26 September 2024

Ferro-Alloy Resources Limited

("Ferro-Alloy" or "the Company" or "the Group")

Interim Results for the six months ended 30 June 2024

and

Carbon concentrate and feasibility study update

Ferro-Alloy Resources Limited (LSE:FAR), the vanadium producer and developer of the large Balasausqandiq vanadium deposit in Southern Kazakhstan, announces its unaudited interim results for the six months ended 30 June 2024 and provides an update on the results from the testing completed on its carbon concentrate and the Balasausqandiq feasibility study.

Overview

Carbon Concentrate

·    Results from the testing of the Company's carbon concentrate to be produced from the tailings of the Balasausqandiq ore have confirmed the suitability of the concentrate for use in tyre rubber manufacture and other carbon black based rubber applications.

·    The testing has shown that the carbon concentrate can be successfully used as a partial substitute for conventional carbon black filler in a passenger car tyre sidewall compound formulation.

·    A marketing report quantifying the value proposition of the concentrate is being finalised.

Feasibility Study

·    Feasibility study for Phase 1 is ongoing:

o  Current focus of the study is on the optimisation of the planned tailings storage facility. Site selection is in progress and preliminary capital estimates have been completed on a staged construction basis to refine initial capital spend.

o  Design capacity of the of the Phase 1 process plant has been increased to 1.65m tonnes throughput per year and the comminution circuit design work has been completed.

o  Reagent optimisation programme commenced to quantify improvements to the project's expected operational expenditure.

o  In order to accommodate the increased design capacity of the Phase 1 process plant and the reagent optimisation programme, the Company now expects the feasibility study to be published during Q2 2025.  

Operations

·    The Plant operated well during the period. Production in H1 2024 was slightly lower than H1 2023 due to lower overall grades of vanadium and molybdenum contained within the catalysts processed.

·    Commissioned two new drying ovens which allow the conversion of ammonium metavanadate by disassociation into vanadium pentoxide which commands better pricing. The Company is evaluating plans to acquire the equipment to produce vanadium pentoxide flake to access a larger market.

·    Test processing of the nickel-rich residues held at the plant site on a commercial scale did not sufficiently replicate the results achieved in the laboratory and consequently the plant will revert to processing bought-in catalysts during Q4 2024. This decision is partly driven by low metal prices. The Plant may resume treating the residues if metal product prices recover.

·    Research and development are ongoing to determine the suitability of the nickel-rich residues for the production of ferro-nickel.

Financial

·    Total revenues of US$2.1m for the period (H1 2023: US$3.3m) reflect the significant decrease in the price of vanadium pentoxide between the two reporting periods.

·    Overall loss for the period of US$3.99m (H1 2023: loss of US$1.53m).

·    Cash balance of US$2.5m at the period end and US$1.1m as at 20 September 2024.

Corporate

·    During the period, the Company listed and sold a third tranche of bonds with a nominal value of US$5m under the terms of the Kazakhstan Bond Programme on the AIX.

Nick Bridgen, CEO of Ferro-Alloy Resources said:

"The success of the carbon test work programme has confirmed the tremendous value of this product in the manufacture of tyres and in the rubber industry generally. This will be factored into the feasibility study which will also include the increased throughput and reagent optimisation programme.

The current vanadium price is exceptionally low, principally caused by the slow-down of construction in China. This is affecting current results, but the long-term forecasts continue to show a deficit of world production as vanadium redox flow batteries ramp up and China recovers. Historically, when a deficit arises, the price moves up strongly."

ENDS

For further information, visit www.ferro-alloy.com or contact:

About Ferro-Alloy Resources Limited:

The Company's operations are all located at the Balasausqandiq deposit in Kyzylordinskoye Oblast in the South of Kazakhstan. Currently the Company has two main business activities:

a) the high grade Balasausqandiq vanadium project (the "Project"); and

b) an existing vanadium concentrate processing operation (the "Existing Operation")    

Balasausqandiq is a very large deposit, with vanadium as the principal product together with several by-products. Owing to the nature of the ore, the capital and operating costs of development are very much lower than for other vanadium projects.    

The most recent mineral resource estimate for ore-body one (of seven) provided an Indicated Mineral Resource of 32.9 million tonnes at a mean grade of 0.62% V₂O₅ equating to 203,364 contained tonnes of vanadium pentoxide ("V₂O₅"). In the system of reserve estimation used in Kazakhstan the reserves are estimated to be over 70m tonnes in ore-bodies 1 to 5 but this does not include the full depth of ore-bodies 2 to 5 or the remaining ore-bodies which remain substantially unexplored.  

The Project will be developed in two phases, Phase 1 and Phase 2, with Phase 1 treating 1.65m tonnes per year.

There is an existing concentrate processing operation at the site of the Balasausqandiq deposit. The production facilities were originally created from a 15,000 tonnes per year pilot plant which was then expanded and adapted to recover vanadium, molybdenum and nickel from purchased concentrates. 

The existing operation is located on the same site and uses some of the same infrastructure as the Project, but is a separate operation which will continue in parallel with the development and operation of the Project.

Interim Management Report

The Company is engaged primarily in carrying out a feasibility study into the giant Balasausqandiq vanadium project which is now entering the final stages.

Concurrently, the Company continues to operate a small-scale process plant to produce vanadium, molybdenum and nickel from purchased concentrates.

Balasausqandiq feasibility study

Carbon black substitute concentrate

The Company's specialist rubber consultants in the UK have completed testing on the carbon black substitute concentrate and the results have confirmed the suitability of the concentrate for use in tyre rubber manufacture and other carbon black based rubber applications.

The testing undertaken has shown that the carbon concentrate to be produced by the Company from the Balasausqandiq ore tailings can be successfully used as a partial substitute for conventional carbon black filler in a passenger car tyre sidewall compound formulation. The results show that with a substitution of up to 10% it was possible to produce compounds with similar physical properties to that made with a control formulation using 100% N660 carbon black, the most commonly used grade of carbon black for tyre sidewalls. Tyres made with this blended material would, therefore, be expected to deliver similar performance. 

Whilst the data did show that the carbon concentrate, when substituted at levels greater than 10%, produced slightly less of a reinforcing effect in the rubber compound than conventional carbon black, some potential advantages in physical properties were identified which could lead to improvements in tyre rolling resistance and sidewall damage resistance.

Specialist marketing consultants are finalising their report which will advise on marketing and the appropriate pricing of the Company's material.

Processing

The feasibility study has progressed with a primary focus on the optimisation of the tailings storage facility by SRK Consulting (Kazakhstan) Limited. Site selection has continued and a final geophysical survey is underway. Preliminary capital estimates have been completed with a focus on staging the construction of the facility to optimise the initial capital spend.

As soon as the final carbon concentrate and vanadium market reports have been received, SRK will commence the mine planning study.

As communicated last year, the 2023 ore reserve that was estimated for Ore-Body 1 of the Balasausqandiq deposit was 35.4% larger than previously estimated, which lead to a review of the appropriate size of the Phase 1 development plan. The Company has now applied to the Ministry of Industry and Construction of the Republic of Kazakhstan for an amendment to the Company's Subsoil Use Agreement which will have the effect of increasing the annual tonnage to be mined during the life of Phase 1 of the project to 1.65 million tonnes per year (including mining dilution) and to defer certain amounts to be mined prior to and during commissioning. Ongoing discussions with a Working Committee of the Ministry have required re-submission of certain documents relating to environmental provisions, future site restoration plans and industrial safety, prior to approval.

In anticipation of approval, the Company has increased the design capacity of Phase 1 of the process plant to 1.65 million tonnes throughput per year. The upgraded design is being progressed by Tetra Tech Limited and the comminution circuit aspects of the design have been completed.

Concurrently, the Company has engaged SGS Canada Inc to conduct a reagent optimisation programme to identify potential improvements to the metallurgical regimes identified in the previously completed metallurgical programme to take account of current reagent prices and delivery costs.

In addition to these items, the main components of the study currently underway include the ecological study, estimate of capital costs and financial evaluation.

In order to accommodate the increased design capacity of the Phase 1 process plant and the reagent optimisation programme, the Company now expects the feasibility study to be published during Q2 2025.  

Operations review

The existing operation

The Company's existing process plant operated well during the period. However, production was slightly lower than the same period in 2023 due to lower overall grades of vanadium and molybdenum contained within the concentrates processed. 

During the period, two new drying ovens were commissioned which allow the Company to convert a proportion of its production into vanadium pentoxide by disassociation of ammonium metavanadate ("AMV"). Currently, the vanadium pentoxide produced by the plant is in the form of powder but the Company plans to acquire equipment for the production of vanadium pentoxide flakes, opening up a larger and slightly higher priced market. The Company has also started to expand the wet-tailings pond to increase pond capacity by almost 50%, potentially allowing an increase in secondary vanadium and molybdenum production from the solutions held in the pond as well as improving product purity.

The Company has previously sold the residues from the treatment of catalysts as a low grade nickel concentrate but, owing to low nickel prices and high transport costs, the Company has chosen to stockpile this material while a process for its further treatment could be developed by the Company's technical department. This process has since been developed allowing a significant amount of the remaining vanadium and molybdenum to be extracted from the residues, raising the overall extraction of these metals from catalysts to very high levels, as well as enriching the nickel content in the remaining residues so that they can be more cost-effectively transported and achieve a higher price. Following good laboratory test results, test processing at a commercial scale during Q3 2024 did not sufficiently replicate the results achieved in the laboratory and consequently the plant will revert to processing bought-in catalysts during Q4 2024. In the event that global metal prices recover to levels that would make the commercial processing of the nickel residues profitable the plant may resume treating the residues either instead of or concurrently with bought-in catalysts.

Research and development work by our technical department is ongoing to determine whether the Company can process the upgraded nickel concentrates to produce ferro-nickel.

Research and development

The Company is participating in three grant-funded research and development projects in Kazakhstan after competitively tendering projects for awards for the most promising opportunities for commercialisation of scientific and scientific-technical activities.

As previously announced, one project is aimed at producing and commercialising mixed vanadium oxides suitable for the production of electrolyte for vanadium redox flow batteries. This project is in conjunction with the Satbayev University in Almaty, Kazakhstan where the electrolytes are produced from Company oxides and tested in a vanadium redox flow battery, following which the agreed plan is for the commercial sale of three tonnes of mixed oxides. The Company plans to position itself to be able to continue supplying into this market on a fully commercial basis according to demand.

A second project is in association with the Kazakhstan National Engineering Academy to build a pilot-scale plant at the existing plant site, in advance of the construction of the mine, to produce a carbon concentrate direct from the Balasausqandiq ore, rather than from the tailings as noted above, and to develop commercial applications.

A third project is working with the Satbayev University on an improved analytical-chemical process in the treatment of ore.

The Company also cooperates with the Satbayev University to offer work experience to promising students, with opportunities for continuing work with the Company.  Not only does this enrich the student experience at the Satbayev University but it also gives the Company a pathway to finding high-quality recruits.

Production

During the period the plant processed 19.4% more tonnes of catalyst compared to the prior year. However, as noted above, the overall metal grades of the catalysts treated were less than those during 2023 resulting in 2% and 32% less vanadium and molybdenum production, respectively. The plant produced 11.7 tonnes more nickel during the period in comparison to 2023, representing a 19.3% increase.  

* partly contained in AMV

** contained in ferro-molybdenum

*** contained in nickel concentrate

Outlook

Current vanadium prices, as detailed below, are exceptionally low and at a level where it is difficult to forecast overall Group profitability notwithstanding the successful operation of the current process plant and the developments that are being achieved in new processes and improved operations. Nevertheless, the plant is capable of generating a significant contribution to the Group's current overheads which would be incurred as it completes the feasibility study in any case. 

Recent monthly average prices of vanadium pentoxide have been in the bottom 4% of such monthly averages, adjusted for inflation, over the last 24 years. Vanadium prices have been impacted by the slow-down in Chinese construction and the sale of Russian product into China at discounted prices. These conditions are not expected to change in the short term but, in the longer term, they must do so to prevent large company closures and reductions in capacity. Significant tonnages are going to be required for planned large-scale vanadium redox flow batteries, most notably in China, and recently announced changes to Chinese re-bar standards will potentially also act to boost demand. Historically, the vanadium price has been volatile and shortages rapidly translate into rising prices, sometimes to extremely high levels.

Meanwhile, the process plant operations are now running smoothly, and the new equipment, products and increased pond and drying capacity will put the Company in a good position to capitalise on rising prices.

Corporate

During the period, the Company listed and sold a third tranche of bonds with a nominal value of US$5m under the terms of the Kazakhstan Bond Programme on the AIX.

Product prices in the period

Vanadium Pentoxide

At the start of 2024, the price of vanadium pentoxide was around US5.75/lb, after which the price fluctuated within a band of US$5.00/lb to US$6.00/lb for the entirety of the reporting period under consideration. As at 20 September 2024, the price of vanadium pentoxide was US$5.00/lb.

Ferro-Molybdenum

At the start of 2024, the price of ferro-molybdenum was around US$48/kg, after which it remained at a similar level until the end of April. From May onwards the price fluctuated within a band of US$51/kg to US$55/kg until the end of the reporting period. As at 20 September 2024, the price of ferro-molybdenum was US$50/kg.

Earnings and cash flow

The Group generated total revenues of US$2.1m for the period compared to US$3.3m for the first six months of 2023, representing a reduction in overall revenue of US$1.2m. The reduction in revenue reflects the significant decrease in the price of vanadium pentoxide between the two reporting periods (the average price of vanadium pentoxide during the first six months of 2023 was US$9.06/lb in comparison to US$5.58/lb in 2024). Additionally, the Group has undertaken a number of tolling contracts during the period instead of processing its own bought-in concentrates.

The cost of sales for the period under review was US$3.6m in line, given the volumes and nature of concentrates processed, with the first six months of 2023 (2023: US$3.6m).

Administrative expenses for the period were US$1.8m (2023: US$1.3m) representing an increase of US$0.5m mainly attributable to broker commission for the issue of the third tranche of bonds noted above and increased salary costs.

The Group made a loss before and after tax of US$3.99m (2023: loss of US$1.53m).

Net cash outflows used in operating activities were US$2.6m (2023: cash outflow of US$1.0m). Net cash used in investing activities during the period was US$1.1m (2023: cash outflow of US$2.3m). Net cash inflow from financing activities was US$4.5m (2023: cash outflow of US$1.1m) representing the proceeds received from the sale of the third tranche of bonds.

Balance sheet review

At the period end, non-current assets totalled US$14.1m (2023: US$11.9m) reflecting the continued capitalisation of expenses incurred by the Group on the development of the Balasausqandiq feasibility study (as an exploration and evaluation asset).

Current assets, excluding cash balances, totalled US$5.1m at the period end compared to US$5.0m for the prior period.

The Group held an aggregate cash balance of US$2.5m at the period end (2023: US$0.6m) and US$1.1m as at 20 September 2024. The board of directors is currently considering the options available to the Group to increase cash levels to ensure the completion of the feasibility study and the support of the ongoing processing operations. An option available to the board would be the issue and sale of a further trance of bonds under the Kazakhstan Bond Programme. 

The Group held non-current liabilities of US$12.4m at the period end (2023: US$ nil) representing the value of the Company's bonds sold since the inception of the Kazakhstan Bond Programme.

Current liabilities at the period end were US$3.9m (2023: US$3.0m) comprising of trade payables and accrued bond interest. 

Environmental, social and governance

Both the existing operation and the planned process plant for Balasausqandiq will have a strongly positive environmental impact. The vanadium from production will benefit energy storage in both vanadium redox flow batteries, the front-running technology for fixed ground long-term energy storage, but also potentially in certain technologies for mobile batteries used in electric vehicles.

The CO₂ emissions created by our production at Balasausqandiq are expected to be a fraction of most other producers which generally require concentration and high-temperature roasting to liberate the vanadium. The carbon concentrate which we plan to market as a replacement for carbon black is produced without burning hydrocarbons, as is the usual production process.

Description of principal risks, uncertainties and how they are managed

(a)   Current processing operations

Current processing operations make up a small part of the Company's expected future value but are intended to provide useful cash flows in the near term and allow the Group to gain valuable experience of the vanadium industry. The principal risks of this operation are the prices of its products (vanadium, molybdenum and nickel), availability of vanadium-bearing concentrates and the efficiency of recovery of products from those concentrates.

The Group is constantly reviewing the market opportunities for supplies of vanadium-bearing concentrates from reliable suppliers that can deliver concentrates on a timely basis in order to ensure that the Group does not incur production shortfalls leading to reduced revenues. The Group aims to extract all the useful components of the raw materials so that ultimately no residues remain on site and so that the maximum value is obtained from each tonne treated.  By these means, we aim to be one of the most efficient and lowest cost secondary vanadium treatment plants so that our competitive position reduces the danger of high prices for raw materials making the operation uneconomic.

(b)   Balasausqandiq project

The Balasausqandiq project will be a much larger contributor to the Company's value than the current processing operations and is primarily dependent on long-term vanadium prices.

The project is also dependent on raising finance to meet projected capital costs (see below) and the successful construction and commissioning of the project's proposed mine processing facilities. It is not unusual for new mining projects to experience unforeseen problems, incur unexpected costs and be exposed to delays during construction, commissioning, and initial production, all of which could have a material adverse effect on the Company's operations and financial position. The Company has taken steps to mitigate such potential adverse effects by engaging globally recognised engineers and consultants to assist with the development and design of the key elements of the project in addition to the Group's own highly qualified workforce.  

(c)    Geopolitical situation

The ongoing invasion of Ukraine by Russia is not directly impacting the Group's operations although current low vanadium pentoxide prices are, in part, likely being driven by Russian producers selling at significant discounts to China. The continued main risk of the conflict is to the Group's import and export transport routes, many of which involve transit through Russia. Whilst these are currently operating without issue, sanctions have been made against Russian and Belarusian vehicles transiting through Europe (but not against vehicles registered in other jurisdictions in the region such as Kazakhstan). There is a risk that further sanctions might prevent transit through Russia. The Company continues to review alternative transit routes for raw material imports and product exports through the West of Kazakhstan, either via the Caspian Sea or overland south of the Caspian Sea.  Routes to China are working normally.

With respect to the global sanctions imposed on certain Russian entities and individuals, the Group monitors the implications of those sanctions on the Group's trading activities on an ongoing basis.

(d)   Financing risk

The Balasausqandiq project will require substantial funds to be raised in debt and equity which will be dependent upon market conditions at the time and the successful completion of the Phase 1 feasibility study.

In March of 2021 the Company signed an investment agreement with Vision Blue Resources Limited ("Vision Blue"). Under the terms of this agreement and in addition to Vision Blue's participation in the 2022 equity fundraise, investments totalling US$14.3m have already been made and Vision Blue has the right to subscribe a further US$2.5m at the original deal price of 9 pence per share at any time up to two months after the announcement of the Phase 1 feasibility study. Vision Blue also has further options to subscribe up to US$30m at higher prices to partially finance the construction of the project.

The favourable financial and other characteristics of the project determined by studies so far completed give the Directors confidence that the outcome of the Phase 1 feasibility study will be successful. Initial discussions with potential providers of debt finance have been encouraging.

(e)   Climate change risk

The Group has not identified any particular climate change related scenarios that would likely have a significant impact on the Balasausqandiq project or the existing operation. The existing operation already functions in an environment that is subject to extreme weather conditions and is, therefore, considered to have a strong resilience to existing and future climate-related scenarios.

(f)    Risks associated with the developing nature of the Kazakh economy

According to the World Bank, Kazakhstan has transitioned from lower-middle-income to upper-middle-income status in less than two decades. Kazakhstan's regulatory environment has similarly developed and the Company believes that the period of rapid change and high risk is coming to an end.  Nevertheless, the economic and social regulatory environment continues to develop and there remain some areas where regulatory risk is greater than in developed economies.

(g)   Commodity price risk:

As already noted above, the success of the Company is dependent upon the long-term prices of the products to be produced by the planned mine processing facilities. As a result of there being no formally established trading markets for the Company's principal products from the project, there is a risk that price fluctuations and volatility for these products may have an adverse impact on the Company's future financial performance.

Directors' Responsibility Statement

We confirm that to the best of our knowledge:

a.    the condensed set of unaudited financial statements which have been prepared in accordance with IAS 34 'Interim Financial Reporting' give a true and fair view of the assets, liabilities, financial position and profit or loss of the Company and its undertakings included in the consolidation as a whole, as required by DTR 4.2.4R;

b.    the interim management report includes a fair review of the information required by DTR 4.2.7R; and

c.     the interim management report includes a fair review of the information required by DTR 4.2.8R.

This interim financial report for the six months ended 30 June 2024 has been approved by the Board and signed on its behalf by:

William Callewaert

Director

25 September 2024

Ferro-Alloy Resources Limited

Condensed unaudited Statement of Profit or Loss and Other Comprehensive Income
for the six months ended 30 June 2024

These condensed unaudited financial statements were approved by the directors on 25 September 2024 and signed by:

_____________________________ 

William Callewaert

Director