convert Pejebu and Ndendemoia Indicated Mineral Resources to Ore Reserves, mining at Pejebu and Ndendemoia will be considered following completion of mining activities at Gbeni and Lanti.

The Sembehun deposit, located approximately 30 kilometres from the current Area 1 operations, is one of the largest and highest quality known rutile deposits in the world, presenting an attractive development opportunity, long mine life and additional exploration potential underpinned by strong medium to long term titanium feedstock fundamentals.

Sembehun Phase 1 construction start is schedule on 2024.


Crushing and Grinding


Processing

  • Electrostatic separation
  • Desliming
  • Spiral concentrator / separator
  • Flotation
  • Magnetic separation

Source: Subscription required

Summary:

During 2019 Iluka completed projects doubling the capacity at both the Lanti and Gangama mining operations in Sierra Leone.

The doubling of capacity of both the Gangama and Lanti dry operations from 500-600 tonne per hour to 1,000-1,200 tonne per hour. [31/06/2019 QREV-Q2, p. 7]

The Gangama project involved the addition of mining fleet and construction of a second concentrator, duplicating the design of existing operations. Commissioning of the Gangama concentrator began in May and was operating at design capacity by June.

At Lanti, a second mining unit was added and the floating concentrator from the decommissioned dredge operation was beached and refurbished. Construction and commissioning activities were completed during August. Both projects were delivered on schedule and on budget.

Concentrator Plants at Lanti: DM1-Commissioned 2013; DM4 - Repurposed concentrator from dredge operations.
Concentrator Plants at Gangama: DM2:1 - C ........

Recoveries & Grades:

CommodityParameter2021202020192018
Heavy Minerals Head Grade, %  ......  Subscription required  ......  Subscription required  ......  Subscription required3
Heavy Minerals Concentrate Grade, %  ......  Subscription required  ......  Subscription required  ......  Subscription required71.4
Rutile Concentrate Grade, %  ......  Subscription required  ......  Subscription required  ......  Subscription required47.7
Ilmenite Concentrate Grade, %  ......  Subscription required  ......  Subscription required  ......  Subscription required20
Zircon Concentrate Grade, %  ......  Subscription required  ......  Subscription required  ......  Subscription required3.7

Production:

CommodityProductUnits20222021202020192018
Rutile Mineral in concentrate kt  ......  Subscription required ^  ......  Subscription required  ......  Subscription required  ......  Subscription required122
Heavy Minerals Concentrate kt  ......  Subscription required  ......  Subscription required  ......  Subscription required  ......  Subscription required
Ilmenite Mineral in concentrate kt  ......  Subscription required  ......  Subscription required  ......  Subscription required  ......  Subscription required
Zircon Mineral in concentrate kt  ......  Subscription required  ......  Subscription required  ......  Subscription required  ......  Subscription required
^ Guidance / Forecast.
Subscription required - Subscription is required.

Operational Metrics:

Metrics2021202020192018
Waste  ......  Subscription required  ......  Subscription required
Ore tonnes mined, LOM  ......  Subscription required  ......  Subscription required
Tonnes processed  ......  Subscription required  ......  Subscription required290 kt of heavy minerals concentrate242 kt of heavy minerals concentrate
Ore tonnes mined  ......  Subscription required  ......  Subscription required8,278 kt8,227 kt
Subscription required - Subscription is required.

Reserves at December 31, 2021:

CategoryTonnage CommodityGradeContained Metal
Proven 134 Mt Rutile 1.5 % 2 Mt
Probable 78 Mt Rutile 1.4 % 1.1 Mt
Proven & Probable 212 Mt Rutile 1.5 % 3.1 Mt
Measured 178 Mt Rutile 1.4 % 2.4 Mt
Measured 178 Mt Ilmenite 0.8 %
Measured 178 Mt Zircon 0.1 %
Indicated 309 Mt Rutile 1 % 3.1 Mt
Indicated 309 Mt Ilmenite 0.6 %
Indicated 309 Mt Zircon 0.1 %
Inferred 265 Mt Rutile 1 % 2.6 Mt
Inferred 265 Mt Ilmenite 0.5 %
Inferred 265 Mt Zircon 0.1 %
Total Resource 752 Mt Rutile 1.1 % 8.1 Mt
Total Resource 752 Mt Ilmenite 0.6 %
Total Resource 752 Mt Zircon 0.1 %

Commodity Production Costs:

CommodityUnits2021202020192018
Cash costs Heavy Minerals AUD  ......  Subscription required  ......  Subscription required  ......  Subscription required 1,155 / t
Subscription required - Subscription is required.

Financials:

Units2021202020192018
Revenue M AUD  ......  Subscription required  ......  Subscription required  ......  Subscription required205.7  
Pre-tax Income M AUD  ......  Subscription required  ......  Subscription required  ......  Subscription required-14.5  
EBIT M AUD  ......  Subscription required  ......  Subscription required  ......  Subscription required-12.5  
EBITDA M  ......  Subscription required  ......  Subscription required  ......  Subscription required30.2  AUD
Subscription required - Subscription is required


Heavy Mobile Equipment:

Mine Management:

Job TitleNameProfileRef. Date
....................... Subscription required ....................... Subscription required Subscription required Jun 24, 2022
....................... Subscription required ....................... Subscription required Subscription required Jun 24, 2022
....................... Subscription required ....................... Subscription required Subscription required Jun 24, 2022
....................... Subscription required ....................... Subscription required Subscription required Jun 24, 2022
....................... Subscription required ....................... Subscription required Subscription required Jun 24, 2022
Subscription required - Subscription is required.

Staff:

Total WorkforceYear
Subscription required 2019

Corporate Filings & Presentations:

DocumentYear
Other 2022
................................... Subscription required 2021
................................... Subscription required 2020
................................... Subscription required 2020
................................... Subscription required 2019
................................... Subscription required 2019
................................... Subscription required 2019
................................... Subscription required 2019
Annual Report 2018
Environmental Assessment 2018
Annual Report 2017
Press Release 2017
Subscription required - Subscription is required.

Aerial view:

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