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MINE FEASIBILITY STUDIES*
D ONALD W. G ENTRY AND T HOMAS J. O'N EIL
Feasibility studies are the heart of the mine evaluation pro- 6. Transportation: description of the additional, necessary
cess. A feasibility study of a mining project represents an engi- transportation facilities (roads, air strips, bridges, harbors, rail
neering/economic appraisal of the commercial viability of that lines).
project. As such, it is the result of a relatively formal procedure 7. Towns and Related Facilities: housing for workers, schools
for assessing the various relationships that exist among the myr- for children of workers, medical facilities, company offices.
iad of factors that directly or indirectly affect the project in 8. Labor Requirements: estimates of work force broken down
question. In essence, the objective of a feasibility study is to according to qualifications (skills) and local availability.
clarify the basic factors that govern the chances for project suc- 9. Environmental Protection: plans to reduce or minimize
cess. Once all the factors relative to the project have been defined environmental damage, description of relevant environmental
and studied, an attempt is made to quantify as many variables legislation.
as possible in order to arrive at a potential value or worth of the 10. Legal Considerations: review of mining laws, taxation,
property. foreign-investment regulations, political risk.
As a mining project progresses from raw exploration through 11. Economic Analysis: cost estimates for plant and equip-
to the time when a management decision is made to develop and ment, infrastructure, materials, labor, other factors; market anal-
mine the property, a number of analyses will be conducted on ysis, including production, consumption, and price formation
the property, each of which will be based on increasing amounts for the relevant minerals; revenue forecasts based on expected
of data, will require increasing amounts of time (and therefore production and mineral prices; cash flow and net present value
expense) to prepare, and will have increasing degrees of accu- analysis; sensitivity analysis.
racy. For example, as exploration occurs on a mining property, Assuming the project continues to appear favorable through-
the intersection of mineralization by a few drillholes typically out the intermediate economic studies, as these studies progres-
triggers the need for some type of initial analysis to assist with sively focus more on engineering and economic aspects and less
necessary decision making. These types of studies are identified on geologic parameters, the project must be formally assessed
by various names (Gocht et al., 1988; Taylor, 1977), but in each through a comprehensive feasibility study. The feasibility study
case they are designed to answer questions pertaining to (1) what represents a detailed analysis of all the parameters contained in
magnitude of deposit might exist rather than what is known to the intermediate economic studies, along with other pertinent
exist, (2) should further expenditures be incurred to look for factors relating to political and legal aspects affecting project
what might exist, (3) should the project be abandoned, or (4) viability. Specific data requirements for incorporation into feasi-
what additional effort and/or expense is necessary before making bility studies are contained in the following segment of this
any of these decisions. chapter; however, in general, the study contains analyses of the
Assuming a favorable decision for continuation of the proj- project’s geology and deposit characteristics, mineralogy, min-
ect, the next sequence of decisions must be predicated on studies eral processing characteristics, designs and plans for mining and
utilizing much more detailed information. These so-called pre- processing equipment requirements, construction schedules, in-
feasibility studies or intermediate economic studies are based on vestment requirements and timing, estimates of revenues and
increasing amounts of data pertaining to geologic information, costs, marketing plans, cash flow calculations, sources and meth-
preliminary engineering designs and plans for mining and pro- ods of financing, and risk and sensitivity analyses of important
cessing facilities, and initial estimates of project revenues and project variables. As stated previously, the purpose of the feasi-
costs. They are constructed to support a continuum of decisions bility study is to assess the technical and economic viability of
relating to the next major spending requirement. Intermediate the project and to assist the organization in making the “go/no-
economic studies of this type typically contain the following go” decision regarding project development.
information and analysis (Gocht et al., 1988): Although there is no prescribed format for reporting the
1. Project Description: geographic area, existing access routes, results of a project feasibility study, the final report must fulfill
topography, climate, project history, concessionary terms, the following essential functions (Taylor, 1977):
schedule for development of mine and any processing facilities. 1. Provide a comprehensive framework of established and
2. Geology: regional geology, detailed description of the proj- detailed facts concerning the mineral project.
ect area, preliminary reserve calculations, plans for detailed tar- 2. Present an appropriate scheme of exploitation complete
get evaluation. with plans, designs, equipment lists, etc., in sufficient detail for
3. Mining: geometry of the ore body, proposed mining plan accurate cost estimation and associated economic results.
(and alternatives), required plant and equipment. 3. Indicate the most likely profitability on investment in
4. Processing: technical descriptions of the ore and concen- the project, assuming the project is equipped and operated as
trate, processing facilities. specified in the report.
5. Other Operating Needs: availability of energy, water, spare 4. Provide an assessment of pertinent legal factors, financing
parts, and equipment (diesel oil, explosives, replacement parts, alternatives, fiscal regimes, environmental regulations, and risk
etc.). and sensitivity analyses on important technical, economic, politi-
cal, and financial variables affecting the project.
5. Present all information in a manner intelligible to the
* This chapter draws heavily from various chapters in Mine Invest- owner and suitable for presentation to prospective partners or
ment Analysis by D.W. Gentry and T. J. O’Neil (1984). to sources of finance. The document must be “bankable.”
393
394 MINING ENGINEERING HANDBOOK
6.2.1 DATA REQUIREMENTS magnitude of mining revenues depends upon factors such as
ore reserves, production rates, commodity prices, markets, and
Nothing improves the results of a project feasibility study metallurgical recoveries. These variables are often extremely dif-
more than good input data. Unfortunately, those preparing feasi- ficult to estimate or predict—particularly for commodities
bility studies for mining projects never possess all the informa- traded in international markets. This topic is discussed in more
tion they would like. In addition to inadequacy or unavailability detail in the following portion of this chapter.
of some needed data, care must be taken not to overlook any The overall operating environment is another area of major
variable that may influence project viability. In this regard, it is concern. In recent years, the national and, to a lesser but growing
often helpful to compile an outline of factors to be considered extent, the international operating environment of mining prop-
when preparing feasibility studies on mining properties. erties has been impacted significantly by environmental and
other regulatory requirements. These constraints have invariably
increased operating and capital cost requirements for the indus-
6.2.1.1 Factors for Consideration try and have reduced or delayed the production of mineral com-
modities. The operating environment of mining operations is
Table 6.2.1. is an outline of some of the pertinent variables also affected by direct economic variables, such as royalties and
that must be studied, considered, and analyzed when evaluating taxes mandated by federal, state, and local taxing authorities.
mining properties. The significance of each variable will be a All these costs, whether direct or indirect, impact profit margins,
function of the specific property being investigated and the min- ore reserves, mineral conservation, and ultimately project via-
eral commodity (metallic, nonmetallic, fuel) involved. Nonethe- bility.
less, all these variables should be assessed during preparation of
the final feasibility study.
A review of Table 6.2.1. suggests there are some fundamental 6.2.1.2 Variable Quantification
issues that are applicable to all mining property feasibility stud-
ies—regardless of the commodity involved. For instance, one of As stated previously, the objective of any feasibility study is
the first tasks associated with any mining property is estimating to assess, clarify, and ultimately quantify the basic factors that
the magnitude and quality of the ore reserves (Chapter 5.6). Ore govern the chances for project success. Once all the geologic,
is, of course, an economic term and is a function of commodity engineering, and other technology-related factors relative to the
prices, production costs, mining method, recoveries, dilution, property have been defined and studied, an attempt is made to
and a number of other variables. Because ore reserves are deter- quantify as many of the variables as possible to arrive at a
mined by ever-changing economic conditions, the exact amount potential value or worth of the property. In this regard, two
of ore contained in a deposit cannot be precisely determined general categories of quantification are extremely important yet
until production ceases. This uncertainty with respect to ore quite troublesome to compute: revenue estimation and cost esti-
reserves has a significant impact on the evaluation of mineral mation.
properties where long-term contracts at stipulated selling prices Revenue Estimation: Annual mine revenue is calculated by
are not available. multiplying the number of units produced and sold throughout
Production technology is another key area of concern when the year by the sales price received per unit. While the arithmetic
performing mining feasibility studies. Technological advance- associated with calculating annual mine revenue is trivial, de-
ments in equipment, mineral processing, and other areas can termining the best value to use for each of these two critical
significantly impact projected operating and capital costs. A variables is much more difficult.
good example of the impact of technology changes on mining There are a number of important considerations in estimat-
costs is the comparison between direct mining costs per ton ing the number of units produced and sold annually. For exam-
(tonne) of rock for underground and surface operations. While ple, estimates must be made of the tonnage of ore produced, the
underground operating costs have been increasing at significant grade of ore mined (including dilution), the percentage recovery
rates in recent years (mainly because of the lack of major techno- of the valuable mineral in the ore, and, finally, the number of
logical advancements and the labor intensity that exists), unit payable units available for sale.
operating costs at surface operations have changed far less. The The second major component of the mine revenue calcula-
technological advancements in mining equipment, yielding pro- tion is the unit sales price. Estimating future mineral prices—
ductivity increases, have prevented direct operating costs in sur- particularly prices far enough into the future to be of use in mine
face operations from escalating at the rates experienced by under- investment analysis—is much more difficult than estimating the
ground producers. The relative stability in surface operating production-related variables and is an exercise in which a high
costs has not been entirely free, however. The technological error of estimation invariably exists. As pointed out in Section
advancements in mining equipment that contributed to this sta- 2.0, mineral prices, like those of any other product, are ultimately
bility in operating costs carried with them significant increases determined by supply and demand. However, there are major
in capital costs. complications on both sides of the supply-demand equation that
Operating and capital cost requirements must be determined seriously impair the value of quantitative econometric modeling
separately when formulating the feasibility study. However, in for estimating mineral prices.
the limiting case, it is the combination of the magnitude and Clearly, the analysis of supply and demand for most mineral
timing of both these costs that ultimately influence the analysis. commodities is complicated. In fact, few analysts are willing to
Any changes in future production technologies must be carefully suggest that reliable forecasts of prices useful in mine investment
analyzed and the impact assessed on overall operating and capi- analysis are possible. The current popular approach to this prob-
tal cost requirements. The estimation of capital and operating lem is for analysts to occupy safer ground and issue price projec-
costs for mining projects that have not progressed to the detailed tions—that is, prices that are likely if certain assumed events
planning and layout stage is discussed in Chapter 6.3. actually occur.
Another area of fundamental interest in feasibility studies of Regardless of the difficulties associated with forecasting or
mining properties that requires considerable data generation and projecting mineral prices into the future, estimates of mining
analysis is the estimation of project revenues. The timing and project annual revenue must be established. Generally, fungible
MINE FEASIBILITY STUDIES 395
Table 6.2.1. Salient Factors Requiring Consideration in
a Mining Project Feasibility Study
I. Information on Deposit G. Government Considerations
A. Geology 1. Taxation: federal, state, local
1. Mineralization: type, grade, uniformity a. Organization of the enterprise
2. Geologic structure b. Tax authorities and regimes
3. Rock types: physical properties c. Special concessions, negotiating procedures, duration
4. Extent of leached or oxidized zones d. Division of distributable profits
5. Possible genesis 2. Reclamation and operating requirements and trends: pol-
B. Geometry lution, construction, operating and related permits, re-
1. Size, shape, and attitude porting requirements
2. Continuity 3. Zoning
3. Depth 4. Proposed and pending mining legislation
C. Geography 5. Legal issues: employment laws, licenses and permits, cur-
1. Location: proximity to population centers, supply depots, rency exchange, expatriation of profits, agreements
services among partners, type of operating entity for tax and other
2. Topography purposes.
3. Access H. Financing
4. Climatic conditions 1. Alternatives: sources, magnitudes, issues of ownership
5. Surface conditions: vegetation, stream diversion 2. Obligations: repayment of debt, interest
6. Political boundaries 3. Type of operating entity: organizational structure
D. Exploration 4. Division of profits: legal considerations
1. Historical: district, property Ill. Mining Method Selection
2. Current program A. Physical Controls
3. Reserves 1. Strength: ore, waste, relative
a. Tonnage-grade curve for deposit, distribution classifi- 2. Uniformity: mineralization, blending requirements
cation; computation of complete mineral inventory 3. Continuity: mineralization
(geological and mining reserves) segregated by ore 4. Geology: structure
body, ore type, elevation and grade categories 5. Surface disturbance: subsidence
b. Derivation of dilution and mining recovery estimates for 6. Geometry
mining reserves. B. Selectivity
4. Sampling: types, procedures, spacing 1. Dilution, ore recovery estimates
5. Assaying: procedures, check assaying 2. Waste mining and disposal
6. Proposed program C. Preproduction Requirements
II. Information on General Project Economics 1. Preproduction development or mining requirements:
A. Markets quantity, methods, time
1. Marketable form of product: concentrates, direct shipping 2. Layout and plans: schedule
ore, specifications, regulations, restrictions 3. Capital requirements
2. Market location and alternatives: likely purchasers, direct D. Production Requirements
purchase vs. toll treatment 1. Relative production
3. Expected price levels and trends: supply-demand, com- 2. Continuing development: methods, quantity, time require-
petitive cost levels, new source of product substitutions, ments
tariffs 3. Labor and equipment requirements
4. Sales characteristics: further treatment, sales terms, let- 4. Capital requirements vs. availability
ters of intent, contract duration, provisions for amend- IV. Processing Methods
ments and cost escalations, procedures/requirements for A. Mineralogy
sampling, assaying, and umpiring. 1. Properties of ore: metallurgical, chemical, physical
B. Transportation 2. Ore hardness
1. Property access B. Alternative Processes
2. Product transportation: methods, distance, costs 1. Type and stages of extraction process
C. Utilities 2. Degree of processing: nature and quality of products
1. Electric power: availability, location, ownership right-of- 3. Establish flowsheet: calculation of quantities flowing,
way, costs specification of recovery and product grade
2. Natural gas: availability, location, costs 4. Production schedule
3. Alternatives: on-site generation C. Production Quality vs. Specifications
D. Land, Water, and Mineral Rights D. Recoveries and Product Quality
1. Ownership: surface, mineral, water, acquisition or secure- 1. Estimate effects of variations in ore type or head grade
ment by option or otherwise, costs E. Plant Layout
2. Acreage requirements: concentrator site, waste dump lo- 1. Capital requirements
cation, tailings pond location, shops, offices, change- 2. Space requirements
houses, laboratories, sundry buildings, etc. 3. Proximity to deposit
E. Water V. Capital and Operating Cost Estimates
1. Potable and process: sources, quantity, quality, availabil- A. Capital Costs
ity, costs 1. Exploration
2. Mine water: quantity, quality, depth and service, drainage 2. Preproduction development (may also be considered op-
method, treatment erating costs)
F. Labor a. Site preparation
1. Availability and type: skilled/unskilled in mining b. Development of deposit for extraction
2. Rates and trends 3. Working capital
3. Degree of organization: structure and strength a. Spares and supplies (inventory)
4. Local/district labor history b. Initial operations
5. Housing and transport of employees c. Financing costs (when appropriate)
MINING ENGINEERING HANDBOOK
4. Mining e. Engineering and contingency fees
a. Site preparation B. Operating Costs
b. Mine buildings 1. Mining
c. Mine equipment: freight, taxes and erection costs, re- a. Labor: pay rates plus fringes
placement schedule b. Maintenance and supplies: quantities, unit
d. Engineering and contingency fees c. Development
5. Mill 2. Milling
a. Site preparation a. Labor: pay rates plus fringes
b. Mill buildings b. Maintenance and supplies: quantities, unit costs
c. Mill equipment: freight, taxes and erection costs, re- 3. Administrative and supervisory
placement schedules a. Overhead charges
d. Tailings pond b. Irrecoverable social costs
Source: Gentry and Hrebar, 1978; Taylor, 1977.
commodities—such as most metals traded on exchanges—suffer must contain operating and capital cost estimates based on actual
from the greatest future price uncertainty. Most metal markets design and layout drawings, manning tables, flow charts, and
are notoriously cyclical, and the amplitude and the period of the equipment lists, specifications, and manufacturer quotations.
cycles defy accurate prediction. The recommended approach to These estimates should be predicated on data relative to unit
mineral price forecasting is not limited to the application of any operations, job functions, job requirements, timetables, and so
one or two specific analytical techniques, and it definitely is on. This requires considerable time and effort; there are few, if
not a mechanical process. Rather, it is a painstaking blend of any, acceptable shortcuts.
economic theory, industry analysis, market analysis, and com-
petitor analysis combined with sound, experienced judgment.
Cost Estimation: The economic evaluation portion of a feasi- 6.2.2 CASH FLOW ANALYSIS
bility study ultimately must be based on information that pro-
vides an answer to the question, “what is it going to cost?” The importance of the pro forma income statement in estab-
lishing the value of a mining project via the income (earnings)
Unfortunately, the answer to this question is not simple, primar-
approach was alluded to in Chapter 6.1. Inasmuch as there
ily because of the significant misunderstandings associated with
are generally major differences between accounting profits and
cost data. Therefore, the components of so-called “total produc-
actual net cash benefits derived from an investment, investors
tion cost” or “total operating cost,” for example, must be care-
are using almost exclusively the concept of project cash flows as
fully identified and defined.
the primary measure of real benefits produced by a capital proj-
When preparing a mine feasibility study, it is essential also
ect. This is predicated on the knowledge that cash flow analyses
to distinguish between operating costs, expenses, and capital
and accounting concepts depict investments differently, as a re-
costs. Operating costs are considered to be all expenses incurred
sult of the timing of costs, and on the belief that the proper
at the plant site, whereas general expenses are off-site manage-
method for evaluating a capital investment is to compare the
ment or corporate-level expenditures. This latter classification
present investment outlay with the expected positive net cash
of expenses may be directly related to mine or plant size, or it flows that will accrue from the project in the future. In making
may contain indirect items incurred by headquarters and allo- this comparison, it is essential that the timing of the various
cated across all production divisions in accordance with some cash flows be recognized by the use of an appropriate interest
corporate allocation scenario. (discount) rate. This aspect of cash flow analysis is discussed
Direct costs, or variable costs, relate to items such as labor, briefly in the following portion of this chapter.
materials, energy, and supplies that are consumed directly in the As indicated, cash flow analyses relate the expenditures asso-
production process and are used roughly in direct proportion to ciated with investment to the subsequent revenues or benefits
the level of production. On the other hand, indirect costs, or generated from such investment. Cash flows are routinely calcu-
fixed costs, are expenditures that are independent of the level of lated on an annual basis for evaluation purposes and are deter-
production— at least over certain ranges. It is obvious that, in mined by subtracting the annual cash outflows from the annual
the limit, few costs are absolutely fixed. cash inflows that result from the investment. Consequently, a
Capital costs (or first cost, or capital investment) are those cash flow analysis may be performed for any investment with
expenditures made to acquire or develop capital assets, the bene- which income and expenditure are associated. Also the annual
fits of which will be derived over several years. The largest cash flows resulting from an investment may be either positive
portion of capital costs is incurred in the initial stages of project or negative. Typically, the net annual cash flows for a new mining
start-up, but some capital expenditures are incurred annually property will be negative during the preproduction years due to
throughout the life of the mine. large capital expenditures. After production commences, the
In general, capital costs fall into one of three classes, de- cash flows will usually be positive, and an inflow of cash results
pending on the treatment of the cost for tax purposes. These are from investment in the project.
depreciable investment, expensed or amortizable investment, and In the US income tax law, net annual cash flow is treated
nondeductible investment. Because of differing tax treatments, basically as a combination of two components: the return on the
the type of capital expenditure involved can be a very important investment and the recoupment of the investment. In the miner-
factor in the evaluation of a new project, in addition to its mag- als industry, net cash flow is generally defined as net profit after
nitude. taxes plus depreciation and depletion minus capital expenditures
The estimation of operating and capital costs for mining and working capital. Within this definition, net profit after taxes
projects is extremely difficult and must be performed with great represents the return on the investment, whereas depreciation
care. Chapter 6.3 illustrates procedures for estimating initial and depletion represent the recoupment of the investment.
capital and operating costs for mining projects being analyzed In a cash flow analysis, each investment receives credit for
via intermediate economic studies. However, the final feasibility income taxes saved. Since the accounting allowances for depreci-
MINE FEASIBILITY STUDIES 397
Table 6.2.2. Components and Basic Calculation ing activities that require consideration in the preparation of
Procedure for Developing Cash Flows cash flow analyses. The appropriate use and manipulation of
these input variables are an extremely important facet of the
cash flow analysis. The concept of a cash flow analysis is a
Calculation Component
particularly useful technique for the evaluation of mineral-
Revenue related projects because of the important impact of the depletion
Less Royalties allowance in the United States.
Equal Gross income from mining In view of the foregoing, it is worthwhile to reiterate the fact
Less Operating costs that in a cash flow analysis, each investment receives credit for
Equal Net operating income
Depreciation and amortization allowance
income taxes saved. Therefore, for profitable organizations, it is
Less
Equal Net income after depreciation and amortization advantageous to maximize pretax deductions and thereby reduce
Less Depletion allowance the amount of taxable income and, consequently, income taxes
Equal Net taxable income paid. In order to take advantage of these tax savings as soon as
Less State income tax possible, the firm would opt to expense all possible expenditures
Equal Net federal taxable income in the year incurred as opposed to capitalizing them followed by
Less Federal income tax subsequent write-offs over the amortization period. Although
Equal Net profit after taxes the total amount of the pretax deduction would be the same in
Add Depreciation and amortization allowances either case, by expensing as soon as possible, the firm realizes an
Add Depletion allowance
Operating cash flow
earlier return of the resulting tax savings. This early return of
Equal
Less Working capital tax savings enables the firm to utilize these dollars sooner than
Equal Net annual cash flow would otherwise be possible.
(6.2.5)
Example 6.2.1. Find the amount that will accrue at the end
of 7 years if $1250 is invested now at 8%, compounded annually.
Given: P = $1250, n = 7 years, i = 8%.
Solution.
Example 6.2.3. If payments of $725 are made at the end of
F = P(1 + i) = $1250 (1 + 0.08)7 = $2142.28 each year for 12 years to an account which pays interest at the
rate of 9% per year, what will be the terminal amount?
The quantity (1 + i)n = (F/P,i,n) has, like other interest Solution .
factors, been tabulated for various values of i and n in so-called
interest tables. Such tables are provided in the appendix of this
volume for select interest rates and discrete compounding.
However, many hand-held calculators can now solve such
problems directly so that interest tables are becoming less nec-
essary.
2. Single payment, present worth (P/F,i,n).
This is Eq. 6.2.1 solved for P.
It obviously makes a considerable difference if the annual
payments are made at the beginning of the year (an annuity
due) rather than at the end of the year (an immediate annuity).
However, the end-of-year convention is more common, and
Example 6.2.2. If $6500 will be needed in 5 years, how much
nearly all interest tables and computer programs are constructed
should be invested now at an interest rate of 7.5%, compounded
on this basis. To verify easily that any particular table or com-
annually?
puter program adheres to this convention, note that for n = 1,
Solution. Given: F = $6500, n = 5 years, i = 7.5%
F = A regardless of the interest rate.
4. Uniform series, sinking fund, (A/F,i,n).
Solving Eq. 6.2.5 for A will enable the analyst to determine
what annual payments must be made to accumulate a specified
amount by some future date at an interest rate i:
Using interest tables to solve this problem becomes some-
what more difficult because one must interpolate between 7
and 8%. For most interest problems, a linear interpolation is
satisfactory. The widespread use of programmed calculators and Example 6.2.4. With interest at 6%, how much must be
computers for solving interest problems facilitates exact solu- deposited at the end of each year to yield a final amount of $2825
tions so that interpolation is often unnecessary. However, the in 7 years?
intellectual problem of calculating exact solutions from highly Solution .
inexact data is of major concern in all investment studies.
3. Uniform series, compound amount (F/A,i,n).
Here the concern is to determine the terminal amount when
equal annual payments are made to an interest-bearing account
for a specified number of years. It is important at this point to
recall that A is defined as occurring at the end of the interest
period. Therefore, for
The concept of a sinking fund is well known, so that the A/
n =1 , F = A F interest factor is often called the sinking fund factor.
5. Uniform series, present worth (P/A,i,n).
n = 2 , F = A(1 + i) + A (6.2.3) This type of problem arises when the current value of a
2
future series of cash flows is desired. This is often the case with
n = 3 ,F = A (1 + i) + A (1 + i) + A investments in securities where an expenditure now will provide
equal interest or dividend payments for several future periods.
or in general, For Eq. 6.2.5,
MINE FEASIBILITY STUDIES 399
be—particularly when values are extracted from interest tables.
Following are some relationships based on given values of i and
n.
Substitute Eq. 6.2.1, 1. The single payment compound amount factor (F/P,i,n)
and the single payment present value factor (P/F,i,n) are recip-
rocals:
(6.2.7)