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Operations
Operations

Quebec - Casa Berardi Project

Outlook

Casa Berardi entered its sixth year of commercial operations in 2012, following the re-commencement of operations in November 2006.

2011 Gold Production
Record gold production from Aurizon's 100% owned Casa Berardi mine for the year ended December 31, 2011, totalled 163,845 ounces from the processing of 698,123 tonnes at an average grade of 8.0 grams of gold per tonne.  Recoveries for the year averaged 91.3%.  Actual gold production was in line with the Company's 2011 guidance of approximately 165,000 ounces and it is anticipated that total cash costs per ounce will be below the Company's guidance of US$535 per ounce for 2011.

Fourth Quarter 2011 Gold Production
Ore processed in the fourth quarter 2011 amounted to 170,283 tonnes at an average grade of 9.1 grams of gold per tonne.  Metallurgical recoveries of 92% resulted in gold production of 45,995 ounces in the quarter.

Forecast Gold Production for 2012
It is estimated that Casa Berardi will produce approximately 155,000 - 160,000 ounces of gold in 2012 at an average grade of 7.5 grams of gold per tonne.  Average daily ore throughput is estimated at 2,000 tonnes per day, similar to 2011.  Mine sequencing in 2012 will result in ore grades that are expected to be approximately 6% lower than those achieved in 2011.  Approximately 42% of production will come from Zone 113, 41% from the Lower Inter Zone, and the residual 17% from smaller zones and development material.

Assuming a Canadian/U.S. dollar exchange rate at parity, total cash costs per ounce for the year are anticipated to approximate US$600 per ounce in 2012.  Onsite mining, milling and administration costs are expected to average $134 per tonne, up approximately 12% from 2011 projected costs as a result of higher stope preparation costs and longer haulage distances.

As quarterly operating results are expected to fluctuate throughout the year, they will not necessarily be reflective of these full year averages.

Capital expenditures at Casa Berardi, funded from operating cash flow, are estimated to total $80 million in 2012, as a result of three major capital projects:  shaft sinking, construction of a paste backfill plant to maximize the extraction of high grade ore from Zone 113 and to allow greater mining flexibility, and continued replacement of mobile equipment.  These expenditures are comprised of the following:

 Capital expenditures

 2012 Budget
(in millions)

 Sustaining capital  

 $29.2

 Shaft deepening

 $16.7

 Property, plant & equipment

 $10.4

 Paste backfill plant

 $12.0

 Tailings pond

  $2.3

 Exploration

 $9.4

 Total

$80.0


Sustaining capital expenditures at Casa Berardi are budgeted to be $29.2 million and will include continued development of the lower portions of Zone 118 and 123.

In 2012, $16.7 million is budgeted for the deepening of the West Mine production shaft a further 285 metres to provide access to the lower portion of the 113, 118 and 123 Zones.  The shaft, currently at a depth of 795 metres, will be extended to approximately 1,080 metres below surface, which will provide access at the 1,010 metre level to develop a drift from the shaft to Zones 118 and 123.  The shaft deepening is expected to be completed near the end of 2012 and commissioned by the first quarter of 2013.

Mining equipment replacement and fleet expansion to support the expanded development activities is budgeted at $10.4 million.  A further $12.0 million will be invested in the construction of a paste backfill plant and $2.3 million will be invested on raising the tailings pond for future capacity.


Q3 2011 Q2 2011 Q1 2011 Q4 2010 Q3 2010
Operating results          
Tonnes milled

188,571

178,233

161,036

191,697 169,913
Grade - grams/tonne 7.95 8.00 6.85 6.86 6.15
Mill recoveries - % 92.2% 90.4% 90.2% 88.6% 89.1%
Gold production - ounces 44,457 41,418 31,976 37,496 29,905
Gold sold - ounces 40,257 39,900 34,306 34,808 30,755
Per ounce data - US$(4)          
Average realized gold price (i) $1,695 $1,521 $1,392 $1,376 $1,119
Total cash costs (ii) $497 $544 $621 $531 $604
Amortization (iii) 250 225 238 263 254
Total production costs (iv) $747 $769 $859 $794 $858

Table footnotes:
(i)     Realized gold prices net of realized derivative gains or losses divided by ounces sold.
(ii)     Operating costs net of by-product credits, divided by ounces sold, and divided by the average
         Bank of Canada Cad$/US$ rate.
(iii)    Depreciation and amortization charges.
(iv)    Total cash costs plus depreciation and amortization charges.

Casa Berardi Shaft Deepening

In the first quarter of 2011, a contract was awarded for the deepening of the West Mine production shaft from the 760 metre level down to the 1,080 metre level.  Deepening the shaft is a component of the overall strategy to have greater mining flexibility in the West Mine.

Shaft deepening commenced in the second quarter and to the end of the third quarter, ramp access from the 880 metre level has resulted in 104 metres of excavation by means of an Alimak raise up to the current shaft bottom, which will allow for accelerated shaft deepening.  In addition, 477 metres of horizontal development has been completed.  The shaft is expected to be completed towards the end of 2012 and will provide access to the lower portion of Zones 113, 118, and 123 once a drift at the 1,010 metre level is completed in 2013.  The estimated cost of the shaft deepening, drift access to Zones 118 and 123, and related infrastructure is approximately $33.5 million.  Expenditures during the third quarter totalled $2.8 million and year to date total $6.6 million.

Casa Berardi Exploration

In 2012, $9.4 million will be invested on exploration at Casa Berardi which will include approximately 88,000 metres of surface and underground diamond drilling.  Up to 3 surface and 5 - 7 underground drill rigs will be active during the course of 2012.  The Company expects to capitalize these costs as the primary objective of the drilling will be to improve the quality of the known reserves and resources as well as exploring for extensions of these structures.

Surface exploration will include testing of the following:

  • Eastern extension of the Principal zone
  • Northwest extension of the Lower Inter Zone in the West mine
  • Extension of Zone 123 at depth
  • Southern area of Zone 123 at depth
  • Potential of the sourthern area between the Principal and the East mine
  • Extension of Zone 160

Underground rigs will primarily focus on definition drilling of the Lower Inter, and Zone 109, 113, 118, and 123.  In addition, exploration drilling will be performed on the Principal, 118 and 140 Zones.

Operating Review for 2010

Casa Berardi performed in line with expectations in 2010 despite a revised mine plan resulting from challenging ground conditions in a localized area of Zone 113 and reduced availability of underground mining equipment.  Gold production was approximately 6% lower than plan and unit operating costs were 4% higher than plan. 

Gold production for the year totalled 141,116 ounces, 11% lower than the 159,261 ounces produced in 2009 as a result of the anticipated sequencing of lower grade ore in 2010.  The average ore grade of 6.75 grams per tonne achieved in 2010 matched expectations.  Increased daily ore throughput of 1,980 tonnes per day in 2010 compared to 1,887 tonnes per day in 2009 was offset by lower ore grades and mill recoveries, resulting in the decrease in gold production in 2010. 

Total cash costs in 2010 were US$541 per ounce, 10% higher than plan and compared to the US$401 per ounce costs in 2009, as lower ore grades, lower mill recoveries, and a strong Canadian dollar impacted costs.  Unit operating costs in 2010 were stable on a Canadian dollar basis at $108 per tonne, matching the prior year’s costs as higher ore throughput offset higher mining costs resulting from additional ground support and lower productivity from mining equipment.  Operating profit margins increased by 18% to US$604 per ounce from US$514 per ounce in 2009, due to higher realized gold prices.

BBA Inc. (BBA) was commissioned by Aurizon to undertake a prefeasibility study on the Principal Mine open pit.  Roscoe Postle Associates Inc. (“RPA”) was commissioned by Aurizon to prepare updated mineral reserve and mineral resource estimates on the rest of the property.  

Proven and Probable Mineral Reserves have increased as a result of:

  • At the West Mine, the 2010 mine production in Zones 113, Lower Inter, North West and 115 have been more than replaced by gains in mineral reserves primarily from the Principal Zone open pit and  Zone 123S.  Additional reserve increases were provided from Zones 118 and 109.
  • As a result of the addition of the lower grade ore from the Principal Zone open pit, tonnage has increased by 77%, grade has decreased by 19% and ounces of gold have been increased by 44% compared to 2009. 
  • Mineral reserves are estimated using an average long-term gold price of US$950 per ounce and a US$/C$ exchange rate of 1:1, compared to US$825 per ounce in 2009 and a US$/C$ exchange of 1:1.09.  A minimum cut off grade of 4.1 grams of gold per tonne was used for the underground zones, based on long term operating costs and gold prices.  A minimum cut off grade of 1.2 grams and 0.5 grams of gold per tonne was used respectively for the East Mine and Principal Zone open pits.  In 2009, the minimum cut off grade was 3.9 grams of gold per tonne for the underground zones.
  • As the mining industry is currently experiencing gold prices that are higher than US$950 per ounce, the operations periodically mine ore that is not included in mineral reserves as the grades are lower than the long term minimum cut-off grades.


Casa Berardi Reserves and Resources - December 31, 2010

The Casa Berardi gold deposits are located along a five kilometre east-west mineralized corridor. They include the East and West mines, and the Principal Zone. The Casa Berardi gold deposits can be classified as an Archean sedimentary-hosted lode gold deposit. The gold mineralization is superimposed on a continuous graphitic mudrock unit corresponding to the Casa Berardi Fault plane. Gold occurs mainly south of the Casa Berardi Fault, and sometimes on both sides of the fault.

The mine has produced over 1.3 million recovered gold ounces since commencing production in 1986, including 636,400 recovered ounces since Aurizon re-commissioned production in December 2006.

Scott Wilson Roscoe Postle Associates Inc. (Scott Wilson RPA) were commissioned by Aurizon to prepare updated mineral reserve and mineral resource estimates on the different zones of the property, in accordance with the Standards of Disclosure for Mineral Projects as defined by N1 43-101.


Click to enlarge


CASA BERARDI MINE
MINERAL RESERVE ESTIMATE
As at December 31,
  2010 2009
  Tonnes Grade
Grams/tonne
Gold
Ounces
Tonnes Grade
Grams/tonne
Gold
Ounces
Measured Mineral Resources            
Lower Inter (LI) 910,000 8.0 233,200 965,000 8.6 266,100
North West (NW) 42,000 5.8 7,900 62,000 5.6 11,200
113 587,000 8.8 167,000 893,000 7.7 222,000
115 147,000 11.4 54,100 156,000 11.3 56,400
Principal -- Open Pit 89,000 6.3 18,000 - - -
East Mine -- Open Pit     407,000 4.2 54,400 407,000 4.2 54,400
East Mine Underground 88,000 6.3 17,800 88,000 6.3 17,800
Total Proven Reserves 2,271,000 7.6 552,400 2,571,000 7.6 627,800
Lower Inter (LI) 30,000 8.2 7,900 32,000 10.2 10,500
South West (SW)     72,000 4.6 10,700 72,000 4.6 10,700
109 114,000 5.7 21,000 68,000 5.4 11,700
111 37,000 5.4 6,400 37,000 5.4 6,400
113 402,000 9.9 127,000 535,000 8.2 141,200
115 0 0.0 0 2,000 4.1 300
117S 19,000 7.0 4,300 19,000 7.0 4,300
118 1,021,000 6.4 208,600 767,000 6.0 148,400
123S 493,000 7.4 117,700 - - -
Principal -- Open Pit 3,072,000 3.6 352,400 - - -
East Mine -- Open Pit 228,000 3.7 26,800 228,000 3.7 26,800
East Mine Underground 63,000 8.2 16,500 63,000 8.2 16,500
Low-Grade Development    31,000 3.9 3,900 40,000 3.9 5,000
Total Probable Reserves 5,583,000 5.0 904,100 1,862,000 6.4 382,000
Total Proven & Probable Reserves 7,854,000 5.8 1,457,000 4,433,000 7.1 1,010,000

Notes:

  1. Open pit mineral reserves were estimated by BBA and underground mineral reserves were audited by RPA.
  2. Mineral reserves and resources estimates have been completed in accordance with the Standards of Disclosure
    for Mineral Projects as defined by National Instrument 43-101.  Mineral resources are exclusive of mineral
    reserves.  Mining depletion for 2010 is included in 2010 Mineral reserves.
  3. Mineral Reserves are estimated at a cut-off grade of 4.15 g/t Au for underground, and 1.2 g/t Au for East Mine
    open pit and 0.5 g/t Au for Principal open pit.
  4. Mineral Reserves are estimated using an average long-term gold price of US$950 per ounce and a
    US$/C$ exchange rate of 1:1.
  5. A minimum mining width of three metres was used.
  6. Totals may not represent the sum of the parts due to rounding.
  7.  pit mineral reserves were estimated by BBA and underground mineral reserves were audited by RPA. 

Note:  An updated resource estimate for the Principal area has been completed in 2010 to incorporate results from a winter drill program.  Refer to the Casa Berardi Exploration section.


CASA BERARDI MINE
MINERAL RESOURCE ESTIMATE
As at December 31,
  2010 2009
  Tonnes Grade
Grams/tonne
Gold
Ounces
Tonnes Grade
Grams/tonne
Gold
Ounces
Measured Mineral Resources            
Lower Inter (LI) 122,000 5.1 19,800 98,000 5.1 16,200
113 290,000 6.6 61,300 155,000 8.1 40,100
113-5 10,000 5.7 1,900 - - -
115 9,000 4.9 1,500 - - -
115-2 34,000 12.2 13,200 - - -
North West     9,000 5.0 1,400 9,000 5.0 1,400
Principal Underground     153,000 7.3 36,000 - - -
East Mine -- Open Pit     311,000 3.1 31,300 311,000 3.1 31,300
East Mine Underground 216,000 6.5 45,500 216,000 6.5 45,500
Total Measured Resources 1,155,000 5.7 211,900 789,000 5.3 134,500
Indicated Mineral Resources





Lower Inter (LI) 3,000 8.8 900 3,000 5.3 600
South West (SW)     300,000 4.7 45,000 300,000 4.7 45,000
Inter 124,000 4.4 17,700 124,000 4.4 17,700
109 21,000 4.3 2,900 - - -
111 52,000 5.2 8,800 52,000 5.2 8,800
113 46,000 5.1 7,600 60,000 4.9 9,500
113-5 2,000 6.0 400 - - -
113(S4) 245,000 5.5 43,000 245,000 5.5 43,000
115 - - - - - -
115-2 4,000 10.3 1,300 - - -
118 518,000 5.2 86,900 265,000 6.0 51,800
123S 136,000 5.4 23,700 - - -
Principal -- Open Pit - - - 1,785,000 6.2 355,300
Principal Underground     1,257,000 7.4 298,500 837,000 6.4 171,700
East Mine -- Open Pit 404,000 2.7 34,500 404,000 2.7 34,500
East Mine Underground    90,000 6.3 18,100 90,000 6.3 18,100
152 125,000 5.8 23,200 125,000 5.8 23,200
Total Indicated Resources 3,327,000 5.7 612,400 4,289,000 5.6 778,100
Total Measured & Indicated Resources 4,481,000 5.7 824,300 5,078,000 5.6 912,600




CASA BERARDI MINE
MINERAL RESOURCE ESTIMATE
As at December 31,
  2010 2009
  Tonnes Grade
Grams/tonne
Gold
Ounces
Tonnes Grade
Grams/tonne
Gold
Ounces
Measured Mineral Resources            
104 115,000 6.6 24,500 115,000 6.6 24,500
113 (S4) 15,000 5.8 2,700 15,000 5.8 2,700
118 369,000 7.9 94,200 1,018,000 6.8 222,100
123S 909,000 8.0 234,100 714,000 9.4 216,300
Principal - Open Pit 655,000 2.5 53,200 841,000 6.0 161,500
Principal Underground     628,000 6.6 132,700 836,000 6.0 160,500
East Mine -- Open Pit     310,000 3.0 30,200 310,000 3.0 30,200
East Mine Underground 156,000 9.1 45,600 156,000 9.1 45,600
152 13,000 8.2 3,500 13,000 8.2 3,500
East Mine Cherty     225,000 6.8 49,300 225,000 6.8 49,300
160 In Pit Resources     131,000 1.7 7,100 - - -
160 Underground 455,000 4.8 70,800 243,000 5.4 42,200
Total Inferred Resources 3,981,000 5.8 747,900 4,487,000 6.6 958,500


Notes:
1. Open pit mineral resources were estimated by BBA and underground mineral resources were estimated by RPA.
2. CIM definitions were followed for Mineral Resources.
3. Mineral Resources are estimated at cut-off grades of:
• 4 g/t Au for West Mine, Principal Mine and East Mine.
• 3 g/t Au for South West, Inter and 104 zones in the West Mine. Those zones were estimated by Aurizon in 2000 using 2D polygons on longitudinal sections and reviewed by RPA in 2005.
• 1.30 g/t Au for the East Mine – Open Pit
• 0.5g/t Au for the Principal – Open Pit Mineral Resources are estimated using an average long-term gold price of US$950 per ounce, and a US$/C$ exchange rate of 1:1.
4. Minimum mining widths of two to three metres were used.
5. Mineral Resources are exclusive of Mineral Reserves.
6. Totals may not represent the sum of the parts due to rounding.
7. Mineral resources which are not mineral reserves do not have demonstrated economic viability