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Feasability Study 1 0F 4
Feasability Study 1 0F 4
NOVEMBER 2003
SUITE 900 - 390 BAY STREET, TORONTO ONTARIO, CANADA M5H 2Y2
Telephone (1) (416) 362-5135 Fax (1) (416) 362 5763
Table of Contents
2.0 INTRODUCTION................................................................................................. 9
2.1 PREPARATION OF THE FEASIBILITY STUDY......................................... 9
2.2 LOCATION, ACCESS AND CLIMATE....................................................... 10
2.3 OWNERSHIP ................................................................................................. 13
4.0 MINING............................................................................................................... 55
4.1 SCOPE OF STUDY........................................................................................ 55
4.2 DATA TRANSFER AND VALIDATION .................................................... 55
4.3 GEOTECHNICAL STUDIES ........................................................................ 56
4.4 OPEN-PIT DESIGN ....................................................................................... 59
4.4.1 Pit Optimization Algorithm ................................................................... 59
4.4.2 Input Parameters for the Economic Model and LG 3D Optimization ... 59
4.4.3 Lerchs-Grossman Pit Optimization........................................................ 60
4.4.4 Detailed Pit Design ................................................................................ 60
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4.4.5 Cut-off Grade ......................................................................................... 62
4.4.6 Evaluation of Dilution............................................................................ 72
4.4.7 Final Mineable Ore Reserves................................................................. 72
4.4.8 Inferred Ore............................................................................................ 73
4.5 MINE PLANNING......................................................................................... 73
4.5.1 Objective of Mine Planning and Sequence of Mining........................... 73
4.5.2 Rate of Mining ....................................................................................... 73
4.5.3 Mine Plan Description ........................................................................... 74
4.5.4 Annual Plans .......................................................................................... 74
4.6 WASTE DUMP .............................................................................................. 79
4.7 MINING EQUIPMENT REQUIREMENT.................................................... 80
4.7.1 Mining Equipment Selection Criteria .................................................... 80
4.7.2 Trucks and Shovels ................................................................................ 83
4.7.3 Blast Holes Drills................................................................................... 84
4.7.4 Track Dozers.......................................................................................... 84
4.7.5 Other Pit Mining Auxiliary Equipment ................................................. 85
4.7.6 Initial Mine Equipment List................................................................... 85
4.7.7 Additional and Replacement Mine Equipment List............................... 86
4.8 MINING OPERATING COSTS..................................................................... 86
4.8.1 Drilling................................................................................................... 87
4.8.2 Blasting .................................................................................................. 87
4.8.3 Loading .................................................................................................. 88
4.8.4 Hauling................................................................................................... 89
4.8.5 Support Services and Maintenance........................................................ 89
4.8.6 Other Mining Costs................................................................................ 90
4.8.7 Mine Labour........................................................................................... 90
4.8.8 Total Mining Cost Summary ................................................................. 91
5.0 PROCESSING..................................................................................................... 92
5.1 METALLURGICAL TESTWORK AND FLOWSHEET DEVELOPMENT92
5.1.1 McClelland Testwork............................................................................. 92
5.1.2 Amdel Testwork..................................................................................... 93
5.1.3 Lakefield Testwork ................................................................................ 93
5.1.4 Testwork Results.................................................................................... 93
5.1.5 Discussion of Results............................................................................. 97
5.2 PROCESS DESIGN CRITERIA .................................................................... 97
5.3 PROCESS DESCRIPTION ............................................................................ 98
5.3.1 Crushing and Ore Handling (drawing A1-22072-0201-F) .................. 100
5.3.2 Grinding Circuit (drawing A1-22072-0202-F) .................................... 100
5.3.3 Leaching Circuit (drawing A1-22072-0203-F).................................... 101
5.3.4 CIP Circuit (Drawing A1-22072-0204-F) ........................................... 102
5.3.5 Carbon Stripping Circuit (drawing A1-22072-0205-F)....................... 103
5.3.6 Carbon Reactivation Circuit (drawing A1-22072-0206-F).................. 104
5.3.7 Refinery Flowsheet (drawing A1-22072-0207-F) ............................... 105
5.3.8 Reagents and Services Flowsheet (drawing A1-22072-0208-F) ......... 105
5.3.9 Water Distribution Flowsheet (drawing A1-22072-0209-F) ............... 106
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5.3.10 Water Distribution Flowsheet (drawing A1-22072-0210-F) ............... 107
5.4 EQUIPMENT LIST ...................................................................................... 107
5.5 DRAWINGS ................................................................................................. 107
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11.2.1 Mining Labour ..................................................................................... 149
11.3 PROCESS OPERATING COSTS ................................................................ 151
11.3.1 Process Labour..................................................................................... 151
11.3.2 Power ................................................................................................... 152
11.3.3 Process Consumables........................................................................... 152
11.3.4 Maintenance Supplies .......................................................................... 153
11.4 GENERAL AND ADMINISTRATION COSTS ......................................... 153
11.5 OFF-SITE COSTS ........................................................................................ 155
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List of Tables
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Table 4.11 Blasting Costs ............................................................................................................. 88
Table 4.12 7-m3 Hydraulic Shovel Operating Cost....................................................................... 88
Table 4.13 5.7-m3 Front-End Wheel Loader Operating Cost ........................................................ 88
Table 4.14 55-t Class Truck Operating Cost ................................................................................ 89
Table 4.15 14H Class Grader Operating Cost .............................................................................. 89
Table 4.16 Dozers Operating Costs .............................................................................................. 89
Table 4.17 Annual Mine Salary Labour Summary....................................................................... 90
Table 4.18 Mine Hourly Labour Requirement and Year 2 Cost................................................... 91
Table 4.19 Summary of Annual Mine Operating Cost ................................................................. 91
Table 5.1 Summary of Grinding Testwork Results ...................................................................... 94
Table 5.2 Summary of Gravity Testwork Results ........................................................................ 94
Table 5.3 Summary of McClelland Cyanidation Testwork Results ............................................. 95
Table 5.4 Summary of Amdel Cyanidation Testwork Results ..................................................... 96
Table 5.5 Summary of Lakefield Cyanidation Bottle Roll Testwork Results .............................. 97
Table 5.6 Summary of Key Process Design Criteria .................................................................... 98
Table 10.1 Choco Project Pre-production Capital Cost Estimate............................................... 132
Table 10.2 Construction Crew Unit Rates and Productivity Factors.......................................... 134
Table 11.1 Summary of Mining Unit Costs................................................................................ 148
Table 11.2 Annual Mining Operating Costs ............................................................................... 149
Table 11.3 Annual Mining Labour Costs ................................................................................... 150
Table 11.4 Summary of Life of Mine Average Process Unit Operating Cost............................ 151
Table 11.5 Annual Process Labour Costs ................................................................................... 152
Table 11.6 General and Administration Labour Costs ............................................................... 154
Table 11.7 Annual General Costs and Expenses ........................................................................ 154
Table 12.1 Economic Evaluation Summary Gold Price $US350 Per Oz ................................... 156
Table 12.2 Sensitivity of Project Life of Mine Cash Flow ($ millions) ..................................... 158
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List of Figures
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LIST OF APPENDICES
Volume 1
Volume 2
Appendix B Pit Slope Design for the Choco Project, Venezuela, Golder Associates,
October 2003
Appendix D Preliminary Design of the Tailings Disposal Facility, Choco Gold Project,
El Callao, Venezuela, Golder Associates, December 2003
Volume 3
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1.0 EXECUTIVE SUMMARY
The two contiguous mineral concessions Choco 10 and Choco 4, are located approximately 15
km west of the mining town of El Callao in Bolivar State, Venezuela. The Venezuelan mining
exploration company Promotora Minera de Venezuela, C.A. (Promiven) held, since the early
1990’s, exploration rights to these concessions through its 70 % ownership of Promotora Minera
de Guayana, C.A. (“PMG”), the holder of the concessions. After a program of exploration work
managed by Promiven, which ended in 1996, gold deposits were identified in the Choco 4 and
Choco 10 concessions, and resource estimates were prepared.
In 2002 Micon International Limited (Micon) was commissioned by TecnoPetrol Inc. (name
subsequently changed to Bolivar Gold Corp.) to review the existing data and advise TecnoPetrol
on a proposed acquisition of Promiven. Micon created a new mineral resource block model and
a resource estimate, referred to as the Micon Resource Estimate of October 1, 2002, prepared a
conceptual development plan, and proposed an in-fill drilling program for the main Choco 10
deposit to allow upgrading of the inferred mineralization.
Results from drilling up to mid-July 2003 have been incorporated in the revised block model and
a new mineral resource estimate completed. The October 2003 estimate has utilized 39 new drill
holes totalling 3,807 m of new in-fill drilling, compared with the approximately 50,000 m of
prior drilling used for the October 2002 resource estimate. Micon’s Resource Estimate dated
October 1, 2003, summarized in Table 1.1, provides the following indicated and inferred
resources.
Table 1.1
Resource Estimate at October 1, 2003
In-fill drilling was completed and step-out exploration drilling commenced after the date for
inclusion of the results in the above resource estimate. Results from this later drilling have been
very encouraging and have been announced in recent press releases.
Based on the stated indicated resource and the accompanying resource model, an open pit mine
design has been completed using the MineSight pit optimizer program, with gold recovery and
cost parameters developed during this study. Golder conducted a geotechnical investigation in
the area of the Rosika pit, and reviewed an earlier study of the shallower saprolite, prior to
recommending pit slope design parameters. Following definition of the optimum economic pit,
detailed mine design was completed. Economic ore within the final pit design comprises the
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mineable ore reserve. The calculated diluted ore reserve comprises a total of 12.582 million
tonnes at a gold content of 2.17 g/t, mined at an average cut-off grade of 0.5 g/t, shown in Table
1.2. A total of 33.835 million tonnes of waste and sub-grade material will be mined during the
planned life of mine, for an average stripping ratio (waste:ore) of 2.69:1.
Table 1.2
Diluted Mineable Reserves and Stripping Estimates
(0.5 g/t Au Cut-off)
Included in the total tonnes of waste to be moved is an estimated 440,000 tonnes of mineralized
material currently considered as inferred, at a grade of 2.11 g/t and containing an estimated
30,000 ounces of gold. Production drilling is expected to convert much of this material to
indicated status.
Based on the mineable ore reserve and the available plant capacity for each of the ore types, a
mine production plan, fleet selection and operating costs were developed. The fleet is based on
55-tonnes capacity haul trucks (7) and 7-m³ excavators (2). Drilling and explosives costs will be
minimized in early years when laterite and weathered ore will be mined. The total rock
movement by year, ore grade and the calculated operating cost, are shown in Table 1.3.
Table 1.3
Mine Production and Cost
Period Ore mined( 000’t) Gold (g/t) Total mined (000’t) Operating cost ($/t)
Year 1 1,913.5 2.37 7,398.9 0.887
Year 2 2,084.0 2,10 7,695.9 0.857
Year 3 1,943.0 2.71 7,149.4 0.964
Year 4 1,950.0 1.82 7,058.6 1.016
Year 5 1,861.0 1.96 6,495.2 1.187
Year 6 1,831.7 2.03 6,313.6 1.212
Year 7 (1/2 year) 999.2 2.30 3,106.3 1.237
Total 12,582.5 2.17 45,217.9 1.027
Metallurgical testing, originally conducted on samples collected during the earlier Promiven
exploration program in 1994-6, and confirmed by testing during 2003 on samples from the current
program, indicates that the ore is free milling and will yield excellent gold extraction with
conventional processing. Grinding to 80 % passing 0.074 mm is proposed to ensure optimum gold
extraction from all ore types. The selected processing flowsheet follows conventional design with
SAG and ball milling and cyanide leaching followed by carbon-in-pulp gold extraction to produce
doré metal. The average gold recovery from the total ore blend is expected to attain almost 93 %.
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Soon after commencement of this feasibility study, Bolivar identified a suitable existing processing
plant available for sale and negotiated its purchase. This is the Grouse Creek mill of Hecla Mining,
located near Challis, Idaho. After installation in 1994, it operated for less than two years and has
been idle since. The mill was designed to process an average of 5,400 t/d of medium hardness gold
ore using a SAG mill and ball mill, leaching and CIP circuits. As of November 2003 the plant has
been dismantled and prepared for shipment to the Choco site, under the supervision of Bolivar
personnel. Some processing equipment required for the Choco plant and not available from the
Grouse Creek facility will be purchased separately. The processing scheme, flowsheets, mass
balance, equipment list and general arrangement drawings prepared for this study are based on the
use of this plant.
The Choco mill production plan is configured to maximize the available mill capacity with each
ore type, ranging from the soft, fine-grained surface material to the hard, unweathered fresh ore.
The design daily processing rate for the surface ore is estimated to be 6,500 t/d, for weathered
deeper ore 5,400 t/d and for fresh ore, 4,700 t/d. The life-of-mine average milling rate is 5,300
t/d or 1.94 Mt/a, a function of the proportion (20 %) of the harder ore in the overall production
plan. The total gold production from the plant is estimated as over 814,000 ounces, based on the
current mineable reserve.
Plant operating costs are developed from reagent and material consumptions for the particular
ore types, the manning list and current local labour rates, and the quoted cost for electrical
power, shown in Table 1.4.
Table 1.4
Summary of Life of Mine Average Process Unit Operating Cost
The site general and administrative (G & A) costs were developed with input by Bolivar. Head
office costs are excluded. The estimated total cost for a typical operating year is $1,474,000,
equivalent to $0.80 per tonne milled.
Project infrastructure includes industrial buildings at the mine site, staff housing in El Callao, site
power supply, a tailings storage area with retaining dams and a water storage reservoir. Golder
Associates has developed designs and quantities for the dam structures after detailed site
investigations and consideration of the site water balance and climate. A water reservoir is
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constructed in the best local catchment area for water storage during the dry season, due to the
uncertainty of a continuous supply from the nearby Yuruari River, which also provides the El
Callao municipal supply. The tailings storage area, selected after comparing reasonable
alternatives, is located in an area north of the plant site. Three earth fill dams provide
containment between natural barriers. Initial dam design provides total storage for approximately
13 million tonnes of tailings, and the dams may be raised for additional containment. Decanted
tailings water is recycled to the plant for process use.
Figure 1.1 illustrates the proposed site plan including locations of the plant, mine, tailings and
water reservoir. The local road passing the project site and concession boundaries are shown.
Environmental baseline and impact studies have been conducted by the Venezuelan firm of
Ambioconsult C.A. This firm has also assisted in the application for construction and operating
permits, and these are expected to be granted in December 2003. An English version of the
Executive Summary of the report “EIA Mining Development Choco 4 and Choco 10” dated
September 2003, was provided to Micon. No major environmental concerns were noted.
The project development schedule, after acceptance of the feasibility study and project
commitment, assumes a start date of mid-November 2003. Detailed engineering and preliminary
site work are the first tasks. Removal of the plant facilities from the Grouse Creek site has been
completed and the material will be shipped to the site once all necessary permits are in place.
The schedule shows that construction completion can be attained in August 2004 and after one
month allowed for plant start-up and commissioning, the full production rate shall be attained
during September 2004. Early completion of the tailings and water reservoir dams, by the end of
May 2004, is important to ensure adequate water supply for the start-up period, which will occur
at the end of the rainy season.
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Figure 1.1
General Site Plan – Choco Project
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The total estimated capital cost is $37.6 million, including the purchase and dismantling of the
Grouse Creek plant and owner’s costs during project construction, shown in summary as Table
1.5. Costs are estimated to be precise within +/- 10 %. The pre-production stripping of the open
pit is capitalized and included in the total capital expenditure of $38.7 million.
Table 1.5
Project Capital Cost Estimate
The total project operating cost over the life-of-mine period is estimated to average $8.44 per
tonne milled, shown in Table 1.6. Anticipated royalty payments total $13 million over the
projected project life. The resulting cash cost of gold produced is $146 per ounce averaged over
the total projected production of 814,000 ounces.
Table 1.6
Project Operating Cost, Life-of-Mine Basis
The economic evaluation of the project is summarized in Table 1.7, showing results of the
discounted cash flow calculation. The evaluation is considered on a project basis and 100 %
equity financing is assumed. A gold price of $350 per ounce is used.
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Table 1.7
Project Economic Evaluation Summary
• Corporate taxation at 34 % of pre-tax income after exhausting tax credits of an existing $14
million plus the capital expense incurred in project development.
• The payment of VAT on operating supplies is excluded. VAT payable on the purchase of
used equipment is included in the total capital cost.
Sensitivity analysis performed on the cash flow model examined gold prices between $300 and
$400 per ounce, and 10 % +/- changes to gold production, operating and capital costs. The project
is most sensitive to gold price and least sensitive to capital cost. Figure 1.2 illustrates the
sensitivities.
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Figure 1.2
Sensitivity Analysis
120
110
Life of Mine Cash Flow
100
($ Millions)
90
80
Gold production
70 Capex
Opex
60
Gold price
50
-10% 0 10%
The feasibility study demonstrates that this is a robust project and Micon recommends its
immediate development to a significant new gold producer. Micon recommends that the
following items of work be commissioned to increase the resource base and reserves, and to
ensure orderly development of the project:
• Continuance of the current exploration drilling program to focus on defining the deeper
mineralization in the Rosika pit area, and possible extensions nearer surface, to define the
likely expansion of the present pit outline.
• Incorporation of recent and forthcoming drilling results in an updated resource model early
in 2004, and an update of the mine design and mine planning based on this revised model.
• Condemnation drilling of the selected plant site, tailings and waste dump areas.
Throughout this study, the monetary unit used and referred to is the US Dollar. Cost estimates
are based on Third Quarter 2003 costs and quotations. Local costs, developed or quoted in
Venezuelan Bolivars, are converted at the current exchange rate of 1,600 Bolivars= $US1.00.
While this study was commissioned by PMG, the study supervision and collection of local data
was conducted mainly by technical representatives or officers of Bolivar. References to each
group throughout this study are considered to be interchangeable.
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2.0 INTRODUCTION
During mid-2002, Micon International Limited (Micon) evaluated the gold deposit of the Choco
10 Concession and prepared the Development Plan for the Choco Concessions 4 and 10 on
behalf of TecnoPetrol Inc. The Development Plan recommended an in-fill drilling program for
the Choco 10 deposit, and completion of a detailed feasibility study and other site studies.
Following the name change of TecnoPetrol Inc. to Bolivar Gold Corp. in January 2003, and
Bolivar Gold Corp.’s acquisition of a 70 % interest in Promotora Minera de Guayana, C.A.
(“PMG”), the holder of the concessions, the feasibility study for the Choco project was
commissioned by PMG in April 2003.
This feasibility study has been prepared by Micon, based on original work by Micon and the
work of other consultants directed by Micon.
Micon prepared the resource model and estimate which incorporates results of the in-fill drilling
up to mid-July 2003, and which is the subject of a Technical Report dated October 31, 2003 by
Stanley Bartlett, Senior Geologist of Micon.
Micon provided the metallurgical testing evaluation, process design parameters, plant and
general operating costs, and the economic evaluation. Micon supervised the development by
Met-Chem Canada Inc. (Met-Chem) of the site plan, process flowsheets, plant arrangement
drawings, construction schedule and the capital cost estimate.
Met-Chem prepared the optimized open pit mine design, mine planning, mine equipment
selection and mine operating cost.
Golder Associates was responsible for the site investigations and engineering designs for the
tailings storage facility (TSF), water collection reservoir, site water management design, and
geotechnical investigations for plant foundation design and pit slope determinations.
Ambioconsult C.A. (Ambioconsult) was engaged by PMG to prepare the environmental baseline
and impact studies, and to assist in permitting.
During the initial period of this study, PMG concluded an agreement to purchase the Grouse
Creek processing plant from Hecla Mining, with the intent to remove it and to install it close to
the deposit to process the Choco 10 ore. In large part the flowsheets and plant arrangement
drawings for the Choco project are based on drawings of this plant provided by Hecla.
All currency amounts are stated in United States Dollars and Venezuelan Bolivars, expressed in
terms of constant mid-2003 value. The current official exchange rate of 1,600 Bolivars = 1.00
Dollar U.S. is employed for conversions.
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Quantities are stated in SI units, the Canadian and international practice, including: metric tonnes
(t), kilograms (kg) for weight; kilometres (km), metres (m) and millimetres (mm) for distance;
hectares (ha) for area; grams (g) and grams per metric tonne (g/t) for gold content. Precious
metals quantities may also be reported in troy ounces (ounces, oz), a common practice in the
gold mining industry.
The Choco property is located approximately 15 km west of the mining town of El Callao which
is located between Guasipati and Tumeremo, in Bolivar State, Venezuela (see Figure 2.1, Map of
Venezuela). The Choco property comprises two contiguous mineral concessions Choco 10 and
Choco 4 as shown in Figure 2.2. They cover a total area of 7,214.51 ha. The coordinates listed
in Table 2.1 define the concessions.
Table 2.1
Choco 4 and 10 Vertices
Micon is not aware of any legal survey being conducted of the concessions, beyond the normal
requirements of the State, through the Ministerio de Energia y Minas (“MEM”) to define the
concession boundaries.
The area of the concessions is covered by gently sloping topography with elevation ranging from
200 m to 300 m above sea level. The annual rainfall of the area is about 1,260 mm and the
average temperature is 25°C. The area is classified as savanna type forest, and most of the
concessions are presently covered by forest.
A paved secondary road passes through the concessions in Choco 10 and provides access to the
town of El Callao, about 15 km to the east from the concessions. El Callao has a population of
approximately 25,000 and is the centre of population in the area. It is a historic gold mining area
and a number of present and past producing mines are located nearby. The main highway,
between the important city of Puerto Ordaz to the north, and other gold mining centres to the
south (El Dorado and Kilometer 88) and the Brazilian frontier, passes El Callao.
A major high voltage 400 kV electrical supply line carrying power from the Guri dam, and
destined for Brazil, passes near El Callao. A sub-station about 5 km from the Choco concessions
supplies power to El Callao. The potential water supply is from the Yuruari River, which passes
north of the concessions, approximately 8 km distant, and from which other local mines and El
Callao municipality draw water.
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Figure 2.1
Map of Venezuela
(after University of Texas)
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