The graphite mineralisation occurs in Archean basement rocks of the Mozambique Belt system which principally comprise metamorphic rocks ranging from schist to gneisses including marbles, amphibolite, graphitic schist, mica and kyanite schist, acid gneisses, hornblende, biotite and garnet gneisses, quartzite, granulite, and pegmatite veins.

Exploration has focused on areas where there is no or minimal overlying younger sedimentary sequences remaining (mostly Cretaceous sandstones and conglomerates).

The ore zones at Bunyu (Namangale) are relatively wide, tabular deposits which are favourable for mining as dilution will be low and this dilution is likely to carry economic graphite material. Dilution and recovery of the ore zone were estimated at 5% and 95% respectively. Therefore the Bunyu (Namangale) deposits are suited to conventional open pit mining methods, of drill & blast, load & haul. Separate fleets will be used for Bunyu (Namangale) North and South due to the distance between the mining areas.

The proposed mining method is a conventional, drill, blast, load and haul, open pit with waste material stacked in waste dumps. Mining is to be undertaken by a contractor under the control and management of VGT personnel and will likely be operated on a 12 hour 365 day per year basis as required. A bench height of 6 metres has been selected, excavated in 3 x 2 metre lifts or flitches. This is considered appropriate for both the orebody and the equipment proposed by mining contractors.

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Processing will be by well-proven crushing, grinding and flotation methods. At Stage 1, ore will be fed to the processing plant, located at Bunyu 1, at a nominal rate of 400,000tpa to produce a nominal 20-24,000tpa graphite product averaging 92-96% TGC at a nominal 93% recovery. This is based on metallurgical testwork programs managed by Battery Limits and undertaken at ALS Laboratory (ALS) Perthassessing the ore from the diamond drill core’s amenability to beneficiation by froth flotation through a range of testwork programs.

The proposed processing flowsheet consists of the following primary activities.
- ROM Bin with grizzly and Apron Feeder;
- Two-stage Crushing Circuit – a primary jaw crusher and secondary cone crusher;
- Grinding – Rod mill in closed circuit with a vibrating screen;
- Flotation consisting of roughing and five stages of cleaners with inter-stage attrition regrinding;
- Secondary cleaner screening to remove coarse flake graphite ........