The Molo Graphite Mine is an operating graphite mine in southwestern Madagascar, wholly owned by NextSource Materials Inc., a Toronto-based company listed on the Toronto Stock Exchange. The project is currently in production with Phase 1 operations producing SuperFlake® graphite concentrate. The Molo Expansion Project (MEP) proposes construction of an additional processing plant and supporting infrastructure to reach steady-state production of 150,000 tonnes per annum of graphite concentrate over an approximately 37-year mine life. The feasibility study update incorporates operational experience from Phase 1 development, which has been accelerating since 2023. No construction timing for the expansion is stated in the recovery methods section of the report.
Critical Data
| Parameter | Value | Unit | Notes |
|---|---|---|---|
| Final plant graphite product capacity | 150,000 | tpa | total for all expansion phases, excludes existing Phase 1 plant |
| Final dry ROM annual throughput | 2.48 | Mtpa | for complete Phase 2 expansion |
| Design overall graphite recovery | 92.0 | % | expected value |
| Minimum concentrate grade | 95 | % graphite | design target |
| Average feed head grade | 6.23 | % total carbon | design basis |
| Phase 2A graphite product | 50 | ktpa | first expansion module |
| Phase 2A ROM feed | 0.83 | Mtpa | dry basis |
| Phase 2B additional graphite product | 50 | ktpa | second module |
| Phase 2C additional graphite product | 50 | ktpa | third module |
| Final crushing circuit design feed rate | 424 | tph | dry solids, after Phase 2C installation |
| Primary milling circuit feed rate | 104 | tph | dry solids, per flotation module |
| Final combined flotation feed capacity | 312 | tph | three modules at 104 tph each |
| Crushing circuit operating hours Phase 2A | 12 | h/d | |
| Crushing circuit operating hours Phase 2B | 16 | h/d | |
| Crushing circuit operating hours Phase 2C | 24 | h/d | |
| Milling and flotation operating hours | 24 | h/d | 365 days per annum at 91% utilization |
| Primary mill product grind | 80% passing 250 | μm | target |
| Primary mill product solids content | 27 | % w/w | target |
| Phase 1 graphite product capacity | 8.0 | ktpa | existing plant, not included in expansion totals |
| Phase 1 plant status | Not stated | Not applicable | will be decommissioned after Phase 2A commissioning |
| Tailings filter cake target moisture | 15 | % | design target |
| Final tailings conveyor design rate | 300 | tph | nominally, for final plant |
| Concentrate filter sizing basis | 6.3 | tph | per module |
| Concentrate dryer sizing basis | 6.3 | tph | per module |
Overview
The recovery methods section describes the process plant design for recovering and concentrating graphite from the Molo ore deposit. Process design is based on metallurgical test work results, the mine schedule, established processing methods and technologies, and lessons learned from Phase 1 operations. The concentrator capacity increases through three incremental design stages called Phase 2A, Phase 2B, and Phase 2C. Each phase adds 50 ktpa of graphite concentrate capacity with a corresponding ROM feed of 0.83 Mtpa. The report notes that within engineering documents the expansion phases align with construction stages designated as Stage 2, Stage 3A, and Stage 3B. Chapter 17 describes the process and operation based on completion of the Phase 2A plant, with Phases 2B and 2C being identical in operation.
The process is expected to achieve 92.0% overall graphite recovery at a minimum concentrate grade of 95% graphite from an average feed head grade of 6.23% total carbon. The graphite concentrate is dry screened to specific size fractions as required by the market. Size fraction ratios can be tuned within the plant to the extent allowed by ore lithology and grade.
Phase 2 design incorporates learnings from Phase 1 operations. Major improvements include a shift from a single plant to phased expansion. The flowsheet reduced its focus on flake preservation and now emphasizes grade control with flexible operation for size fractions through bypass and regrind options. Equipment is sized with design margins for adequate surge and peak capacity. Provision for blending ROM material reduces variation in grade, particle size, and lithology. Equipment selection criteria focus on application, duty, and maintainability. The plant scale and equipment sizing provide stabilizing factors for higher overall recovery, supported by larger flotation cells. The flotation circuit includes increased cleaning stages with flexibility to use 7 to 10 stages. Flotation columns have been replaced with conventional flotation cells. A larger plant and longer residence time allow stabilization and testing of intermediate product. Corrections can be implemented through flexible flowsheet paths, which negates re-treatment of off-spec product through all process stages. Pressure filter technology replaces vacuum belt filtration for both tailings and concentrate dewatering. An air swept classifier reduces deck loads on product screening units.
Key Process Stages
The ore processing circuit includes ore receival, stockpiling and crushing, primary milling and classification, flotation with concentrate upgrading through cleaner/scavenger circuits and attritioning, graphite concentrate dewatering by pressure filtration and drying, final product sizing and bagging, tailings thickening and dewatering, dry tailings stacking, reagents mixing and dosing, and air and water services.
The three-stage crushing circuit has capacity to treat the final throughput for all phases. Some equipment installation can be delayed until Phase 2B. The final crushing circuit after Phase 2C installation is designed for 424 tph dry solids feed. For Phases 2A, 2B, and 2C the crushing circuit operates for 12, 16, and 24 hours per day respectively. ROM is delivered by haulage trucks and stockpiled according to grade. Reclaiming from multiple stockpiles facilitates blending for consistent feedstock. Material enters the primary apron feeder with 80% passing 375 mm and top size of 750 mm. The primary jaw crusher reduces material to 80% passing 125 mm. A self-cleaning magnet removes tramp metal. The secondary screen has top and bottom apertures of 35 mm and 12 mm. Secondary and tertiary crushers are short-head style cone crushers. The three-stage crushed product reports to the fine ore bin, which provides surge capacity between crushing and the primary ball mill. At Phase 2A, the crushing circuit allows fine ore bins to be filled within an eight-hour shift. An emergency feed hopper enables fine crushed ore from a mobile unit or Phase 1 crushing circuit to be redirected to the fine ore bins.
The primary milling circuit treats 104 tph dry solids, equivalent to one third of final plant capacity. Crushed material at approximately 80% passing 10 mm feeds the primary ball mill. Water is added to maintain slurry discharge density of 1.51 t/m3. Grinding media of 70 to 80 mm diameter steel balls are added regularly. The ball mill trommel removes oversize media and scats. Classification screens have two decks with apertures of 4 mm and 0.3 mm. Screen oversize returns to the ball mill; undersize goes to the rougher conditioning tank. Lime powder is added for pH control. The primary mill circuit is expected to produce a grind of 80% passing 250 microns with 27% w/w contained solids.
The flotation process includes rougher and rougher scavenger flotation with up to 10 cleaning stages, 2 intermediate polishing stages, and 3 intermediate attritioning stages. If the 7th cleaner concentrate grade permits, stages 8, 9, and 10 can be bypassed. Flotation cells are fitted with oversize double-sided froth paddles into jumbo launders to address the high froth factor observed during Phase 1.
Rougher flotation uses four Metso OK 16 style cells of 16 m3 each. Rougher scavengers consist of two banks of four cells each. The rougher concentrate is lightly ground in the first polishing mill using 12 mm ceramic media. First cleaner flotation uses four Metso OK 8 style cells of 8 m3 each. First cleaner scavengers use a further bank of four cells. The first cleaner concentrate goes to the second polishing mill. Second and third cleaner flotation use three and two Metso OK 8 cells respectively, with tailings from the second cleaner going to the combined cleaner flotation tailings tank. Two attritioning mills operate in series using 6 mm ceramic media at 20% loading. Fourth and fifth cleaners each consist of two Metso OK 8 cells. Sixth and seventh cleaners each consist of two Metso OK 8 cells. Eighth, ninth, and tenth cleaners each consist of two Metso OK 8 cells. The 10th cleaner concentrate goes to the final concentrate trash screen feed box.
Final tailings are fed from a combined tailings sump to the tailings thickener. Thickener overflow reports to the process water tank. Underflow is pumped to agitated tailings filter feed tanks. Three tailings filters operate in batch process to produce filter cake with a target of 15% moisture. Filtrate is recycled to the thickener. Filter cake discharges onto conveyors and is stockpiled, then reclaimed by front-end loader for transport to the dry stacking area.
Final concentrate from the 10th cleaner circuit passes over a trash screen and is distributed between two agitated filter feed tanks. Filtration is a batch operation. Filter cake discharges onto a conveyor and into a surge bin for drying. The diesel-fired concentrate dryer produces dry graphite powder that is pneumatically transferred to an air swept classifier feed bin. The classifier removes fine dust. De-dusted powder is stored in the final concentrate sizing feed bin. Two screening circuits operate in parallel with multi-deck screens producing five size fractions: +35 Mesh, -35+50 Mesh, -50+80 Mesh, -80+100 Mesh, and -100 Mesh. The -80+100 Mesh fraction is screened a second time. Identical size fractions from both circuits are combined. The -100 Mesh fraction combines with fine product from de-dusting stages.
Additional Interesting Data and Summary
Reagents include lime for pH control, diesel as collector, and Methyl Isobutyl Carbinol (MIBC) as frother. Collector is dosed at nine designated points including the rougher conditioning tank, rougher scavenger cells, and multiple cleaner cells. Frother is dosed at five points. Flocculant is delivered in powder form and mixed with raw water in batches. Three flocculant dosing pumps deliver to dilution boxes ahead of the tailings thickener and concentrate filter filtrate thickener. Provision is made for future addition of coagulant and dispersant.
Low pressure air is required for the flotation circuit and pneumatic conveying in the screening and bagging area. High pressure air is required for pressure filters and instrumentation.
A single process water tank is installed with capacity for the final plant. Raw water is pumped from a well-field into a raw water tank, with lower volume reserved for firefighting duty. Potable water is produced from raw water through a potable water plant. High- and low-pressure pump gland water systems are provided.
The expanded concentrator reaches final production capacity through three expansion phases. In Phase 2A, the crushing plant ROM capacity is limited to 212 tph because the second tertiary crusher is absent. After Phase 2B, the crushing plant reaches its maximum of 424 tph. There is no increase in crushing capacity in Phase 2C. Each expansion phase includes a separate flotation module treating 104 tph, giving a final total of 312 tph for three modules. Graphite filtration, screening, and bagging areas have 50,000 tpa capacity per phase, providing 150,000 tpa final capacity. Equipment sizing and installation strategies for each expansion phase are detailed across all plant areas including tailings thickening and filtration, concentrate filters, thickeners, dryers, dust collection, screening, bagging, reagents, and water services.
Key Processes
- Three-stage crushing circuit (primary jaw crusher, secondary and tertiary short-head cone crushers) with inter-stage screening; final design rate 424 tph dry solids; operating hours vary by expansion phase from 12 to 24 per day
- Primary ball mill circuit with classification screens; design rate 104 tph per module; target product grind 80% passing 250 microns at 27% w/w solids
- Rougher and rougher scavenger flotation using Metso OK 16 style cells (16 m3 each)
- Multi-stage cleaner flotation using Metso OK 8 style cells (8 m3 each): up to 10 cleaning stages with bypass option after 7th cleaner
- Two intermediate polishing mills using 12 mm ceramic media
- Three intermediate attritioning mills using 6 mm ceramic media at 20% loading
- Tailings thickening, pressure filtration to 15% moisture target, and dry-stack disposal with conveyor transport and front-end loader reclamation
- Final concentrate pressure filtration (batch operation), diesel-fired drying, air swept classification for fines removal
- Multi-deck screening producing five size fractions: +35 Mesh, -35+50 Mesh, -50+80 Mesh, -80+100 Mesh, -100 Mesh; secondary screening for -80+100 Mesh fraction
- Reagent systems: lime for pH control, diesel collector dosed at nine flotation points, MIBC frother dosed at five points, flocculant for thickening
Source: Molo Graphite Mine Expansion NI 43-101 Technical Feasibility Study Update Report 2026, August 7, 2026. Project website: Molo Graphite Mine
Consolidated report summaries
The following former standalone pages about this operation were consolidated here on October 25, 2026. They are retained for source traceability; dates and figures reflect each report’s own effective date and may be superseded by the current information above.
Molo Graphite Project — 2024 Technical Report Update
This report update describes the process design basis for a proposed graphite concentrator at the Molo Graphite Project in Madagascar, including crushing, milling, flotation, chemical upgrading, and product handling.
Report context
This technical report update is dated 22 March 2024 and relates to the Molo Graphite Project, located at Fotadrevo, Province of Toliara, Madagascar. The report documents a preliminary economic assessment level design for processing graphite mineralized material and is prepared in accordance with NI 43-101 requirements.
Processing route
Overview
The proposed processing circuit will consist of three-stage crushing, followed by primary milling and a flotation separation circuit. The process has been designed assuming an expected recovery of 89% and an average head grade of 8.5% carbon, delivering an estimated 84,000 tonnes per annum of graphite concentrate at the designed throughput tonnage of 1.16 Mt per annum. Varying graphite head grades could lead to reduced recoveries or less graphite product for the same feed tonnage into the plant.
Design criteria and basis
The process design is based on an annual production capacity of 1,160,000 tonnes of material feed at a nominal head grade of 8.5% carbon. Test work was performed during the course of the study, and the results form the basis of the process design criteria. Design information sources were coded in the report as follows: A (assumed, based on current information), B (previously reported), C (as instructed or determined by the client), D1 (selected based on test work results), D2 (selected based on design experience), D3 (calculated based on other inputs), D4 (selected based on OEM recommendations), and E (information not available).
Key design parameters for mineralized material include a solids density of 2.4 t/m³, a broken bulk density of 1.5 to 2 t/m³, and a graphite head grade of 8.5% carbon. The estimated plant feed rate is 1,160 ktpa, with an estimated plant recovery of 89%. The estimated final concentrate grade is 88% carbon at 5% mass pull, without chemical treatment. The estimated final concentrate production is 84 ktpa.
The plant design operating schedule specifies that ROM mineralized material will be delivered at 1,160 ktpa over 7 days per week, 2 shifts per day, and 10 hours per shift. The crusher schedule is 7 days per week, 3 shifts per day, at 8 hours per shift, with an assumed utilisation of 67%, giving 5,869 operating hours per annum. The crushed material rate is calculated at 197.6 t/h. The milling schedule is 365 days per annum at 24 hours per day, with an assumed utilisation of 92.0%, giving 8,060 operating hours per annum. The circuit feed rate is 144 t/h dry.
Concentrate production design parameters include a filter feed rate of 7.19 t/h dry, a filter running time of 18 hours per day, and a filter availability of 75%. Drying plant availability is assumed at 92%. The dryer is specified as a T1500 EBR Torbed type with a size of 8 t/h. Cake moisture after drying is specified at 1% w/w. Product classifier sizes are listed as -75 µm, -150 to +75 µm, -300 to +150 µm, and +300 µm.
Crushing and sizing
The three-stage crushing circuit is designed to operate at 67% availability, equating to a feed capacity of approximately 200 tonnes per hour. ROM material will be delivered to a ROM feed bin feeding the crushing and screening section of the plant. A single tramp screen will remove any oversize material. Material will be crushed to a product size of P80 of 10 mm via the three-stage crushing process, incorporating a single primary screen after the second crushing stage. It is currently envisaged that the primary crusher will be a jaw or impact crusher, while the secondary and tertiary crushers will be cone crushers or mineral sizers. A further screening section is to be developed on the basis that large graphite flake will be screened out as a salable product ahead of the milling and flotation stages.
Primary milling
A single-stage primary milling circuit has been employed, operating in closed circuit with classifying cyclones. The primary ball mill would be approximately 4.3 metres in diameter with an effective grinding length of 6.2 metres. The motor installed power would be approximately 3,000 kW. The comminution circuit capacity will accommodate the full tonnage of 1.16 Mt per annum. The overflow from the cyclone cluster will feed the primary rougher flotation circuit of the plant.
Secondary milling
A single-stage secondary milling circuit will consist primarily of a stirred media detritor for the regrind of the primary cleaner tail. The mill will operate in open circuit with a dewatering cyclone cluster. The underflow from this cluster will feed the secondary mill, while the overflow will discharge to the secondary mill discharge sump. The secondary milling circuit product will feed the secondary cleaner section of the flotation plant. Due to the lower mass pull to the cleaner circuit, the milling circuit is expected to be relatively small, with an installed power of 90 kW.
Tertiary milling
A single-stage tertiary milling circuit will also consist of a stirred media detritor for the regrind of the secondary cleaner circuit tail. The mill will operate in open circuit with a dewatering cyclone cluster. The underflow from this cluster will feed the tertiary mill, while the overflow will discharge to the tertiary mill discharge sump. The tertiary milling circuit product will feed the tertiary cleaner section of the flotation plant. Installed power to the mill will be limited to 90 kW.
Rougher flotation
The rougher feed, consisting of the primary mill cyclone overflow, is gravitated to a transfer tank or conditioner ahead of a bank of box-type flotation cells in series. Rougher concentrate recovered will be pumped to the primary cleaner flotation circuit, while the rougher tail is to be pumped directly to the tailings storage facility via a rougher tail transfer sump and multi-stage pumps. The rougher flotation circuit has been designed to accommodate the full plant throughput capacity of 1.16 Mt per annum at an average head grade of 8.5% carbon.
Primary cleaner flotation
The primary cleaner feed, consisting of the rougher flotation concentrate together with the tail from the primary re-cleaner cell, is pumped directly to a bank of box-type flotation cells in series. Primary cleaner concentrate will be pumped to the primary re-cleaner cell. The primary cleaner tail will be pumped to the secondary mill dewatering cyclone cluster. Concentrate from the primary re-cleaner cell will be pumped directly to a concentrate thickener for final product handling.
Secondary cleaner flotation
Secondary cleaner feed, consisting of the secondary mill discharge, is pumped from a surge tank to a bank of box-type flotation cells in series. The secondary cleaner concentrate will be pumped to the tertiary cleaner flotation circuit. The secondary cleaner tails will be pumped to the tertiary milling circuit surge tank for regrind and polishing.
Tertiary cleaner flotation
The tertiary cleaner feed, consisting of the combined streams of the secondary cleaner flotation concentrate together with the tertiary mill discharge, is pumped directly to a bank of box-type flotation cells in series. The tertiary cleaner concentrate will be pumped to the tertiary re-cleaner float cell. The tertiary cleaner tail will be pumped to the rougher tail transfer sump together with the rougher tail to be transferred to the tailings storage facility. Concentrate from the tertiary re-cleaner cell will be pumped directly to the concentrate thickener for final product handling.
Concentrate thickening
The flotation circuit was designed to produce approximately 84,000 tonnes of concentrate per annum at the average head grade of 8.5% carbon. The final concentrate produced from the flotation circuit is transferred to a high-rate thickener ahead of the filtration and drying process. The thickened concentrate slurry is pumped into one of two existing stock tanks. Overflow from the concentrate thickener is clarified, and overflow from the clarifier is gravitated to the process water tank, while the underflow from the clarifier is pumped to the stock tanks. Concentrate slurry is periodically pumped from the stock tanks to a plate and frame filter for dewatering.
Concentrate chemical upgrading
Preliminary test work indicated that two methods could be used to enhance the grade of the graphite concentrate: a hydrofluoric acid leach, or alternatively a caustic hydration and hydrochloric acid dehydration process. Due to the hazardous nature of the hydrofluoric acid leach, the hydration and dehydration process was adopted. Concentrate from the concentrate thickener is transferred to an agitated leach tank where caustic soda will be introduced. A 24-hour leach residence time will be applicable, after which the concentrate will be transferred to a second agitated tank where hydrochloric acid is introduced. The concentrate is leached in acid for a further period of 24 hours. The leached concentrate is finally transferred to a third neutralisation tank. The neutralized pulp is filtered ahead of the drying and sizing plant.
The concentrate grade expected to be achieved in the flotation process is approximately 88% carbon. Utilizing a chemical treatment process, the concentrate purity could be increased to 99% carbon, resulting in battery-grade carbon. The chemical treatment plant can be isolated from the rest of the circuit without any major changes, allowing for the opportunity to bring the plant online at a later stage to defer capital costs.
Concentrate filtration and drying
Final concentrate will be periodically pumped from the stock tanks to a plate and frame type filter press, where the pulp is dewatered to acceptable moisture levels ahead of the drier. The filter cake so produced will be transferred to a drying circuit where the remaining moisture and entrapped volatiles will be driven off.
Concentrate despatch
A vendor-supplied bagging plant will be utilised. The final concentrate will be weighed and bagged into 1-tonne bulk bags. A batch reserve of 20 bags will be made up, equivalent to the full load requirement of a sea freight container, with each bulk bag in the reserve being spear sampled to form a final composite sample. The composite sample will be analysed for graphite content and moisture together with any gangue mineralization pertinent to the final product specification requirements. The bulk bags are finally sealed and covered with an ultraviolet-resistant plastic cover and placed on a wooden pallet ready for storage ahead of despatch. The graphite concentrate will be despatched on a daily basis and transferred to the warehouse in Soalara ahead of sea freighting.
Tailing disposal
The rougher tail, or final tail, from the flotation circuit will be transferred directly to the tailings storage facility at the normal flotation operating density. The rougher tail transfer tank will be equipped with two pump trains of three pumps in series per train. The two pump trains, one operational and one standby, will utilise a common discharge line. A dedicated gland service water system will be installed to service the pumps. The tailings pipeline will be HDPE above ground with knife gate valves on the discharges, and the return water line will also be HDPE.
The final flotation tail will be pumped to the tailings storage facility via three pumps installed in series. No thickening of the flotation tail will be required, and the pulp will be pumped at the nominal flotation operating density. The slimes dam will be operated employing a conventional day wall system and floating penstock to recover clarified water. The water so recovered will be pumped directly back to the plant to the process water tank via the floating penstock, eliminating the use of a return water reservoir. The TSF will be located within a kilometre radius of the process plant. The TSF has been sized by a specialist consultant, and it is proposed that the TSF will be an unlined facility constructed using waste material from the open pit mining operations. The initial TSF footprint with the capacity to accommodate 2 years of operations is proposed to be constructed in order to reduce upfront capital costs. The initial TSF will have a wall height of 10 m and a footprint of 28.8 hectares.
Services
Instrument-quality air is produced from a compressed air installation at the plant, consisting of two compressors and associated dryers and receivers. Blower air will be generated from positive displacement blowers to service the flotation cells.
The water circuit will be configured to minimise raw water usage. Raw water will only be used for reagent make-up, potable water, and process top-up water. In addition to raw water supply to a raw water dam, a facility to supply raw water directly to the process water dam will be provided. Supply sources are designated as follows: reagent make-up water will be unfiltered raw water supply; gland service water will be raw water supply; spray water will be supplied from process water; potable water will be supplied from the dedicated raw water supply, filtered and treated. Potable-quality water will be for human consumption only. Process-quality water will be used for services required within the confines of the plant, such as spray water usage and hosing. Fire water, reagent make-up, and mill bearing cooling water will be raw-water quality. Unfiltered process water will be used for mill circuit dilution.
Reagents
Dispersant make-up is fully automated and will be supplied in bulk bags. Dry powder is stored in a hopper, with storage in excess of 24 hours. A hydration time of 4 hours is allowed during reagent mixing. Dosage of the reagent will be done from a dedicated ring main system using flow control valves and flow meters at each addition point.
Illuminating paraffin or diesel will be used as the collector. The collector will be delivered in 1 m³ plastic tanks. These tanks will be mounted on a concrete slab on ground level as close as possible to the required dosing point. Small, adjustable dosing pumps will be installed directly on the dosing tanks, pumping directly to the dosing point.
Powder flocculant will be supplied in 25 kg bags and diluted as required with an automated make-up plant. Dry hopper storage in excess of 24 hours has been allowed. Dosage is from variable speed pumps, duty and standby, to the concentrate thickener.
DOW200 will be used as the activator. The activator will be delivered in 1 m³ plastic tanks similar to the collector. These tanks will be mounted on a concrete slab on ground level as close as possible to the required dosing point. Small, adjustable dosing pumps will be installed directly on the dosing tanks, pumping directly to the dosing point.
Energy, water and process materials consumption
The plant energy requirements have been calculated using the mechanical equipment list and applying a utilisation percentage to each processing unit. The plant installed power is 7.3 MW, with the primary milling plant constituting 41% of the installed power. The operational power demand is anticipated to be 4.9 MW. Power will be generated using diesel power generators.
The major water source was identified through the surface hydrology study conducted. Water will be supplied from a catchment dam situated 17 km from the processing plant and will supply the plant with raw water. Raw water from the dam is to be clarified and purified for human consumption and village requirements. Raw water make-up requirements will be 206 m³/h, of which process water requirements will make up 125 m³/h.
Most reagents will be consumed in relatively low quantities, with depressant being the only exception. Consumption of grinding media would need to be determined based on further comminution test work. The grinding media would need to be imported, as would most of the other process consumables. For the purpose of the study, the grinding media consumption is based on vendor information and estimates and assumptions used in relevant milling simulations.
Key reported parameters
| Parameter | Units | Value | Basis |
|---|---|---|---|
| Plant feed rate | t/h dry | 144 | Calculated |
| Annual feed tonnage | ktpa | 1,160 | Calculated |
| Head grade | % C | 8.5 | Test work |
| Plant recovery | % | 89 | Test work |
| Final concentrate grade | % C | 88 at 5% mass | Test work |
| Final concentrate production | ktpa | 84 | Calculated |
| Solids density | t/m³ | 2.4 | Test work |
| Broken bulk density | t/m³ | 1.5-2 | Test work |
| Crusher feed capacity | t/h | 197.6 | Calculated |
| Crusher availability | % | 67 | Design experience |
| Crusher operating hours | h/a | 5,869 | Calculated |
| Milling operating hours | h/a | 8,060 | Calculated |
| Primary mill diameter | m | 4.3 | Not specified |
| Primary mill EGL | m | 6.2 | Not specified |
| Primary mill installed power | kW | 3,000 | Not specified |
| Secondary mill installed power | kW | 90 | Not specified |
| Tertiary mill installed power | kW | 90 | Not specified |
| Filter feed rate | t/h dry | 7.19 | Calculated |
| Filter running time | h/day | 18 | Calculated |
| Filter availability | % | 75 | Assumed |
| Drying plant availability | % | 92 | Assumed |
| Dryer size | t/h | 8 | OEM recommendation |
| Cake moisture after drying | % w/w | 1 | OEM recommendation |
| Leach residence time, caustic | h | 24 | Not specified |
| Leach residence time, acid | h | 24 | Not specified |
| Plant installed power | MW | 7.3 | Calculated |
| Operational power demand | MW | 4.9 | Calculated |
| Raw water make-up | m³/h | 206 | Not specified |
| Process water requirement | m³/h | 125 | Not specified |
| Initial TSF wall height | m | 10 | Not specified |
| Initial TSF footprint | ha | 28.8 | Not specified |
Project website: https://www.nextsourcematerials.com/energizer-resources-finalizes-molo-graphite-project-acquisition/
Project website: https://www.nextsourcematerials.com/assets/molo-graphite-mine/
Technical qualifications
This report presents a preliminary economic assessment level design. Several limitations apply to the information presented.
The process design for crushing, milling, and flotation is based on test work performed during the course of the study; however, the flowsheet development and design will follow once confirmatory test work has been concluded and specific equipment sizes have been established. The report notes that the flowsheet for the large-flake recovery circuit is to be developed following confirmatory test work.
Consumption of grinding media would need to be determined based on further comminution test work. For the purpose of the study, grinding media consumption is based on vendor information and estimates and assumptions used in relevant milling simulations.
Several design criteria are based on assumptions rather than test work or detailed engineering. These include the ROM delivery schedule, crusher schedule, milling schedule, filter availability, and drying plant availability.
The chemical treatment section notes that preliminary test work indicated two possible methods for upgrading the graphite concentrate, with the caustic hydration and hydrochloric acid dehydration process being adopted. The report states that utilizing chemical treatment, the concentrate purity could be increased to 99% carbon, resulting in battery-grade carbon.
The report also notes that the further screening section for large graphite flake removal is to be developed, and that the specific equipment sizes for the large-flake recovery circuit have not yet been established.
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Source: Molo Graphite Project, Fotadrevo, Province of Toliara, Madagascar, PEA Technical Report Update, NI 43-101, 22 March 2024, Section 17, Recovery Methods.
