Sovereign Services has announced the long-awaited Definitive Feasibility Study (DFS) results for the world-class Kasiya Rutile-Graphite Project, which has unveiled plenty of benefits for Malawi from the planned rutile-graphite mine.
Kasiya, located in central Malawi, hosts the world’s largest natural rutile deposit and the second largest flake graphite deposit. Both titanium and graphite are officially classified as Critical Minerals by the United States and the European Union.
If market conditions prevail, the mine has the potential to generate revenues of approximately US$700 million per year during its initial life of 25 years with the Malawi Government expected to gain from corporate tax, royalties, payroll taxes and a shareholding arrangement with Sovereign Services in accordance with the country’s laws and the Mining Development Agreement (MDA) that it expects to sign with the company before the onset of mining operations.
The study indicates that the local community will also enormously benefit from the mine through job opportunities, corporate social responsibility projects and a community development agreement that Sovereign Services is expected to sign with the Kasiya Community, allocating a fraction of earnings from the mine to the local community in accordance with the Mines and Minerals Act.
The Study results indicate that at steady-state, Kasiya is forecast to deliver approximately 222 kt of rutile and 275 kt of graphite annually – positioning Sovereign as potentially the world’s largest producer of both natural rutile and natural flake graphite.
The study further confirms the capital investments required for rail, roads, power and water infrastructure which will bring positive economic development to the district and export route to the port of Nacala, with substantial secondary economic opportunities.
Managing Director and CEO Frank Eagar commented: “The completion of this DFS marks a defining milestone for Kasiya and for the global titanium and graphite supply chains. To deliver a DFS of this quality, depth and confidence, rarely achieved by a pre-production company, reflects the calibre of partnerships that Sovereign has assembled around this project: Rio Tinto's technical expertise, alignment with International Finance Corporation (IFC) Performance Standards under our Collaboration Agreement, and offtake interest driven by U.S. and Japanese supply chain security priorities.”
“The successful completion of large-scale field trials, combined with the expertise of our experienced owner’s team and the technical support provided by Rio Tinto, reinforces Kasiya’s potential to be a long-life, low-cost, and reliable source of two critical and globally strategic minerals. Kasiya is not simply a mining project – it is a globally strategic asset.”
The DFS outlines a large-scale, long-life operation that delivers substantial volumes of premium quality natural rutile and graphite while generating significant returns across a range of price scenarios.
Eagar explains that while global primary rutile supply is in structural decline, Kasiya’s natural rutile has demonstrated premium chemical characteristics and suitability across all major end-use applications, with high TiO₂ content, low impurity levels, and favourable particle size distribution – positioning it as a preferred high-purity feedstock within a structurally undersupplied market.
Kasiya’s 222ktpa of natural rutile would represent a significant addition to Western-accessible non pigment rutile supply, directly addressing the structural feedstock deficit facing the US, Japanese and European titanium industries.
Graphite is essential to lithium-ion battery anodes, refractories and a range of advanced industrial applications. China currently dominates global natural graphite production and processing, accounting for approximately 77% of worldwide output and an even larger share of battery-grade anode material. The US has designated graphite as a critical mineral and is actively seeking to diversify supply away from Chinese-controlled sources, including through the US$12 billion Project Vault strategic reserve initiative.
Kasiya’s incremental cost of graphite production is estimated at US$216/t. Eagar explains that based on public disclosures by listed graphite developers with studies at or beyond the pre-feasibility stage, this positions Sovereign as the lowest-cost graphite producer globally, including China.
Compared with single-commodity hard-rock graphite operations, Kasiya benefits from a soft, free dig orebody and a simple processing flowsheet. The majority of operating costs are allocated to the primary rutile stream, enabling the production of high-purity, coarse-flake graphite at materially lower costs.
“Independent testing has confirmed that Kasiya graphite performs exceptionally well as an anode material for lithium-ion batteries, while also meeting specifications for traditional industrial markets such as refractories.”
Dry Mining Method Confirmed
Using real-world data collected from the Pilot Mining, the DFS confirms a dry mechanical mining method using draglines and 100t rigid dump trucks. The soft, free-dig saprolite orebody requires no drilling, blasting, crushing or milling. A two-bench approach (5m top cut, up to 15m bottom cut) keeps the draglines above the water table, eliminating the need for production equipment below groundwater level. This represents a significant de-risking step from the hydro-mining method originally considered in the original Pre-feasibility Study (PFS).
No Conventional Tailings Storage Facility
A major advancement in the DFS is the elimination of the conventional Tailings Storage Facility (TSF) leading to a significant reduction in the mining footprint and providing a flexible, lower-risk tailings management solution. All tailings will be stored via hydraulic co-disposal backfilling of mined-out pits, designed in compliance with the Global Industry Standard on Tailings Management (GISTM), aiming for zero harm to people and the environment. The 50:50 fines-to-sand backfill ratio closely matches the existing soil profile, supporting progressive rehabilitation. This has also reduced the raw water dam wall height from 23m to 20.7m and storage capacity from 16.4 to 11Mm³.
Hydropower-Sourced Grid Electricity
The DFS is based on connection to Malawi’s national hydropower grid via a 132kV overhead line to the Nkhoma substation. Electricity Supply Corporation of Malawi (ESCOM) has confirmed significant grid expansion is underway, including a 400kV Mozambique interconnector (2025) and the 375MW IFC/World Bank-funded Mpatamanga hydropower station (2030). Grid connection delivers substantially lower power costs and a favourable emissions profile.
Processing Flowsheet
Ore will be trucked to the processing plant for scrubbing and screening before entering the Wet Concentration Plant (WCP). The WCP employs a low-energy gravity separation process to produce a Heavy Mineral Concentrate (HMC). The HMC is then fed to the Mineral Separation Plant (MSP), where electrostatic and magnetic separation yield premium-quality rutile (+95% TiO₂), suitable as a direct feedstock for titanium sponge production or use in high-end titanium alloy applications, including aerospace and defence. Graphite-rich concentrate recovered from the spirals is processed in a dedicated flotation plant, producing a high-purity, high-crystallinity, coarse-flake graphite product. Independent testing has confirmed that Kasiya graphite performs exceptionally well as an anode material for lithium-ion batteries and meets specifications for traditional industrial markets such as refractories.
Dual Plant Configuration
The DFS confirms a staged development with two 12Mtpa processing plants – South Plant from Year 1 and North Plant from Year 5 – positioned at the respective resource centres of gravity to minimise haulage distances and costs. The configuration provides operational flexibility and a phased capital profile.
Logistics and Export Infrastructure
Kasiya’s products will be railed directly from a purpose-built dry port at the mine site eastward along the Nacala Logistics Corridor (NLC) to the container terminal at the Port of Nacala on the Indian Ocean. The existing heavy-haul rail line and deep-water port provide a proven, operational export route – a significant infrastructure advantage over comparable undeveloped projects. Product transport cost is estimated at US$117/t product (FOB Nacala).
Kasiya is positioned with access to two rail corridors for the transport of rutile and graphite products to export ports – the NLC and the Sena Rail Line leading to the Port of Beira (the Beira Corridor). The NLC provides the preferred logistics route, offering a direct connection to the deep-water Port of Nacala on the Indian Ocean for exports to global markets. This well-established, operational corridor delivers substantial capital and operating cost advantages for the Project. To access the NLC, Sovereign plans to construct a 6 km rail spur linking the mine site and processing plant directly to the main line, significantly improving the efficiency of both inbound and outbound freight movements relative to road transport alternatives.
Rutile and Graphite Pricing
The DFS adopts a life-of-mine weighted-average realised rutile price of US$1,670/t (real, FOB Nacala), based on an independent TZMI market study. Japanese titanium metal producers OSAKA Titanium Technologies Co., Ltd. (Osaka Titanium) and Toho Titanium Co., Ltd. (Toho Titanium) are expected to drive the growth in rutile demand for titanium manufacturing over the next 10 years. Graphite pricing is based on an independent Benchmark Minerals Intelligence (BMI) price forecast, resulting in a life-of-mine average price of approximately US$1,288/t (FOB Nacala) – effectively in line with the OPFS assumption of US$1,290/t. The graphite basket price is derived from FOB China benchmarks, adjusted for an East Africa premium and weighted by Kasiya’s concentrate flake size distribution.
IFC Performance Standards Integrated into Design
The DFS has been prepared in alignment with IFC Performance Standards, with a comprehensive Environmental and Social Impact Assessment (ESIA) nearing completion and the full suite of environmental and social specialist studies completed. Sovereign’s established on-the-ground social team of 22 core staff and 90-member Community Liaison Team represent a level of social preparedness rarely achieved at DFS stage.
Mining and Rehabilitation Trials – Proven in Practice
Large-scale mining and rehabilitation trials were completed during the DFS period, covering excavation, backfilling, soil remediation and crop establishment. During Pilot Mining, the Company successfully completed dry and hydraulic mining trials, excavating a test pit at Kasiya. The test pit covered the planned area of 120 metres by 110 metres and was excavated to a depth of 20 metres through the weathered ore at Kasiya. Post mining, the rehabilitated pit has achieved maize yields of 5.2 tonnes per hectare within six months of backfilling – over five times the local community average of approximately 1 tonne per hectare. The Pilot Mining validated the progressive rehabilitation approach and confirmed that mined land can be returned to productive agricultural use within one to two years.
Kasiya has been designed to minimise social and environmental impact. The operation will systematically extract and process ore, then progressively backfill and rehabilitate the open pits. The objective of the Project is to minimise disturbance to land resources, while keeping the active mining footprint as small as practically possible.
Human Resources
The project's proximity to Lilongwe offers several benefits, including access to a large pool of professionals and skilled tradespeople. Malawian national employees will be employed predominantly from the Kasiya area and the capital city of Lilongwe.
During construction, Kasiya will employ a total of 2,000 workers, the majority of whom will be employed in the construction of plant and infrastructure. During steady-state operations, Kasiya will employ nearly 1,100 people, the majority of whom will be employed in plant operations. Expatriates make up approximately 9% of the planned workforce. Similar projects in Africa typically witness a flow-on effect for employment in local communities. For every person employed directly in the project, a significant multiplier of people will be employed in indirect jobs supporting the project.
Sovereign has structured training and skills transfer programs covering on-the-job training for full time employees, as well as programs for local graduates and interns. The programs will focus on building skills capacity in the surrounding community. The Company currently has 80 full-time employees and is an equal opportunity employer with a gender diverse workforce. Currently, 30% of Sovereign’s professional Malawian staff and at least 50% of our regular interns are female.
Soils and Rehabilitation Stewardship
Sovereign is committed to ensuring that all mined-out land is appropriately rehabilitated to support sustainable farming practices after closure. The Company has adopted agronomist principles and practices to revitalise local soils. Sovereign will return a good mix of soils as part of the backfilling and introduce carbon and soil nutrients through organic and inorganic inputs.
Local communities will expect that any mined land be restored post mining, such that it is available for agricultural use. This is a foundational commitment made by Sovereign, and all proposed soil remediation and rehabilitation work has been planned to restore the land so that it yields improved agricultural outcomes.
To meet this commitment, the proposed soil remediation and rehabilitation approach is based on sound, tested farming and soil husbandry methods commonly adopted in both small-scale and commercial farming in Malawi. Through Sovereign’s on-site rehabilitation trials, the Company has tested a range of remediation and rehabilitation options over two farming years.
Heavy rare earth minerals potential not included in DFS
Sovereign recovered monazite concentrates from rutile processing circuit with exceptionally elevated levels of heavy rare earths during the study with Dysprosium, Terbium and Yttrium now a potential third revenue stream at minimal incremental cost — all three elements subject to Chinese export restrictions.
A dedicated monazite evaluation program is now underway to assess scale, recovery and economic potential.