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Crystallex International Corporation is a Canadian-based gold company with a successful record of developing and operating gold mines in Venezuela and elsewhere in South America
334396 – Las Cristinas Feasibility Study J:\334396\30 - PMC\30 - PMC\RA - Misc Reports & Forms\Final Report 40k Tpd Feasibility Study\Section 1.0.Doc 1-1 1.0 EXECUTIVE SUMMARY 1.1 Introduction In response to a verbal request from Crystallex International Corporation (Crystallex), in October, 2003, SNC-Lavalin Engineers & Constructors Inc. (SNC-Lavalin) submitted a proposal dated October 23
rd
, 2003 to prepare a feasibility study for a 40,000 t/d
production rate for the Las Cristinas gold project. The feasibility study proposal was accepted on October 24
th
, 2003 and SNC-Lavalin was authorized to proceed with work
on the project immediately. Contractually this work is considered as an extension of the 20,000 t/d feasibility study completed by SNC-Lavalin in September, 2003, the formal contract for which was signed on July 10
th
, 2003.
Section 2.2 of this report summarizes the terms of reference of SNC-Lavalin and other participants in the study. The terms of reference and scope of services are conventional for the type of study completed, one that could be presented to financial institutions for the purpose of raising financing to construct and commission the project. This Executive Summary is provided for the convenience of the reader of this report, and should not be relied on except in conjunction with reliance on the contents of the entire report. The key findings of the Las Cristinas Gold project are summarized in the bullet points below (all figures are estimates) and explained in more detail in the body of the report: The key findings of the Las Cristinas Gold project are summarized in the bullet points below and explained in more detail in the body of the report:
·
Mineralization 2% to 5% sulphides (pyrite and chalcopyrite)
·
Mineral Reserves (per CIM definition) 297 million t (1.17 g/t average grade, 11.12
million oz. contained gold)
·
Gold Recovery 89.0 %
·
Gold Recovered 9.9 million ounces
·
Operating Cost $5.964 /t ($178.90/oz without royalty)
·
Capital Cost $ 365.4 million (without VAT)
·
Sustaining Capital $169.5 million (without VAT)
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·
Mine Life 20 years
·
Mining Equipment Trucks and Shovels
·
Mine Stripping Ratio 1.04 to1
·
Process Plant Conventional Gravity and Carbon-in Leach
·
At an assumed gold price of $325/oz the project is estimated to have the
following results before taxes:
o
IRR 17.7 % (before VAT)
o
Net Cash Flow $ 746 million
o
Payback 4 years
·
Environmental Risks
o
Effluent Discharge Low
o
Tailings Dam Failure Low
o
Closure Challenges Low
o
Acid Generation Potential Low to Marginal
o
Permitting expected to be straight forward
The report was prepared by SNC-Lavalin with input from others and also Crystallex, through the provision of numerous technical reports. Sections of the report that have been primarily prepared by others are as noted below:
·
Section 3 Property Description and Location by Mine Development Associates
(MDA) utilizing material supplied by Crystallex.
·
Section 4 Geology, Mineral Resources and Mineral Reserves and Section 5
Mining by MDA. Confirmatory drilling and a review of the geology were completed, reserves were estimated and a mine plan was developed by MDA.
·
Section 6 Metallurgy by J.G. Goode and Associates with the assistance of SNCLavalin
in the design and supervision of a test work program including a metallurgical carbon-in-leach pilot plant run by SGS Lakefield Research for 21 days and treating 1 tonne of representative drill core.
·
Section 10 Administration and Operations by Harapiak-Buckland utilizing
personnel and payroll figures estimated by SNC-Lavalin and MDA. SNC-Lavalin’s involvement in those parts of the report primarily prepared by others was to edit for consistency of report formatting and to satisfy itself that the reported scope of
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work and reporting were appropriate on their face for a feasibility study (described
throughout this report as “editing for content and consistency”). SNC-Lavalin has no
reason to believe that any of the information or opinions provided by others is erroneous
but it has not taken any steps to independently confirm such information or opinions,
except where specific steps taken to confirm such information are described in detail in
this report.
1.2 Property Description and Location (Crystallex)
The Las Cristinas Property consists of 4 contiguous concessions (LC 4-5-6-7) totaling
3,885.6 hectares. The property is located in Bolivar State, southeastern Venezuela, 6
km west of the village of Las Claritas and approximately 670 km southeast of Caracas.
Access to the property is via Troncal 10, the main paved highway linking Puerto Ordaz
with the Brazilian border. A soon to be upgraded 19 km unpaved road will connect
Troncal 10 to the Las Cristinas camp. Current access is via a 6 km dirt road from Las
Claritas. An air strip at Las Cristinas allows for the landing of small aircraft. Commercial
airstrips are located at El Dorado and Luepa, 80 km north and south , respectively,
relative to Las Cristinas. The concessions are located in flat terrain at elevations ranging
from 130 m to 160 m above sea level. The climate is tropical and humid.
On September 17, 2002, Crystallex and the Compañia Venezolana de Guayana (CVG)
signed a Mining Operation Contract (MOC) for the development of Las Cristinas 4, 5, 6
and 7. The MOC provides Crystallex with the exclusive right to explore, design and
construct facilities, exploit, process and sell gold from Las Cristinas. An official
translated version of the MOC is available on the Company’s website
(
www.crystallex.com
).
The MOC has been entered into in accordance with applicable Venezuelan laws and under authority granted to the CVG by the Ministry of Energy and Mines. A report in late February, 2003 from the Commission of Energy and Mines of the National Assembly of Venezuela confirms the legal and administrative process by which the contract rights of Minca, a previous partner with the CVG, were terminated. The report also confirms the process by which the related assets were acquired by the Republic of Venezuela, and by which the government, through the CVG, entered into the Mining Operation Contract with Crystallex.
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1.3 Geology and, Resources and Reserves (MDA)
1.3.1 Geology and Mineralization
The Las Cristinas property is located in a poorly understood part of the Archean to early
Proterozoic granite-greenstone terrain of the Guayana Shield. Supracrustal sequences
on the property are predominantly intermediate metavolcanic and pyroclastic rocks.
Several rock types intrude the stratigraphic package; some post-date the mineralization.
There are two main deposits at Las Cristinas: Conductora/Cuatro Muertos and
Mesones/Sofia. At Conductora/Cuatro Muertos, gold and copper mineralization are
associated with pyrite-chalcopyrite disseminations, veinlets (2-5% sulfides) and blebs
generally oriented parallel to the foliation, which strikes north-northeast and dips
moderately to steeply west to southwest. The occurrence of sulfide mineralization is not
associated with any particular rock type, but rather, with alteration assemblages that
include secondary biotite and a younger carbonate-epidote assemblage. On a
microscopic scale, gold can be found as free grains in quartz and as blebs and fracture
fillings in pyrite and/or chalcopyrite. Silicate-carbonate-sulfide veins tend to parallel
foliation. At Mesones/Sofia, gold-copper mineralization occurs within tourmaline breccia
zones, which have obliterated primary tuffaceous textures. Sulfide concentrations are
coarser grained and more chalcopyrite rich than those at Conductora/Cuatro Muertos.
Extensive weathering has led to the development of saprolite to depths of over 90 m
locally. The upper part of the saprolite is oxidized. Within the oxidized saprolite, copper
has been predominantly leached, but the gold remains generally in its original
distribution. The sulfide saprolite, which has been enriched in copper leached from the
overlying oxide saprolite, also retains the original gold distribution. Copper and gold
grade distributions in the bedrock have not been affected by weathering.
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Data and Verification
Under the terms of the September 2002 agreement between Crystallex and the CVG,
Crystallex obtained an electronic database from CVG, which included drill, topographic,
geologic, and engineering data. derived from Placer Dome Inc.’s (PDI) work. No original
hard copy assay sheets were available. Presently, data from 1,174 drill holes and 108
trenches are included in the Las Cristinas database (Table 1-1).
Table 1-1 Drill Data Description
Data Data
Drill holes 1,174
Meters of drilling* 160,600
Gold assays 162,806
Copper assays 145,547
Copper CN Soluble assays 40,655
Silver assays 145,221
Trenches 108
*Includes trenches
Mine Development Associates (MDA) visited the Las Cristinas site in October 2002 and
found drill pads, drill collars, drill core and samples, core photographs, and other
supporting data demonstrating that exploration was done in a fashion described in the
documentation of Placer Dome Inc’s (PDI) work. Based on the previous operator’s
descriptions, exploration and sampling procedures conform to or exceed industry
standards. Nevertheless, Crystallex drilled 2,188 m in twelve diamond drill holes, for a
total of 1,087 core samples, to verify the presence and tenor of mineralization. In
addition, 275 quality assurance/quality control (QA/QC) samples were analyzed. The
Crystallex drill results and check samples corroborate the general tenor of gold
mineralization reported by the previous operator. For additional confirmation, Crystallex
re-assayed 262 pre-existing pulps, 200 pre-existing coarse rejects and 342 pre-existing
quarter core samples. Mean grades are similar for both datasets.
1.3.2 Mineral Resource Estimates
MDA completed a resource model that incorporated geology and analytical data. The
model contains estimates of gold, copper, cyanide soluble copper, silver, rock type, rock
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density and metallurgical type. The estimation process began with the creation of cross
sections and interpretation of the geology., modifying only slightly the previous
operator’s interpretation. Once the geologic model was defined, mineral domains for
gold and copper were identified and modeled. All of this data was refined on level plans
and used to code the block model.
There are seven material/rock types defined in the Las Cristinas model, listed from the
deepest to the surface: carbonate-stable bedrock (CSB), carbonate-leached bedrock
(CLB), saprock, sulfide saprolite (SAPS), mixed sulfide and oxide saprolite, oxide
saprolite (SAPO), and overburden. Gold was modeled in three mineral domains
(“unmineralized”, low-grade and higher-grade) across all material types except
overburden. Copper was modeled in four separate geologic domains: a) bedrock and
saprock (a thin veneer of partially saprolitized rock lying on top of the bedrock); b)
saprolite sulfide and mixed saprolite zones; c) oxide saprolite; and d) overburden. For
Mesones/Sofia, the bedrock copper was also modeled in three copper domains. Silver
was modeled without domains across all material types except for overburden, which
was estimated separately. A summary of the total gold resources, following National
Instrument 43-101 classifications, is given in Table 1-2. Note that copper and silver
resources are not reported as the rights to revenue from these metals have not yet been
granted to Crystallex.
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Table 1-2 Las Cristinas Mineral Resources (Including Reserves)
Total Measured and Indicated
Cutoff Tonnes Gold Gold
(g Au/t) (g/t) Ounces
0.5 438,931,000 1.09 15,328,000
0.6 354,171,000 1.22 13,841,000
1.0 169,467,000 1.72 9,354,000
Total Inferred
Cutoff Tonnes Gold Gold
(g Au/t) (g/t) Ounces
0.5 207,889,000 0.91 6,064,000
0.6 144,999,000 1.07 4,966,000
1.0 47,726,000 1.76 2,703,000
*Note
(1) Mineral Resources include mineral reserves
(2) Mineral Resources which are not Mineral Reserves do not have demonstrated economic viability.
For comparison, the last resource estimate reported by Placer, at a cutoff of 0.6 g Au/t,
totaled 448,857,000 tonnes grading 1.19 g Au/t, for a total of 17,200,000 ounces of gold,
which compares to the MDA total of 499,000,000 tonnes grading 1.17 g Au/t for a total of
18,807,000 ounces of gold (Measured, Indicated and Inferred; reported together for
comparison purposes only). MDA’s estimated resource is larger presumably because
Placer’s reported resource is that material contained within the limits of an “optimistic”
pit, whereas the MDA resource is not limited.
1.3.3 Interpretations and Conclusions
Las Cristinas contains a gold deposit that is unique in terms of its geologic
characteristics and size. The geometry and size of the deposit give the project
operational flexibility that will allow optimal exploitation. The deposit is open ended at
depth and, with increased metal prices, decreased costs, and/or increased metallurgical
recoveries, reserves could increase. Additional drilling may result in upgrading some or
all of the Inferred resources to Measured or Indicated, which could add to reserves.
As in all projects, there are certain aspects of the project and resource estimate that can
use additional study. The following recommendations regarding the geology and
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resources are given not to show deficiencies, but rather to provide a higher level of
understanding of the project.
Additional drilling should be done which may to upgrade resources from Inferred to
Measured and Indicated which could and potentially increase reserves. Given the same
economic, mining, and engineering criteria, it is likely that the reserves can be increased
at depth but potentially also at Potaso where drilling could not be done in an area of
historic mining.
In a future stage there will be a heterogeneity study carried out to optimize sampling
protocol and minimize sample variance.
1.4 Reserves and Mining (MDA)
The Las Cristinas deposit is planned to be mined as a traditional truck/shovel operation.
The bedrock will be mined by Crystallex using hydraulic excavators and standard-rearwheel-
drive-haul trucks while the saprolite material will be mined by a contractor using a
different equipment fleet more suited to the material characteristics.
Deposit reserves were developed by MDA from the MDA resource model using the
Canadian Institute of Mining, Metallurgy and Petroleum reserve definitions. The
reserves are summarized in Table 1-3.
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Table 1-3 Las Cristinas Mineral Reserve Estimates
Parameters used to estimate the reserves, define cutoffs and develop pit designs are
summarized in Tables 1-4 and 1-5.
Category Ore Grade Contained Waste Strip
(applies to ore only)
kt (Au g/t) Au oz x1000 kt Ratio
PROVEN 42,671 1.27 1,739 Bedrock 31,204 1.24 1,247
Total 281,585
Saprolite 11,467 1.33 491 Bedrock 225,593 PROBABLE 227,793 1.15 8,441 Saprolite 55,992
Bedrock 176,991 1.17 6,667 Saprolite 50,802 1.09 1,774 PROBABLE 26,396 1.11 944 Total 27,063 Bedrock 15,308 1.20 589 Bedrock 12,731 Saprolite 11,088 0.99 355 Saprolite 14,332 PROVEN 42,671 1.27 1,739 Bedrock 31,204 1.24 1,247 Total 308,648
Saprolite 11,467 1.33 491 Bedrock 238,324 PROBABLE 254,189 1.15 9,384 Saprolite 70,324
Bedrock 192,299 1.17 7,256 Saprolite 61,890 1.07 2,129 PROVEN & PROBABLE 296,860 1.17 11,123 Total 308,648 Bedrock 223,503 1.18 8,503 Bedrock 238,324 Saprolite 73,357 1.11 2,620 Saprolite 70,324 Total 1.04:1 Deposit Conductora Mesones/Sophia 1.04:1 1.03:1 Total 1.04:1 334396 – Las Cristinas Feasibility Study J:\334396\30 - PMC\30 - PMC\RA - Misc Reports & Forms\Final Report 40k Tpd Feasibility Study\Section 1.0.Doc 1-10 Table 1-4 Pit Design Parameters Description Value CSB Gold plant recovery 87.6% CLB Gold plant recovery 87.6% SAPO Gold plant recovery 98.0% SAPS Gold plant recovery 86.8% Specific gravity (varies by rock type) 1.56-2.79 Saprolite bench height 6m Bedrock bench height 12m Road width 25m Maximum road grade saprolite 8% Maximum road grade bedrock 10% Overall slope angle in saprolite 35° Overall slope angle in CLB 45° Overall slope angle in CSB east wall 45° Overall slope angle in CSB west wall 50°+ Slope angle south wall all rocks 25° Overall slope angle in deep saprolite >70 m 30° Table 1-5 Economic Parameters Value Description Units (US$) $325 Gold price $/oz $1.00 Cost of mining bedrock $/DMT 1 $1.13 Cost of mining saprolite $/DMT 1 $0.21 General and Administration $/DMT ore
$3.54 Cost of milling-processing CSB $/DMT ore
$2.89 Cost of milling-processing CLB $/DMT ore
$2.11 Cost of milling-processing SAPO ore
$4.43 Avg Cost of milling-processing SAPS ore
(saps cost=2.178+0.0024235*CNSCu) 2204.62 Pounds per tonne conversion lb/tonne 31.1035 Grams per oz conversion g/oz 99.8% Gold payable in dore oxide % $1.50 Gold refining oxide $/oz Royalty on gold 1.0% If gold is <= $280/oz % 1.5% If gold is < $350/oz and > $280/oz % 2.0% If gold is < $400/oz and >= $350/oz % 3.0% If gold is >= $400/oz % 3.0% Exploitation tax % 1 DMT = Dry Metric Tonne 2 Saprolite processing cost includes $0.15/t for ore control 334396 – Las Cristinas Feasibility Study J:\334396\30 - PMC\30 - PMC\RA - Misc Reports & Forms\Final Report 40k Tpd Feasibility Study\Section 1.0.Doc 1-11 MDA used Medsystem-MineSight computer software to estimate and report the reserves. The general procedure was to generate a suite of ultimate pit shells for a range of gold prices using the Medsystem Lerchs-Grossmann program. A specific pit shell, based on the $325 gold price was chosen as a template for the final pit design. The final design includes haul ramps and excludes areas that cannot be mined. (The Lerchs-Grossmann program does not produce a designed pit.) Two separate pits were designed, the larger Conductora, which contains the bulk of the reserves and the Mesones/Sophia (referred to as Mesones). The Conductora pit was divided into five phases or pushbacks to improve project economics and delay waste mining as much as possible. Pit slope angles were based on the pit slopes in the 1996 Placer Dome feasibility study. The angles were reviewed by Brawner Engineering Ltd (Vancouver B.C., Canada) for appropriateness and some angles modified where changes were deemed necessary. Waste dumps were designed using Placer Dome and SNCL criteria, which follow general industry standards. Because there is the potential for some of the mined waste to be acid generating, this material will be encapsulated within the largest of the dumps and surrounded by acid neutralizing materials. Placer Dome estimated that approximately 31 million tonnes of saprolite sulfide and carbonate-leached bedrock waste need encapsulation. The final pit and dump designs are shown in Figure 1-1 10 0 100 200 300 SCALE IN METRES 400 500 LIMITE DE LA CONCESION LIMITE DE LA CONCESION CARRETERA DE ACCESO CANAL DE DESVIACION CAMINO A LA REPRESA DE COLAS ESCOMBRERA SUR TAJO POTASO ESCOMBRERA DE SAPROLITA CENTRAL ESCOMBRERA DE SAPROLITA SUR ESCOMBRERA DE MEDIO-OCCIDENTE TAJO MESONES ESCOMBRERA ESTE ESCOMBRERA NORTE ESCOMBRERA OESTE ESCOMBRERA DE SAPROLITA NORTE CONCESSION BOUNDARY EAST WASTE DUMP SOUTH WASTE DUMP CONCESSION BOUNDARY ACCESS ROAD TAILINGS ROAD NORTH WASTE DUMP MID-WEST ROCK WASTE DUMP CENTRAL SAPROLITE STOCKPILE SOUTH SAPROLITE STOCKPILE POTASO PIT DIVERSION CHANNEL WEST ROCK WASTE DUMP NORTH NORTH SAPROLITE STOCKPILE Reno Nevada not to scale MINE DEVELOPMENT ASSOCIATES DATE DRAWN BY CHECKED BY SCALE 12 DEC 2003 MDA MDA LAS CRISTINAS PROJECT Ultimate Pit Design 2 - 6 t CAP. CIL TOWER CRANES 40000 RADIUS RBpCrCrueoetapktoelisdne edB yg Rroouanddway Modeler DN SLOPE SLOPE SLOPE SLOPE SLOPE SLOPESLOPE SLOPE SLOPE SLOPE C C C C C C C C C C C C C SLOPE SLOPEOFFICE C 22 + + MESONES PIT N 683000 N 684000 N 685000 N 686000 N 687000 N 688000 E 668000 E 669000 E 670000 E 671000 Figure 1-1 334396 – Las Cristinas Feasibility Study J:\334396\30 - PMC\30 - PMC\RA - Misc Reports & Forms\Final Report 40k Tpd Feasibility Study\Section 1.0.Doc 1-13 Because the region experiences considerable rainfall, over three metres per year on average, water will be a major factor in mining. Measured rainfall from a weather station on the site was used for the surface water flows. SRK Consultants of Santiago Chile reviewed the available documentation and developed anticipated surface and groundwater inflows using computer modeling techniques. Further groundwater testing is recommended to better understand pit dewatering requirements. The mine production schedule is based on providing the plant with 40,000 tonnes of ore per day, or 14.6 million ore tonnes per year. This schedule results in an estimated mine life of 21.5 years. Estimated waste to ore stripping ratios range from 0.21:1 in the second quarter of the first production year to a maximum of 1.7:1 in year 16. Saprolite oxide ore is accessible on the surface from startup. During the pre-production period an estimated 900,000 tonnes of saprolite are mined. The production schedule is shown in Table 1-6. Year Pre Production Q1 Q2 Q3 Q4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Total Mill Throughput (kt) 296,860
Contained Gold, kg 4,892 5,105 5,345 5,423 20,766 18,493 21,143 18,804 14,339 14,697 15,075 18,012 18,679 14,712 15,225 17,285 13,991 14,343 15,583 15,999 16,583 19,728 21,833 18,299 2,382 345,972
Contained Gold, oz (000's) 157 164 172 174 668 595 680 605 461 473 485 579 601 473 489 556 450 461 501 514 533 634 702 588 77 11,123
Au (g/t) 1.34 1.40 1.46 1.49 1.42 1.27 1.45 1.29 0.98 1.01 1.03 1.23 1.28 1.01 1.04 1.18 0.96 0.98 1.07 1.10 1.14 1.35 1.50 1.38 0.38 1.17
Gold Recovery (%) 98.0% 97.9% 96.0% 94.2% 96.5% 91.6% 88.0% 91.4% 87.8% 88.5% 90.1% 88.8% 88.2% 87.5% 87.6% 87.7% 87.8% 89.3% 87.7% 87.5% 87.6% 87.6% 87.6% 87.6% 98.0% 89.0%
Recovered Gold, kg 4,794 4,999 5,131 5,106 20,031 16,935 18,597 17,180 12,596 13,006 13,581 16,003 16,474 12,872 13,337 15,156 12,277 12,805 13,670 14,006 14,521 17,280 19,126 16,030 2,335 307,816
Recovered Gold, oz (000's) 154 161 165 164 644 544 598 552 405 418 437 515 530 414 429 487 395 412 440 450 467 556 615 515 75 9,896
Saprolite Oxide (kt) 47,957
Percentage of Total 16.2%
Au (g/t) 1.00
Contained Gold, kg 48,180
Contained Gold, oz (000's) 1,549
Gold Recovery (%) 98.0%
Recovered Gold, kg 47,217
Recovered Gold, oz (000's) 1,518
Saprolite Sulphide (kt) 25,400
Percentage of Total 8.6%
Au (g/t) 1.31
Contained Gold, kg 33,294
Contained Gold, oz (000's) 1,070
Gold Recovery (%) 86.8%
Recovered Gold, kg 28,899
Recovered Gold, oz (000's) 929
Carbonate Leach Bedrock (kt) 71,268
Percentage of Total 24.0%
Au (g/t) 1.06
Contained Gold, kg 75,367
Contained Gold, oz (000's) 2,423
Gold Recovery (%) 87.6%
Recovered Gold, kg 66,022
Recovered Gold, oz (000's) 2,123
Carbonate Stable Bedrock (kt) 152,235
Percentage of Total 51.3%
Au (g/t) 1.24
Contained Gold, kg 189,130
Contained Gold, oz (000's) 6,081
Gold Recovery (%) 87.6%
Recovered Gold, kg 165,678
Recovered Gold, oz (000's) 5,327
Cyanide Soluble Copper, ppm 865
1 oz = g
1 year = Q WASTE Pre Production Q1 Q2 Q3 Q4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Total Saprolite Oxide (kt) 38,253
Saprolite Sulphide (kt) 32,070
Carbonate Leach Bedrock (kt) 67,986
Carbonate Stable Bedrock (kt) 170,340
TOTAL 308,650
TO STOCKPILE Pre Production Q1 Q2 Q3 Q4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Total Saprolite Oxide (kt) 6,195
Saprolite Sulphide (kt) 0 Carbonate Leach Bedrock (kt) 0 Carbonate Stable Bedrock (kt) 0 TOTAL 6,195
FROM STOCKPILE Pre Production Q1 Q2 Q3 Q4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Total Saprolite Oxide (kt) 6,195
Saprolite Sulphide (kt) 0 Carbonate Leach Bedrock (kt) 0 Carbonate Stable Bedrock (kt) 0 TOTAL 6,195
STOCKPILE VOLUMES Pre Production Q1 Q2 Q3 Q4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 (end of period) Saprolite Oxide (kt) 0 79 213 368 425 425 778 1,400 2,688 2,814 2,817 2,933 3,467 3,983 3,987 4,302 4,684 4,834 5,909 6,183 6,195 6,195 6,195 6,195 6,195 0 Saprolite Sulphide (kt) 0 0 0 0 0 0 TOTAL 0 79 213 368 425 425 778 1,400 2,688 2,814 2,817 2,933 3,467 3,983 3,987 4,302 4,684 4,834 5,909 6,183 6,195 6,195 6,195 6,195 6,195 0 STOCKPILE GRADES Pre Production Q1 Q2 Q3 Q4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 (end of period) Saprolite Oxide (g/t) 0.39 0.39 0.39 0.39 0.39 0.39 0.39 0.39 0.39 0.39 0.39 0.38 0.38 0.38 0.38 0.38 0.38 0.38 0.38 0.38 0.38 0.38 0.38 0.38 0.00 Saprolite Sulphide (kt) Table 5-5 Production Scheduling by Period 334396 – Las Cristinas Feasibility Study J:\334396\30 - PMC\30 - PMC\RA - Misc Reports & Forms\Final Report 40k Tpd Feasibility Study\Section 1.0.Doc 1-15 Different mining equipment is used in the saprolite and bedrock due to the significantly different material characteristics. A contractor will mine the saprolite using a fleet of allwheel- drive trucks and excavators. Crystallex will mine the bedrock using conventional 136 tonne haul trucks and 21m capacity excavators and loader. The bedrock requires
drilling and blasting while the saprolite does not. The number of trucks in the bedrock mining fleet starts at 2 and reaches a maximum of 20. Appropriate support equipment is planned to maintain the site roads and access roads as well as the pit and dumps. Mine manpower requirements vary with production levels but start at a base level of 97 people. This figure includes 20 in mine engineering and geology, 30 in mine maintenance and 47 in mine operations. The maximum manpower level is 282 during year 16. The mine operations manager, chief mine engineer and maintenance superintendent are initially expatriates and are replaced by Venezuelan nationals after the second operating year. The life-of-mine mine operating cost is estimated to be $2.53 per tonne of total ore or $1.24 per total mined tonne, including saprolite mining. Pre-production contract mining ($1.3 million) is considered a capital cost and not included in operating costs. Total bedrock mining costs without the contract saprolite mining amount to $0.89 per mined tonne or $1.82 per ore tonne. Costs for major consumables and labour are based on prices reported by Crystallex from their current Venezuelan operations. Fuel prices are low in Venezuela, $0.04 per litre is assumed for this study. Contract saprolite mining is estimated to be $1.45 per dry tonne based on budgetary bids from contract mining firms currently working in Venezuela. Currently in Venezuela the prices for explosives are established by a non-competitive market and consequently are higher than prices in most other South American countries. The costs used in this study of $1830/tonne for emulsion and $1000/tonne for ANFO are based on the actual prices paid by Crystallex at their existing operations and averages of other quotes received by MDA and Crystallex. Crystallex currently pays $1200/tonne for ANFO at a Venezuelan mine much smaller than Las Cristinas. 334396 – Las Cristinas Feasibility Study J:\334396\30 - PMC\30 - PMC\RA - Misc Reports & Forms\Final Report 40k Tpd Feasibility Study\Section 1.0.Doc 1-16 1.5 Metallurgy (J. R. Goode and Associates) Several samples of saprolite oxide (SAPO), saprolite sulphide (SAPS), carbonate leached bedrock (CLB) and carbonate stable bedrock (CSB) ore from the Conductora pit were examined in bench tests and pilot plant operations by SGS Lakefield Research (Lakefield) during the months of April through December 2003. Samples of waste from the Conductora pit and four samples of Mesones ore were also studied. Sub-samples of Conductora ore were sent to McGill University for gravity recovery testwork. Outokumpu conducted pilot plant settling tests on several samples. The various test programs were designed to confirm relevant data generated by Placer, determine the gold recovery and reagent requirements for the proposed gravity-leach flowsheet, and generate plant design data. Grinding data are generally in accordance with data generated by Placer Dome. Pilot scale gravity concentration tests at Lakefield on Conductora ore show about 30% gold recovery from both a SAPO-CSB blend and a SAPO-SAPS-CLB-CSB blend at mass concentration ratios of about 4000:1. Preliminary data for Mesones shows an even better response. Intensive cyanidation of the concentrates from Conductora gave >99% leach recovery. Tests at McGill to determine the gravity recoverable gold (GRG) content of Conductora SAPO and CSB samples showed 39% and 46% GRG, respectively which would translate into practical recoveries of about 25%. Thirty-six hour bottle roll leach tests on Conductora gravity tailings confirm that SAPO leaches very well to give about 99% overall (gravity+leaching) extraction and a 0.02 g/t tailing. With a 24 h leach time, tailings were 0.03 g/t corresponding to 98% extraction. CSB gives about 85% overall extraction (0.17 g/t tailing). Cyanide additions for SAPO and CSB have been less than 1 kg/t ore. Pure SAPS samples with cyanide soluble copper (CNSCu) levels of 370 ppm or less have been tested and gave 85 to 88% extraction, albeit with cyanide additions of 1.7 to 1.9 kg/t. Mixtures containing SAPO, SAPS and CSB gave 85 to 90% overall extraction provided that sufficient NaCN was present. The NaCN addition varied with the CNSCu level in the ore. An initial gravity-leach test on each of the four Mesones samples showed an average 85% overall gold extraction and modest reagent consumption. It is believed that higher extraction could be obtained with optimization of the leach conditions. 334396 – Las Cristinas Feasibility Study J:\334396\30 - PMC\30 - PMC\RA - Misc Reports & Forms\Final Report 40k Tpd Feasibility Study\Section 1.0.Doc 1-17 Duplicate bench scale tests on a series of samples containing 20%CLB and 80% CSB and between 1 and 2 g/t gold yielded an average of 88.7% overall gold recovery (gravity and leaching) with no measurable dependency on head grade. A 2 kg/h pilot plant was operated for three weeks in which batch-ground/gravity concentrated Conductora ore was subjected to carbon-in-leach (CIL) processing. During the first 13 days (PP1), a blend of 20% SAPO and 80% CSB was leached with 0.7 kg/t of cyanide to give a final overall gold extraction of 89.6% (tailings average of 0.15 g/t). A SAPO-SAPS-CLB-CSB blend was processed for the last week (PP2). The plant tailing was 0.15 g/t for an extraction of 89.3% with a cyanide addition of 0.8 kg/t. Viscosity measurements by Lakefield indicated nothing problematical in the mixtures that will be handled in the Las Cristinas plant. Outokumpu conducted high-rate thickening tests on nine sample blends, ranging from pure SAPO to pure bedrock, using its pilot-scale thickener. At 50% solids in the underflow, all blends containing 50% SAPO or less could be processed at 0.46 t/m2/h or greater. Allowing for a 15% scale-up, the data showed that a 50 m diameter thickener would give at least 47% solids in the underflow when processing up to 20 000 t/d of a 50% SAPO, 50% CSB mixture. Acid-base-accounting (ABA) tests and various geotechnical studies were performed by Lakefield on several samples to determine the potential for acid generation. Data are discussed in Section 14 of this study report. Natural degradation tests and continuous INCO Air/SO2 cyanide destruction tests have been performed on pilot plant tailings. Natural degradation under Lakefield climatic conditions reduced CNWAD to below 20 ppm in about 40 d for pilot plant tailings from PP1 and 100 d for PP2 tailings. The INCO process then reduced CNWAD to <0.3 ppm and Cu to about 1 ppm under industry-typical operating conditions. INCO tests on naturally-degraded PP2 tailings solution gave <0.1 ppm CNWAD and <0.5 ppm Cu. 334396 – Las Cristinas Feasibility Study J:\334396\30 - PMC\30 - PMC\RA - Misc Reports & Forms\Final Report 40k Tpd Feasibility Study\Section 1.0.Doc 1-18 1.6 Processing 1.6.1 General All equipment, with the exception of secure areas such as gravity circuits and refinery, electrical and control rooms, is located in open sided structures or outdoors. The processing plant is fenced for gold security reasons. Installed spare pumps are provided for all critical process streams. The process plant consists of single line crushing, semi-autogenous primary grinding (SAG) followed by secondary grinding using a ball mill. A pebble crusher is incorporated in closed circuit with the SAG mill. A gravity circuit is included in closed circuit with the cyclones in order to recover any coarse, free gold prior to regrinding in the ball mill. Gold extraction is achieved in a conventional carbon-in-leach (CIL) circuit. Gold is removed from the loaded carbon by pressure stripping, electrowinning and smelting a gold dore product. 1.6.2 Primary Crushing CLB and CSB ore is delivered by mine truck to the double dump primary crushing station which is permanently located to the east of the process plant. The primary crusher product discharges via an apron feeder on the stockpile feed conveyor. 1.6.3 Ore Storage and Reclaim CLB and CSB ore is reclaimed from the coarse ore stockpile using apron feeders located in the reclaim tunnel situated below the stockpile. The ore is loaded onto the SAG mill feed conveyor. 1.6.4 Saprolite Crushing SAPO and SAPS ore is delivered by mine truck to the double dump saprolite crushing station. The mine trucks direct dump into a feed hopper which is positioned over top of 334396 – Las Cristinas Feasibility Study J:\334396\30 - PMC\30 - PMC\RA - Misc Reports & Forms\Final Report 40k Tpd Feasibility Study\Section 1.0.Doc 1-19 an apron feeder. The apron feeder passes the saprolite ore into a mineral sizer in order to reduce over sized clumps before being fed on to the SAG mill feed conveyor. 1.6.5 Grinding The SAG mill feed conveyor delivers a combination of saprolite, CLB and CSB ore directly to the SAG mill. The SAG mill is driven by a wrap around, variable speed motor with a cycloconverter. The SAG mill discharge is screened by two double deck vibrating screens to remove over sized 12 mm pebbles. The 12 mm pebbles from the vibrating screens are crushed in a cone crusher prior to being recycled back to the SAG mill feed chute. Provision has also been made so the pebbles can be recycled directly back to the SAG mill without further size reduction or can be stockpiled outside the process plant building. The under sized product from the vibrating screens drops into the cyclone feed pump boxes where it is combined with the discharge from the parallel ball mills. The ball mills are driven by a wrap around, variable speed motors through a cycloconverter drive units. The combined SAG and ball mill discharges are diluted in the parallel grinding circuit pump boxes with process water and pumped to dedicated cyclone clusters which sorts the ore particles by size and returns the over size to the ball mills for further size reduction. Also included in each parallel grinding circuit is a gravity recovery circuit. A portion of each ball mill discharge is diverted over a vibrating screen with the under size fed to one of two centrifugal concentrators. Gravity concentrate from each centrifugal concentrator is stored in the same secured holding cone until it is leached in a semi-batch, high intensity cyanide leach reactor. Gravity and leach reactor tailings are pumped backed to each parallel grinding circuit. The gold loaded solution from the leach reactor is pumped to a dedicated electrowinning circuit located in the secured gold room. 1.6.6 Carbon-in-Leach (CIL) Slurry from each parallel grinding circuit cylcone overflow, after trash removal, is gravity fed to one of two thickener feed collection boxes where slurry flows into a 50 m diameter thickener. The two thickener overflows flow by gravity into the process water tank. Each 334396 – Las Cristinas Feasibility Study J:\334396\30 - PMC\30 - PMC\RA - Misc Reports & Forms\Final Report 40k Tpd Feasibility Study\Section 1.0.Doc 1-20 thickener underflow is pumped at 50% solids by weight into dual parallel 12-stage CIL circuits. Cyanide and lime are staged added to each tank train. On an intermittent basis, loaded carbon is pumped counter current to the slurry flow in order to increase the gold loading. Loaded carbon is removed from the head end of each tank train and is transferred to the acid wash vessels via a dedicated loaded carbon vibrating screen. 1.6.7 Carbon Desorption and Regeneration Loaded carbon from the two parallel CIL circuits captured by the vibrating screens drops by gravity into the acid wash vessels. Each acid wash vessel is part of a dedicated, parallel elution and carbon regeneration circuit consisting of duplicate elution columns, electric immersion heater, heat exchangers, barren eluate tanks and kilns. The description to follow refers to either parallel elution and carbon regeneration circuit. A 3% acid solution is pumped into the acid wash vessel and overflows the top and returns to the acid mix tank. Acid washing takes approximately 1 hour. After acid washing is complete, the spent acid is neutralized with sodium hydroxide before discarding it to the tails pump box. The desorption elution cycle starts with the preparation of a 3% sodium cyanide and 2% sodium hydroxide solution in the barren eluate tank. The solution is initially pumped through the strip solution heater and returns to the barren eluate tank until its temperature reaches 80 C. The solution is then directed through a recovery heat
exchanger, and through the strip solution heater to bring its temperature up to 145 C
before entering the elution column. Barren eluate solution at operating temperature and 300 kPa pressure enters the bottom of the elution vessel through in-line screens then flows up through the carbon bed. The solution desorbs the metal loaded onto the carbon then exits from the top of the elution vessel and passes through a screen basket to retain carbon. The new solution passes through the solution/solution heat exchanger where it transfers its thermal energy to the incoming barren eluate solution. The pregnant solution exits the hot side outlet of the heat recovery exchanger at 65 C. This
pregnant solution stream then flows to the pregnant elution tank in the electrowinning and refining area. Stripped carbon is evacuated from the bottom of the elution vessel and is transferred to a vibrating screen at the top of the carbon regeneration kiln feed hopper. Carbon is screened out and drops by gravity into the hopper. Screen fines flow by gravity to the 334396 – Las Cristinas Feasibility Study J:\334396\30 - PMC\30 - PMC\RA - Misc Reports & Forms\Final Report 40k Tpd Feasibility Study\Section 1.0.Doc 1-21 carbon fines tank. Water collected in the carbon fines tank is pumped through a plate and frame filter press to capture any carbon fines. The activity of the stripped carbon is restored in a kiln. After passing through the kiln, the carbon drops out into a quench tank and is transported to the reactivated / fresh carbon sizing screen. Screened carbon from either parallel circuit drops by gravity to same the reactivated carbon transfer hopper where it is mixed with washed fresh carbon. Screen fines flow by gravity to the carbon fines tank. Water collected in the carbon fines tank is pumped through a plate and frame filter press to capture any carbon fines. There is some carbon loss through attrition and is made up with fresh carbon. Mixed regenerated/fresh carbon in the transfer hopper is moved to the last leach tank in each CIL train via a horizontal recessed impeller pump. 1.6.8 Electrowinning and Refining Pregnant eluate solution from the desorption circuits reports to the pregnant eluate tank. Pregnant eluate solution is pumped to six electrowinning cells (three rows of two in parallel). Gold metal is electrowon loosely on the stainless steel wool cathodes in the electrowinning cells. Depleted solution flows from the outlet of each cell to the barren eluate return tank and is then transported either back to the barren eluate tank or recirculated back through the electrowinning cells via the pregnant eluate tank. Pregnant eluate from the concentrate leach circuit is pumped to the leach reactor pregnant eluate tank in the refinery area. Pregnant eluate solution is transported from the tank to two electrowinning cells in series. Gold metal is electrowon loosely on the stainless steel wool cathodes in the electrowinning cells. Depleted solution flows from the outlet of the last cell to the leach reactor barren eluate return tank and is then transported either to the CIL circuit or recirculated back through the electrowinning cells via the leach reactor pregnant eluate tank. At the end of the run, the cathodes are removed from the cells; the gold bearing sludge is washed off and then pumped to a plate and frame filter press. The filter cake is mixed with fluxes, usually borax, soda ash and occasionally sodium nitrate and fed to an 334396 – Las Cristinas Feasibility Study J:\334396\30 - PMC\30 - PMC\RA - Misc Reports & Forms\Final Report 40k Tpd Feasibility Study\Section 1.0.Doc 1-22 electric induction furnace. The doré metal and slag separate in the furnace, and the slag is poured off to slag pots then the doré metal is poured into bars for shipment. 1.6.9 Cyanide Destruction The cyanide destruction process is air/SO using sodium metabisulphite as the source of
SO . At present only reclaim water from the TMF will be treated however provision for
future treatment of CIL tailings has been made, if deemed necessary. This will not have a significant economic impact on the project and current Crystallex experience in Venezuela indicates that this will not be necessary. The cyanide destruction tanks are each fitted with an agitator consisting of dual impellers supported from a bridge mounted on the tank shell. Air is introduced through a bottom entering line to an inverted cone under the centre shaft of the agitator. The air bubbles then travel upward into the maximum shear zone of the impeller blades. Sodium metabisulphite solution is added at a rate sufficient to reduce the free cyanide to below detection limits along with the level of weak acid dissociable (WAD) cyanide complexes in the tailings pond water. Provision is made to add lime slurry to maintain pH between 8 and 8.5. 1.7 Infrastructure and Services 1.7.1 Site Access The Las Cristinas site is situated in south eastern Venezuela and is some 6 km west of the village of Las Claritas on Troncal 10 the main highway running from the Brazilian border to the Venezuelan port of Puerto Ordaz on the Orinoco River. The site is some 360 km by road from Puerto Ordaz and the road presents no significant obstacles to the transportation of goods and materials to the site. Access to the site will be from Troncal 10 along an existing unpaved road that will be upgraded to take construction and operational traffic. This route is 19 km long and being north of Las Claritas circumnavigates all the local villages and will thus avoid any disruptions to the local population. 334396 – Las Cristinas Feasibility Study J:\334396\30 - PMC\30 - PMC\RA - Misc Reports & Forms\Final Report 40k Tpd Feasibility Study\Section 1.0.Doc 1-23 1.7.2 Power Supply An existing 400 kV power line parallels Troncal 10 and a new substation was constructed in 2001 just south of Las Claritas at Km 86 to service the area. The substation has two 150 MVA power transformers and provision has been built in to supply Las Cristinas with a 230 kV power line. The site power demand is estimated at 60 MW which can be adequately supplied by the substation. Power to the site will be carried via a new overhead power line, a distance of approximately 6 km, and will terminate at a new substation to be built on site from where power will be distributed at 6.6 kV. 1.7.3 Site Water Supply Potable water will be drawn from on-site wells and will be chlorinated prior to distribution for consumption. Make-up water for process requirements will be drawn from the Potaso Pit, an old mining pit that is permanently flooded. During operations the Potaso pit will be charged with water from the diversion ditch. 1.7.4 Sewage Treatment Domestic sewage will be collected by a system of gravity sewers and treated biologically with the resulting effluent being pumped to the tailings pond. 1.7.5 Existing Facilities In 1998 a 3,058 person construction camp was constructed at the Las Cristinas property. The camp included dormitories for workers and supervisors, kitchen and canteen facilities, administration building, water and firewater plant and a sewage treatment plant. The camp was subsequently abandoned and has been subject to neglect and minor vandalism. For the current project the construction camp will not be utilized except that the administration building will be refurbished and will serve as the main administration 334396 – Las Cristinas Feasibility Study J:\334396\30 - PMC\30 - PMC\RA - Misc Reports & Forms\Final Report 40k Tpd Feasibility Study\Section 1.0.Doc 1-24 centre, the kitchen and canteen will be converted to a construction and operations warehouse and the existing water plant will be brought on line. Sewage from the camp site will be redirected to the new sewage treatment plant. 1.7.6 Ancillary Buildings Aside from the main administration facilities located in the existing construction camp additional buildings will include a Guard House at the entrance to the process plant area, a Mill Administration and Dry, a Truck Maintenance and Mine Dry and a Truck Wash. 1.7.7 Site Water Management Scheme and Water Balance Tailings area water management forms a large component of overall site water management. Therefore the tailings area water balance was developed in combination with the overall site water balance to support the development of the site water management scheme. The water balance provides an indication of average process water flow rates, range of tailings pond operating volumes, average treatment rates for water treatment plants, average pumping rates from water management ponds and average discharge rates of excess water to the environment. The site water management scheme has been developed so that pumping and treatment costs are minimized by isolating clean runoff from potentially contaminated runoff and process water streams. Environmental impact is reduced by providing appropriate containment and treatment to all potentially contaminated site water before discharge, and by maximizing the use of water recycling. Six site water management ponds are proposed in addition to the tailings pond. All runoff from waste rock dumps and saprolite waste dumps will be collected in ponds to provide settling of suspended solids. All runoff from waste rock dumps will be monitored for acid drainage. Process reclaim water from the Tailings Management Facility (TMF) water reclaim system will pass through a cyanide destruction facility before use in the process plant. Freshwater makeup will be supplied by pumping from the Potaso Pit. This water will require treatment in a sedimentation/filtration plant before entering the process stream. Any seepage from the TMF dike will be collected by a perimeter ditch and pumped back. 334396 – Las Cristinas Feasibility Study J:\334396\30 - PMC\30 - PMC\RA - Misc Reports & Forms\Final Report 40k Tpd Feasibility Study\Section 1.0.Doc 1-25 Excess TMF pond water will be considered suitable for discharge to the environment following cyanide removal if suspended solids are within an acceptable range. Clean surface water from upstream drainage areas will be collected into a diversion channel and conveyed around the perimeter of the site. Clean surface runoff from undisturbed drainage areas within the mine site will be collected and diverted to the Potaso Pit which overflows into the river diversion system. Site drainage was designed for a 1:25 year flood event and the river diversions for 1:100 year events. 1.8 Tailings Management Facilities 1.8.1 Field Investigations A field program for the Tailings Pond area was undertaken by Bruce Geotechnical Consultants Inc. (BGC), in 1994 and 1995 and reported in the Las Cristinas Feasibility Study (BGC, 1996). BGC drilled 9 boreholes, excavated 27 test pits and carried out geologic mapping of outcrops. The geologic horizons were described as follows. The upper horizon consists of a thin laterite soil horizon from 0.5 to 1.0 m thick. The next two units are saprolite which will form the foundation immediately beneath the tailings dikes. The upper layer of saprolite oxide (SAPO) is from 0 to 40 m in thickness, while the thickness of the underlying layer of sulphide stable saprolite (SAPS) varies from 0 m to 65 m. Below the saprolite is a layer of saprock, generally less than 1 to 2 m thick. Beneath the saprock, bedrock is subdivided into CLB (carbonate leached bedrock) and CSB (carbonate stable bedrock). The results of BGC’s geotechnical investigation were used by SNC-Lavalin for the feasibility level design of the Tailings Management Facility (TMF). In addition, SNCLavalin carried out analysis of samples collected from the sand and gravel deposit in the tailings area. Results show that the sand and gravel is suitable material for filter, drainage and other granular usages. 1.8.2 Tailings Dike Design and Construction Concepts Design criteria for the TMF were selected to optimize groundwater protection, physical stability and mine closure conditions, and to make maximum use of mine waste materials on a cost effective basis. Due to the presence of cyanide in the tailings slurry, 334396 – Las Cristinas Feasibility Study J:\334396\30 - PMC\30 - PMC\RA - Misc Reports & Forms\Final Report 40k Tpd Feasibility Study\Section 1.0.Doc 1-26 the TMF was designed to withstand a maximum credible earthquake and to contain the runoff from a 24 hour probable maximum flood event, based on internationally and nationally accepted practice and risk ratings. A cyanide destruction plant will be built to treat the Weak Acid Dissociable cyanide concentration in the water discharged with the tailings slurry. It is not expected that treatment of an acidic runoff will be required during mine operations. Previous studies by BGC (BGC, 1996) identified a tailings facility comprised of two cells. A two celled facility is no longer required due to changes in mining plan and therefore, a single celled facility is proposed. In addition, the proposed dike alignment differs from that proposed by BGC. The tailings dike does not extend as far south as the previous layout since there is an area of sand and gravel deposit along the old south dike perimeter. This material is not suitable as a foundation material and therefore, the alignment was adjusted. The alignment of the tailings dike was selected to provide a natural low permeability foundation, to provide sufficient storage for tailings and water management, and to utilize available natural topographic conditions. The starter dike will form the first stage before operations begin and subsequent stages will be constructed during operations. The starter dike will be sized to provide tailings storage and water management for the first three years of operation. It will be of low permeability design with foundation preparation and seepage control measures for adequate structural and hydraulic stability. The TMF basin floor is saprolite 20 m to 40 m thick with permeabilities ranging from 8x10 cm/s which will provide highly
competent containment of contaminants. The tailings dike will be raised in stages using mine waste materials from open pit stripping. The ultimate crest elevation of the tailings dike provides storage for 299.5 Mt of tailings. Crest raising by the centreline method of construction will involve fill placement on the tailings beach for the upstream part of the lift. To facilitate this, tailings discharge will be carried out from the dike crest. The tailings dike is designed so that supernatant water and runoff reporting to the tailings pond are recycled for use in the mill process. Water will be pumped to the plant using a reclaim water barge. 334396 – Las Cristinas Feasibility Study J:\334396\30 - PMC\30 - PMC\RA - Misc Reports & Forms\Final Report 40k Tpd Feasibility Study\Section 1.0.Doc 1-27 Seepage analyses were carried out to estimate the seepage through the tailings dike for the purpose of sizing the chimney and finger drains as well as the perimeter collection ditch. Stability analyses were carried out using parameter values based on analyses carried out by BGC as reported in the Feasibility Report (BGC, 1996). The dike structure is stable under various loading conditions and suitable for post-closure environment. The minimum and maximum normal operating volumes used for design of the tailings pond are 500,000 m . The minimum normal operating volume
provides sufficient water depth to meet barge and reclaim pumping requirements, as well as settlement of solids. The maximum normal operating volume is based on the seasonal fluctuation in precipitation and the water treatment plant capacity. In average conditions, the maximum water level will occur in the tailings pond during the month of September, at the end of the wet season. Maintaining the tailings pond volume during normal operations at a minimum 1,800,000 m will maintain enough water in the pond for reclaim requirements in the event of a dry
year of up to a 1 in 10-year return period. In the event of such a dry year occurring during start-up, the tailings pond may have to be supplemented from another on-site source, such as pit dewatering. To ensure dike safety and satisfactory performance as tailings depository, instrumentation is required to be installed in the dike structure. This includes pore water pressure monitoring, settlement monitoring and groundwater monitoring during operation and post-closure. 1.9 Administration and Operations (Buckland-Harapiak) For the 20,000 t/d feasibility study Buckland Harapiak (B-H) was engaged by Crystallex to carry out a study and make recommendations for the appropriate organization structure for the Las Cristinas operation, with a particular focus on the Finance & Administrative functions. SNC-Lavalin has revised the B-H work to account for the higher number of employees that will work on the 40,000 t/d operation. The organization proposed would support the 40,000 t/d open pit mine and CIL processing facility with a total peak work force of approximately 450 employees. Research for this report included interviews with senior management from Crystallex, including in-country management; feasibility work previously completed by SNC-Lavalin and MDA; the 1996 Socio 334396
– Las Cristinas Feasibility Study Economical Study conducted on behalf of PDI; the Las Cristinas Development Plan (presented earlier this year by Dr. Sadek El-Alfy and Julio Rojo) and various other sources of information on Venezuela and comparable mining operations around the world. 1.10 Environmental Management 1.10.1 Introduction A number of conclusions and recommendations can be drawn from environmental analyses and the preliminary assessment of the potential environmental impacts conducted during the feasibility stage of the Las Cristinas Project, as well as development of the preliminary concept for site closure and rehabilitation. A detailed Environmental Impact Study (EIS) of the Las Cristinas project is required by both Venezuelan legislation and World Bank standards/guidelines. A significant amount of environmental baseline data and impact analysis necessary for EIS preparation was undertaken by PDI throughout the early to mid 1990’s. PDI submitted an EIS document to the Venezuelan Government for review and approval in 1996. A Land Occupation Permit was issued for the project in July 1997, and a Permit to Impact Renewable Natural Resources was issued in August 1997. PDI withdrew from the project in July 2001. Building on the work conducted by PDI, and in consultation with the Venezuelan Ministry of Environment and Natural Resources (MARN), Crystallex recently developed an update of the approved EIS to reflect changes in project design and environmental characteristics, which will be submitted to MARN in the near future. The main environmental activities conducted during this feasibility stage were: · Review of the Venezuelan environmental permitting and approval process and
standards/guidelines of the World Bank to ensure that regulatory and Bank requirements are addressed/accounted for in the project development schedule and work plan, and project design; · Collection and review of all available PDI documents and databases and other
available published data; · Initial consultation with the Ministry of Environment and Natural Resources; · Initial consultation with local community leaders and residents; 334396 – Las Cristinas Feasibility Study J:\334396\30 - PMC\30 - PMC\RA - Misc Reports & Forms\Final Report 40k Tpd Feasibility Study\Section 1.0.Doc 1-29 · Survey of local residents, indigenous peoples, artisanal miners and
community/political leaders; · Updating of demographic data for the local and regional communities
incorporating 2001 census data, and updated characterization of the affected communities; · Additional acid base accounting testing of waste rock and ore materials; · Testing of cyanide destruction processes on pilot plant tailings; · Review of the Crystallex project design and assessment of potential
environmental impacts and measures that can be reasonably implemented to minimize or eliminate environmental effects; · Development of a preliminary site closure concept; · Establishment of objectives and guidelines for the development of an
Environmental Management Plan; · Iterative interaction with project designers to ensure that mitigation measures
identified to minimize/eliminate impacts have been incorporated into project design concepts and capital/operating cost estimates; and · Identification of studies and testing that must be undertaken in subsequent
stages of design, construction and operations to provide the data necessary to further assess potential risk and address concerns , and to meet “equatorial principles” recently adopted by leading private financial institutions. 1.10.2 Conclusions The following are key conclusions of the feasibility stage environmental impact assessment and preliminary site closure and rehabilitation concept for the Las Cristinas project: Risk of significant environmental contamination from effluent discharges is low · The Las Cristinas project can be developed in a manner that minimizes impacts
to the physical and biological environment. · The Las Cristinas project is being designed in accordance with applicable
Venezuelan legislation and regulations, and World Bank standards. · Initial acid base accounting (ABA) tests conducted on representative samples of
waste rock and ore composites indicate that almost most waste rock (oxidized saprolite and carbonate bedrock) will be non-acid generating and approximately 9% of waste rock will be potentially or likely acid generating. The waste rock dumps will be designed to ensure that acid-generating waste is placed over the 334396 – Las Cristinas Feasibility Study J:\334396\30 - PMC\30 - PMC\RA - Misc Reports & Forms\Final Report 40k Tpd Feasibility Study\Section 1.0.Doc 1-30 low-permeability saprolite soils (to retard downward migration into subsurface soils and ground water) and covered/buffered by non-acid generating or net acid consuming waste. · Low ARD generation in TMF at closure due to oxide saprolite (SAPO) cover and
potential to drain the TMF pond. · As precipitation exceeds evaporation over the course of a full annual cycle, there
will be a net discharge of water from the Las Cristinas site, however the site is being designed and can be operated to effectively manage site drainage in a manner which prevents erosion and ensures that all site effluent discharges to surface receivers will meet Venezuelan and World Bank standards. · /air cyanide destruction plant is included in the process plant design; the
plant will treat all reclaim from the tailings management facility prior to use in the process. Excess treated water (reclaim which is not required for the process) will be released to the environment via the runoff collection pond, and from there to quebrada Amarilla. The CN concentration of this effluent is unknown at this
early stage of design until testwork is completed. If concentrations cannot be reasonably reduced to levels which comply with Venezuelan regulations and World Bank standards (0.5 mg/L CN ) the destruction plant could be reoriented
to treat tailings as they exit the plant, for storage in the TMF facility. · Treated effluent from the sewage treatment plant will be discharged to the
tailings management facility during periods of low flow (dry season). · Sludges generated at the sewage treatment plant, the potable water plant and
(later if necessary) the ARD treatment plant will be stored in the tailings management facility, adding less than 2% to total volume over the operating life of the facility. · Periods of flooding and potential site inundation may result in over-topping of site
runoff ponds; dilution from these flood waters is expected to minimize any concern of contamination. · Risk Of Tailings Management Facility (TMF) Failure or Environmental
Contamination is Low · The Las Cristinas site area is in seismic activity zone that presents one of the
lowest possible risk of seismic activity. · The TMF dam is designed to a stability factor of 1.3 (initial) and 1.5 (final
configuration and closure condition), which exceeds the widely accepted Canadian Dam Association standard of 1.1. · The TMF is designed to contain a 24 hour Probable Maximum Precipitation flood
(PMF). 334396 – Las Cristinas Feasibility Study J:\334396\30 - PMC\30 - PMC\RA - Misc Reports & Forms\Final Report 40k Tpd Feasibility Study\Section 1.0.Doc 1-31 · The tailings dam structure is designed to include a low permeability “clay” core
(saprolite soils) with a lower permeability hard rock shell on the downstream face. A chimney drain and finger drains will be provided to minimize head build-up and high phreatic head levels in the tailings; dam seepage will be collected in a perimeter drain and released or re-circulated by a series of perimeter sumps back to the tailings pond for long-term storage. Estimated seepage rate will be approximately 11 m /hr for the ultimate
configuration. · The entire tailings basin will be cleared of vegetation and founded on a low
permeability saprolite soil layer with an average conductivity rate of 1 x 10 cm/s,
and an average layer thickness of 30 m to 40m, providing a competent containment barrier to contaminant migration. · The tailings dam “clay” core will be keyed into the low permeability saprolite soils,
preventing any inadvertent by-pass through intermittent sand or gravel lenses. · Risk of Schedule Delays Resulting from Uncertainties in the Permitting
Application and Approval Process is Low · The Las Cristinas project can be developed in a manner which meets
Venezuelan environmental standards. · The Ministry of Environment and Natural Resources (MARNR) has indicated
verbally that EIS requirements for the Las Cristinas project can be met with submission of a summary of updates and revisions to the PDI environmental impact assessment, submitted and approved by MARNR in the late 1990s; no significant regulatory hurdles are expected. · Crystallex maintains routine on-going discussions with CVG, MARNR and local
political leaders; issues are identified early and addressed as quickly as possible; there are no known concerns on the part of any government agency or political party that would present a significant risk of opposition to the project. · The draft Imataca Forest Reserve Plan recently released for public consultation,
permits the development of mining within the Las Cristinas concessions. The Government of Venezuela has repeatedly reinforced its support for this exclusion from the protection areas within the reserve, and is expected to approve the current Plan without any changes to the permitted uses within the concessions. · Leaders of the 6 main unions whose membership incorporates most of the small
miners operating within the Las Cristinas concessions indicated verbal support for the project during recent interviews carried out by Proconsult C.A. on July 2003. · Crystallex has committed to providing technical assistance to small-scale miners
including the identification of suitable areas where small-scale mining can continue, plus maintenance of the existing Las Rojas process plant, and will be 334396 – Las Cristinas Feasibility Study J:\334396\30 - PMC\30 - PMC\RA - Misc Reports & Forms\Final Report 40k Tpd Feasibility Study\Section 1.0.Doc 1-32 examining alternate employment opportunities for other small-scale miners in the next stage of project design. · The national government is required by law to provide assistance and technical
support to small-scale mining activities. Risk of contamination following closure is low · A detailed site closure and rehabilitation plan will be prepared in the next stage of
project design. · The preliminary concept for site closure and rehabilitation at closure is developed
on the basis that final land use for the site area will be natural, consistent with objectives for the Imataca Forest Reserve Plan. · Crystallex will maintain an active presence at the site for an undefined interim
period following termination of mine production, and prior to “walking away” from the site. During this period they will operate an ARD treatment plant (if considered necessary), and treat all site drainage necessary to ensure that site effluents are released to the environment in compliance with regulatory and World Bank standards. Only essential services such as access roads, some buildings and some power supply will be maintained during the interim period. All other buildings, equipment, roads, and above ground services (e.g., transmission lines; water supply lines, pumps, etc.) will be removed at closure (at latest following the active interim closure period), and all slopes will be graded for public safety and establishment of vegetation. Non-essential dams and berms will be breached and graded to blend in with surrounding topography. The interim period will end once Crystallex can demonstrate that all slopes are physically stable and that all site drainage can be released to the environment without treatment in compliance with Venezuelan and World Bank water quality standards. · Overall conclusion · In summary, it is concluded at this stage that the risk of significant environmental
impacts and/or schedule delays arising from environmental or socio-economic concerns, either during operation, or following closure, is considered to be low. Additional studies and analyses at a higher level of detail will be conducted in subsequent stages of development to confirm these conclusions. 1.10.3 Recommendations A number of recommendations for specific work tasks to be conducted in subsequent design stages are considered routine (such as preparation of a detailed environmental impact assessment), and are not provided in the following summary. Crystallex will develop a work plan that contains these activities prior to initiating the next stage of 334396 – Las Cristinas Feasibility Study J:\334396\30 - PMC\30 - PMC\RA - Misc Reports & Forms\Final Report 40k Tpd Feasibility Study\Section 1.0.Doc 1-33 design. The recommendations provided below are those that are considered most significant in the consideration of project feasibility. · It is recommended that Crystallex conduct additional acid base accounting and
long-term static tests to confirm results of the initial acid generation potential testing conducted during the feasibility stage; details of the test program will be developed by the selected engineer with other team members at the outset of the next stage of project design. · It is recommended that Crystallex conduct additional interviews and surveys of
the local political leaders, residents, and business operators (including the smallscale miners) to obtain input on the potential social and economic impacts of the project (positive and negative), as well as development of an action plan which will address mitigation required to offset impacts caused as a result of lost employment once the small-scale miners are permanently removed from the Las Cristinas concessions. These activities should be conducted in accordance with established World Bank procedures. Although not specifically required by Venezuelan regulation, it is recommended during the next stage of project design that Crystallex arrange for, hold and attend a series of community meetings in strategic locations throughout the Zone of Influence of the project to describe the Las Cristinas project and receive public feedback on potential impacts of the project and design measures which could be implemented to minimize the significances. 1.11 Capital Cost Estimates The Las Cristinas estimated capital costs are summarized in the Table 1-7. Table 1-7 Summary of Capital Cost ITEM ESTIMATED COST ($US x 1,000) Mine 11,777 Process Plant 142,074 Tailings Management Facility 62,904 Infrastructure 29,289 SUB-TOTAL DIRECT COSTS 246,044 Owner’s Costs 15,000 Indirect Costs 104,356 TOTAL COSTS 365,400 334396 – Las Cristinas Feasibility Study J:\334396\30 - PMC\30 - PMC\RA - Misc Reports & Forms\Final Report 40k Tpd Feasibility Study\Section 1.0.Doc 1-34 In addition, sustaining capital totalling $169.5 million over the 20 years of the mine will be required. These estimates do not include VAT of which is recoverable once gold sales commence. 1.12 Operating Cost Estimates The estimated Operating Costs for the project, based on life of project averages are in Table 1-8 as follows (before royalties). Table 1-8 Operating Cost Estimates ITEM OPERATING COST/t ORE OPERATING COST /OZ GOLD Item Estimated Operating Cost/t Ore Estimated Operating Cost /oz Gold Mining $2.531 $75.93 Processing $3.206 $96.17 G & A $0.227 $6.80 TOTAL $5.964 $178.90 Note: *Does not include royalties 1.13 Financial Analysis The findings in Table 1-9 were estimated by the financial analysis using a gold price of $325/oz. Table 1-9 Financial Summary Capital Cost (excluding financing and inflation) 2003 US$ before start of operation US$ 368,670,000 Before VAT & Tax Before Tax After Tax IRR Project (without debt financing) 17.3% 16.4% 11.8% Payback Period-Years 4 6 J:\334396\30 - PMC\30 - PMC\RA - Misc Reports & Forms\Final Report 40k Tpd Feasibility Study\Section 1.0.Doc 1-28