Ivanhoe Mines installs new primary crusher as underground mine upgrading work nears completion at the historic Kipushi zinc-copper-silver-germanium mine in the Democratic Republic of Congo Kipushi’s unmined Big Zinc Deposit has an estimated 10.2 million tonnes
May 29, 2018
Ivanhoe Mines installs new primary crusher as underground mine upgrading
work nears completion at the historic Kipushi zinc-copper-silver-germanium
mine in the Democratic Republic of Congo
Kipushi’s unmined Big Zinc Deposit has an estimated 10.2 million tonnes
of Measured and Indicated Mineral Resources grading 34.9% zinc, 0.65% copper,
19 grams per tonne silver and 51 grams per tonne germanium
Updated mineral resource estimate expected in June;
definitive feasibility study scheduled for release later this year
KIPUSHI, DEMOCRATIC REPUBLIC OF CONGO – Robert Friedland, Executive Chairman of Ivanhoe Mines
(TSX: IVN; OTCQX: IVPAF), and Lars-Eric Johansson, Chief Executive Officer, announced today that a large-
capacity rock crusher now has been successfully installed 1,150 metres below surface at the upgraded Kipushi
zinc-copper-silver-germanium mine in the Democratic Republic of Congo (DRC).
The Sandvik jaw crusher has a maximum capacity of 1,085 tonnes an hour. After the 54-tonne machine was
disassembled on surface, the pieces were lowered down Kipushi’s main production shaft – Shaft 5 – and
installed in the crusher chamber. Reassembly of the crusher is underway and commissioning is expected to
begin in June.
“The installation of the massive new rock crusher at the bottom of Shaft 5 is a noteworthy engineering
accomplishment,” said Mr. Friedland. “It marks the final, major underground infrastructure upgrading project
needed to resume underground mining, crushing and hoisting operations at Kipushi.”
Main frame of the new underground rock crusher secured onto the base plate
at the 1,150-metre level, ready for reassembly and commissioning.
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Mr. Friedland said negotiations are ongoing with government agencies – Gécamines, the state-owned miner
and Ivanhoe’s partner at Kipushi, and Société Nationale des Chemins de Fer du Congo (SNCC), the DRC’s
national railway company – and potential project financiers to advance agreements to launch a new era of
commercial production at Kipushi.
“Since acquiring our 68% interest in the Kipushi Project in 2011, our team has worked with Gécamines to
achieve our shared objective of resuming commercial production,” Mr. Friedland added. “In parallel with
ongoing mine upgrading work and completion of the definitive feasibility study, we are evaluating a number of
proposals we have received to fund the remaining infrastructure construction.”
Ivanhoe’s planned resumption of production at Kipushi focused on mining
the high-grade Big Zinc Deposit
The Kipushi Mine is owned by Kipushi Corporation (KICO), a joint venture between Ivanhoe Mines (68%) and
Gécamines (32%). Kipushi is on the Central African Copperbelt in the province of Haut-Katanga, approximately
30 kilometres southwest of the provincial capital of Lubumbashi and less than one kilometre from the
international border with Zambia.
Built and then operated by Union Minière for 42 years, Kipushi began mining a reported 18% copper from a
surface open pit in 1924. Then it transitioned to become a high-grade, underground copper, zinc and
germanium mine. State-owned Gécamines gained control of Kipushi in 1967 and operated the mine until 1993,
when it was placed on care and maintenance due to a combination of economic and political factors. The
planned restoration of production at Kipushi is based on initial mining that will be focused on the Big Zinc
Deposit.
Before Kipushi was idled in 1993, Gécamines discovered the Big Zinc Deposit at a depth of approximately
1,250 metres below surface and adjacent to the producing Fault Zone (see Figure 1). No mining ever has been
conducted on the Big Zinc’s mineral resources.
Ivanhoe’s drilling has upgraded and expanded the Big Zinc Deposit’s Measured and Indicated Mineral
Resources to an estimated 10.2 million tonnes grading 34.9% zinc, 0.65% copper, 19 grams/tonne (g/t) silver
and 51 g/t germanium, at a 7% zinc cut-off – containing an estimated 7.8 billion pounds of zinc.
During a span of 69 years, Kipushi produced a total of 6.6 million tonnes of zinc and 4.0 million tonnes of
copper from 60 million tonnes of ore grading 11% zinc and approximately 7% copper. It also produced 278
tonnes of germanium and 12,673 tonnes of lead between 1956 and 1978. There is no formal record of the
production of precious metals as the concentrate was shipped to Belgium and the recovery of precious metals
remained undisclosed during the colonial era. However, drilling by Ivanhoe Mines has encountered significant
silver values within Kipushi’s current deposits that are rich in zinc and copper.
Most of Kipushi’s historical production was from the Fault Zone, a steeply-dipping ore body rich in copper and
zinc that initially was mined as an open pit. The Fault Zone extends to a depth of at least 1,800 metres below
surface, along the intersection of a fault in carbonaceous dolomites (see Figure 1).
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Figure 1. Schematic section of Kipushi Mine.
Key steps toward the start of a new era of mining at Kipushi
Excellent progress has been made by KICO in modernizing the Kipushi Mine’s underground infrastructure as
part of preparations for the mine to resume commercial production. With the underground upgrading program
nearing completion, KICO’s focus now will shift to modernizing and upgrading Kipushi’s surface infrastructure
to handle and process Kipushi’s high-grade zinc and copper resources.
The current mine redevelopment plan, as outlined in the December 2017 independent, pre-feasibility study
(PFS), has a construction period of less than two years, with a life-of-mine average annual production rate of
225,000 tonnes of zinc and cash costs of US$0.48/lb of zinc over an 11-year initial mine life.
The 2017 PFS estimated that Kipushi would have an after-tax NPV of US$683 million and 35% IRR, based on
long-term zinc price of US$1.10/lb, with pre-production capital of US$337 million. At the current zinc price of
approximately US$1.40/lb, the PFS estimated that Kipushi would have an after-tax NPV of US$1.2 billion and
IRR of 51%.
A definitive feasibility study (DFS) is underway to further refine and optimize the project’s economics, taking
into consideration the significant capital already invested to date on critical rehabilitation work. Ivanhoe expects
to complete the DFS later this year.
“Since the PFS was issued six months ago, we have continued to make important strides toward completion of
the underground infrastructure upgrading program,” Mr. Johansson said. “Our goal is to establish Kipushi as
one of the world’s major zinc mines.”
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Highlights of the 2017 PFS, based on a long-term zinc price of US$1.10/lb, include:
After-tax net present value (NPV) at an 8% real discount rate of US$683 million.
After-tax real internal rate of return (IRR) of 35.3%.
After-tax project payback period of 2.2 years.
Pre-production capital costs, including contingency, estimated at US$337 million.
Existing surface and underground infrastructure allows for significantly lower capital costs than
comparable greenfield development projects.
Life-of-mine average planned zinc concentrate production of 381,000 dry tonnes per annum, with a
concentrate grade of 59% zinc, is expected to rank Kipushi, once in production, among the world’s
largest zinc mines.
Life-of-mine average cash cost of US$0.48/lb of zinc is expected to rank Kipushi, once in production, in
the bottom quartile of the cash cost curve for zinc producers globally.
The 2017 PFS was prepared by OreWin, MSA Group, SRK Consulting, Murray & Roberts, Golder Associates
and MDM Engineering, a subsidiary of Amec Foster Wheeler. The PFS was prepared in compliance with
Canadian National Instrument 43-101 – Standards of Disclosure for Mineral Projects (NI 43-101).
Figure 2: World’s top 20 zinc projects, by contained zinc.
Source: Wood Mackenzie.
Note: All tonnes and zinc grades of the above-mentioned projects (except for Kipushi) are based on public disclosure
and have been compiled by Wood Mackenzie.
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Upgrading of existing underground infrastructure nearing completion;
focus now turns to upgrading surface infrastructure, including the rail siding
and line from the mine to the existing network at Munama
KICO has completed the refurbishment of a significant amount of underground infrastructure at the Kipushi
Project, including a series of vertical mine shafts, with associated head frames, to various depths, as well as
underground mine excavations. A series of crosscuts and ventilation infrastructure still are in working condition.
The underground infrastructure also includes a series of pumps to manage the influx of water into the mine. A
schematic layout of the existing development is shown in Figure 1.
The main production shaft for the Kipushi Mine, Shaft 5 (labelled as P5 in Figure 1), is eight metres in diameter
and 1,240 metres deep, and has been upgraded and re-commissioned. The main personnel and material
winder has been upgraded and modernized to meet global industry standards and safety criteria. The Shaft 5
rock-hoisting winder, which had an annual hoisting capacity of 1.8 million tonnes, also has been upgraded to
international standards and is fully operational.
The main haulage way on the 1,150-metre level between the Big Zinc access decline and Shaft 5 rock load-out
facilities has been resurfaced with concrete so the mine now can use modern, trackless, mobile machinery.
In October 2017, Ivanhoe Mines and the DRC’s state-owned railway company, Société Nationale des Chemins
de Fer du Congo (SNCC), signed a Memorandum of Understanding (MOU) to rebuild 34 kilometres of track to
connect the Kipushi Mine with the DRC national railway at Munama, south of the mining capital of Lubumbashi.
Under the terms of the MOU, Ivanhoe has appointed R&H Rail to conduct a front-end engineering design study
to assess the scope and cost of rebuilding the spur line from the Kipushi Mine to the main Lubumbashi-
Sakania railway at Munama. The study is underway and construction on the Kipushi-Munama spur line could
start later this year. Ivanhoe will finance the estimated US$32 million (plus contingency) capital cost for the
rebuilding, which is included within the overall Kipushi 2017 PFS capital cost.
The proposed export route is to utilize the SNCC network from Kipushi to Ndola, connecting to the north-south
rail corridor from Ndola to Durban. The rail corridor to Durban via Zimbabwe is fully operational and has
significant excess capacity.
Optimized zinc processing methodology for the PFS
The optimized plant design used for the PFS utilizes dense media separation (DMS), followed by milling and a
flotation recovery plant. The addition of milling and a flotation recovery plant resulted in an overall recovery of
89.6%, producing a consistent, high-grade concentrate of 58.9% contained zinc. DMS is a simple density-
concentration technique that preliminary test work has shown yields positive results for the Kipushi material,
which has a sufficient density differential between the waste rock (predominantly dolomite) and mineralization
(sphalerite). Furthermore, the addition of a milling and flotation circuit to DMS is expected to improve the
project economics as a result of higher concentrate grades.
Given the significant, very-high-grade zinc resource at Kipushi, which is rich in potential by-product credits
including copper, silver and germanium, Ivanhoe and the Gécamines technical team are continuing to
investigate additional downstream processing options.
Germanium is a strategic metal that is a key component of fibre-optic systems, infrared optics, high-efficiency
solar-cell applications, and light-emitting diodes. The current spot price of germanium is approximately
US$2,300 a kilogram.
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New Mineral Resource estimate for Kipushi expected in June
Ivanhoe initiated a second phase of underground drilling at Kipushi in April 2017 with the goal of upgrading
Inferred Mineral Resources on the Southern Zinc and Fault zones to Indicated Mineral Resources, expanding
Mineral Resources in the Série Recurrent Zone and collecting additional sample material for metallurgical
flotation testing.
Logging and sampling of the holes was completed at the end of 2017 and the final assays have been received.
Geological interpretation of the results is ongoing and a new resource update is planned for release in June.
The updated Mineral Resource will be used in the preparation of the Kipushi DFS.
The DFS will focus on the mining of Kipushi’s Big Zinc Deposit, which has an estimated 10.2 million tonnes of
Measured and Indicated Mineral Resources grading 34.9% zinc. This zinc grade is more than twice as high as
the Measured and Indicated Mineral Resources of the world’s next-highest-grade, major zinc project, according
to Wood Mackenzie, a leading, international industry research and consulting group.
In addition to the Big Zinc Deposit, Kipushi has several copper-rich zones that also contain silver, germanium
and zinc. Measured and Indicated Mineral Resources contained in the copper-rich Série Récurrente Zone,
Fault Zone, and Fault Zone Splay total 1.63 million tonnes at grades of 4.01% copper, 2.87% zinc and 22 g/t
silver, at a 1.5% copper cut-off, containing 144 million pounds of copper. Inferred Mineral Resources in these
zones total an additional 1.64 million tonnes at grades of 3.30% copper, 6.97% zinc and 19 g/t silver.
The crusher’s largest single unit, the 19-tonne main frame, being prepared to be
lowered down Shaft 5.
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The crusher’s main frame at Shaft 5’s 1,150-metre-level station.
The main frame being transported to the 1,150-metre-level crusher chamber.
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Main frame being moved into position at the crusher chamber.
About the Kipushi Mine
Kipushi is a historic, high-grade, copper-zinc-sliver-germanium mine that operated from 1924 to 1993 in the
DRC’s Central African Copperbelt, adjacent to the town of Kipushi.
After being placed on care and maintenance in 1993, the lower levels of the mine flooded in early 2011 due to
a lack of pumping maintenance over an extended period. Ivanhoe Mines acquired a 68% interest in Kipushi in
November 2011 and assumed responsibility for ongoing redevelopment, dewatering and drilling. In December
2015, Ivanhoe achieved a major milestone in its upgrading of Kipushi’s underground infrastructure when the
water level in Shaft 5 was pumped below the mine’s main pumping station 1,210 metres underground. The
water level now is maintained below the 1,210-metre level and the mine has clear and safe access to all of the
main underground workings, including the Big Zinc Deposit.
Qualified Person, Quality Control and Assurance
The scientific and technical information in this news release has been reviewed and approved by Stephen Torr,
P.Geo., Ivanhoe Mines’ Vice President, Project Geology and Evaluation, a Qualified Person under the terms of
National Instrument 43-101. Mr. Torr is not independent of Ivanhoe Mines. Mr. Torr has verified the technical
data disclosed in this news release.
Ivanhoe has prepared and filed a current independent, NI 43-101 technical report for the Kipushi Project, titled
“Kipushi 2017 Prefeasibility Study”, with an effective date of January 25, 2018, which is available under the
company’s SEDAR profile at www.sedar.com and on the company’s website at www.ivanhoemines.com. The
technical report includes relevant information regarding the effective dates and the assumptions, parameters
and methods of the mineral resource estimates on the Kipushi Project cited in this release, as well as
information regarding data verification, exploration procedures, sample preparation, analysis and security, and
other matters relevant to the scientific and technical disclosure contained in this release in respect of the
Kipushi Project.