The Steenkampskraal monazite mine (SMM) has officially broken ground on its new processing plant in the Western Cape.
This milestone advances the mine’s phased development plan and positions South Africa to become a producer of high-grade monazite concentrate, serving as critical feedstock for rare earth elements essential to renewable energy, electronics, medical and defence technologies among many others.
The announcement builds on recent operational achievements at the site.
Notably, SMM has successfully commissioned its on-site laboratory and, for the first time in more than 60 years, produced monazite concentrate from its metallurgical circuit.
“The initial product has demonstrated about 50% total rare earth oxide (TREO) content, confirming the high-grade nature of the deposit. In parallel, the mine’s hydrometallurgical laboratory circuit is currently undergoing optimisation.
“Early results have been encouraging, with production of mixed rare earth carbonate (MREC) and cracked thorium anticipated in the near term,” says SMM CEO Graham Soden.
The monazite processing plant facility, located close to the existing underground decline shaft exit, will receive monazite-rich ore directly through a purpose-built conveyor belt system. Ore will then be transported from underground workings to the surface plant for initial concentration using a proven gravity separation and flotation technology.
Further, the monazite processing plant has been designed to achieve steady-state output of about 13 400 t/y of monazite concentrate containing more than 50% TREO. During the initial ramp-up period, production will start at about 6 600 t/y, increasing to full capacity toward the end of the first year, Soden says.
“This phase will use proven gravity separation and flotation technology, optimised through modern refinements and pilot testing by research organisations the Saskatchewan Research Council and Mintek.
“The process flow draws on the successful methods used during diversified miner Anglo American’s historic operations at Steenkampskraal between 1952 and 1963. It has been adapted for modern environmental standards and incorporates a multi-gravity separation circuit, currently under evaluation for enhanced recovery efficiency,” Soden adds.
The processing plant will be supplied with material from existing stockpiles and underground ore, thereby reducing upfront capital requirements and lowering operational risk.
Importantly, Soden says this strategy enables early revenue generation while work to refurbish underground infrastructure proceeds at the same time. The plant design incorporates a front-end comminution and milling circuit to deliver consistent feed to the concentrator and support effective grade control.
Soden adds that Phase 1 creates the basis for later processing stages, including hydrometallurgical treatment, oxide separation and downstream product manufacturing, all of which are planned to take place within South Africa to enhance local beneficiation and retain great value domestically.
“This phase represents the practical realisation of our strategy to re-establish Steenkampskraal as a globally significant source of rare earth materials.
“We are leveraging proven metallurgical processes, supported by modern technology and strong compliance standards, to ensure a sustainable and efficient operation that benefits both the national economy and local communities,” SMM executive chairperson Professor Enock Mathebula adds.
Through the development of dedicated ore transport and processing infrastructure, this project, Mathebula adds, will establish South Africa’s first purpose-built monazite concentration facility, and the resulting concentrate will be the operation’s first revenue-generating product and will supply downstream value-adding processes, including the production of MREC and thorium.
With funding secured and construction now underway, the company is on schedule to establish a revenue-generating process before the end of this year, generating early revenue, creating jobs, supporting local communities and contributing to South Africa’s critical minerals strategy.
Offtake discussions for the concentrate are already well advanced with international partners.
Moreover, Mathebula says the Steenkampskraal deposit is widely regarded as one of the highest-grade rare earth and thorium resources globally, with a current National Instrument 43-101-compliant resource of 665 000 t grading at 14.5% TREO, alongside valuable co-products such as thorium at 2.14%.
He adds that the shovel-ready project is supported by established underground and surface infrastructure, full regulatory approvals and an experienced mining partner in mining services company Bora Mining Investments.
Mathebula concludes that SMM remains focused on responsible development, including environmental rehabilitation, community skills development and strict adherence to all nuclear and environmental regulations.
Lumkile Nkomfe
www.miningweekly.com