REG - Empire Metals Ltd - Breakthrough in Process Development

Empire MetalsAnnouncement

28/08/2025 07:00

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RNS Number : 0239X  Empire Metals Limited  28 August 2025

Empire Metals Limited / LON: EEE, OTCQB: EPMLF / Sector: Natural Resources

 

28 August 2025

Empire Metals Limited

("Empire" or "the Company")

 

Breakthrough in Process Development - Exceptional Titanium Recoveries and
High-Purity Product

 

Empire Metals Limited, the AIM-quoted and OTCQB-traded exploration and
development company, is pleased to report significant progress in
metallurgical testwork at its Pitfield Project in Western Australia
('Pitfield' or the 'Project'). These results confirm that the weathered ore at
Pitfield can be processed using conventional separation and refining
techniques, delivering industry-leading recoveries and a high-purity titanium
dioxide (TiO₂) product.

 

Highlights

·    Exceptional flotation performance: Recoveries of 77% (rougher stage)
and 90% (cleaning stage) from fine, weathered ore samples.

 

·    Outstanding leach results: Direct acid bake and hot-water leach
achieved 98% titanium dissolution, leaving inert quartz residues.

 

·    High recoveries: Overall titanium recovery from flotation feed to
final product is circa 67% and expected to improve with further optimisation
of the mineral separation stages.

 

·    High-purity final product: TiO₂ grading 99.25% with negligible
impurities, suitable for titanium sponge metal or pigment production.

 

·    Cost and environmental advantages: Low Fe₂O₃ (~5%) reduces acid
consumption, minimises waste, and supports higher recoveries over typical
ilmenite feedstock processing.

 

·    Simplified, expedited development pathway: Amenability to standard
mineral separation eliminates the need for a costly bespoke demonstration
plant, enabling a lower-cost continuous pilot programme using accredited
commercial laboratories.

 

Shaun Bunn, Managing Director, said:

"These results mark a step change in Pitfield's development. We now have clear
evidence that the ore is ideally suited to conventional mineral separation and
refining, producing a high-purity titanium product with strong recoveries.
This sets Pitfield apart from ilmenite-based projects, which typically face
lower recoveries, higher costs, and significant environmental challenges.

 

"Pitfield already stands out for its exceptional scale, continuity of
high-grade near-surface mineralisation, and Tier 1 location with access to
infrastructure. With this breakthrough in process development, we can now
demonstrate a highly efficient and environmentally responsible route to
producing multiple high-value titanium products."

 

Metallurgical Testwork Summary

Empire has committed substantial financial resources to developing a
metallurgical flowsheet that can economically extract titanium and produce a
high value titanium product: such as TiO(2) pigments, and/or feedstock for the
TiO(2) pigment or titanium sponge metals industries.

 

The approach to flowsheet development has included:

 

·    Extensive mineralogical investigations on exploration samples,
testwork feed samples and testwork products

·    Wide ranging literature reviews, including industry and
cross-industry research

·    Idea generation and testing of concepts and conditions in the
laboratory

·   A fast-tracked separate work programme to prove that an impurity free
high grade product can be made from samples taken at Pitfield.

 

Initial mineralogical and metallurgical testwork was undertaken on the fresh,
titanite-rich bedrock mineralisation at Pitfield and returned encouraging
results. Following the identification of the extensive in-situ weathered cap,
which independently represents a generational-scale mining opportunity,
subsequent testwork programmes have been directed toward this material. The
weathered cap contains mainly anatase and rutile, and is distinguished by its
soft, friable texture, elevated titanium grades, and near-surface exposure
which offer significant advantages from both a mining and processing
perspective.

 

Empire has employed two full time process engineers to work on the process
flowsheet development, both of whom have extensive experience in mineral
separation and elemental extraction (hydrometallurgy). In addition, Empire has
contracted with two titanium expert consultants, each of which has over 40
years' experience in the industry. The process development programme is also
supported by further specialist input from the technical team at Strategic
Metallurgy, scientists from Federal Government agencies and process engineers
from local Engineering & Process Design Consultants.

 

Testwork results achieved to date are encouraging and support the conceptual
process flowsheet that was announced 4 September 2024 "Positive Results
Achieved from Initial Processing Testwork on Pitfield Titanium Ore" (refer
Figure 1).

Figure 1. Conceptual Process Flowsheet.

 

Recent testwork has been focused on the fine, saprolite ores from the Thomas
prospect. Testwork results to date suggest that Empire can expect to achieve
an overall recovery of circa 65-75%, and produce a high-purity, +99% TiO(2)
product. This is based on early stage testwork with limited optimisation, and
the success to date is a good indicator that the Pitfield ores are
non-refractory and free of deleterious contaminants that affect product
quality (such as U, Th, Cr, P and V).

 

Whilst it is difficult to provide comparable projects to Pitfield, given its
scale, grade and unique ore characteristics, the processing route being
evaluated for Pitfield has similar stages to that found in the
well-established heavy mineral sands industry. For instance, the ilmenite
within the mineral sands is first separated (by gravity and magnetics) and the
ilmenite concentrates are then beneficiated by a combination of reduction
roast and leach to produce synthetic rutile. This in turn becomes feedstock to
the TiO(2) pigment or Ti sponge metal producers, both of which use strong
oxidants (Cl gas or sulphuric acid) and high temperatures to transform the
feedstock into pigments or TiCl(4).

 

The whole process of recovering titanium from ilmenite; concentrating,
beneficiation and then transforming it into a high-purity product is
inefficient (generally low recoveries), expensive (high energy consumption and
expensive consumables) and environmentally unfriendly (substantial Fe residues
to dispose of from the breakdown of the ilmenite). The unique ore
characteristics of Pitfield provide an opportunity to design a new processing
route that is more efficient, lower cost and has greater optionality over the
products it can produce than that currently experienced by the ilmenite
processors, who account for 95% of the titanium supply chain.

 

Metallurgical Samples

Samples being used for the testwork programme have been collected from
drilling programmes conducted across the deposit. These include drill core
samples from diamond drilling, and bulk samples from air core drilling
programmes. Samples have been collected from both exploration targets -
Cosgrove ('COS') and Thomas ('TOM'). Separate Saprolite ('SAP') and Weathered
Sandstone ('WS') zones have been identified. Some of the testwork samples are
a blend of the two zones and some have been kept separate to understand the
performance of the weathering profile.

Mineralogy

A number of mineralogy techniques are being used to develop the understanding
of the Pitfield mineralogy and morphology. SEM based TIMA analysis has been
undertaken at Automated Mineralogy Incubator (AMI) on exploration samples,
testwork feed samples and testwork products.

 

Figure 2.  Mineralogist at AMI discussing Pitfield TIMA analysis results with
Empire Metallurgist

 

Key information collected from TIMA analysis on testwork feed samples and
exploration samples includes the titanium and gangue minerals present, the
grain sizes, and the mineral association.

 

Testwork product samples have also been analysed using TIMA to understand the
deportment of the different titanium minerals and effectiveness of each of the
processing steps. More than 100 samples have been analysed using TIMA,
including geology samples, testwork feed samples and testwork products.

 

XRD analysis has also been used on a range of samples. This has been used to
help with mineral identification that SEM cannot determine - such as the
crystal structure of titanium oxide minerals, identifying them as either
anatase or rutile.

 

Microprobe analysis, at CSIRO in Melbourne, has been used on a small number of
samples: to measure impurities in titanium minerals in particular.

 

Testwork - Flowsheet Development

Some early testwork programmes were undertaken using fresh mineralisation from
Pitfield, however once an understanding of the mineralogy and volume of the
weathered zone was developed, the focus shifted to this material.

 

Comminution and Mineral Separation

Several comminution tests have been completed on drillcore samples to
investigate potential for low energy input comminution such as scrubbers and
log washers. The optimal regrind liberation size range and the energy input
required, which appears to be very low, continues to be investigated.

 

A wide range of unit processes are being investigated for mineral separation
utilising whole-of-ore samples as well as separated coarse and fine fraction
samples.

 

Testwork on the coarse fraction has focused on gravity and enhanced gravity
separation, testing shaking tables, spirals, and a Multi Gravity Separator
(MGS). The shaking table tests and MGS tests were completed at batch scale
(~5-20kg), whilst the spiral tests were undertaken on a much larger, bulk
scale (~300-600kg).

 

Testwork on the fine fraction looked at enhanced gravity (MGS) and froth
flotation. A range of flotation reagents and conditions are being tested.
Relevant examples exist in the non-sulphide flotation industry, including
anatase flotation from kaolin clay minerals in the kaolinite industry.

 

Whole-of-ore testwork is in the planning stages for comparison against gravity
separation performance. This testwork will focus on grinding, flotation and
then further treatment of the flotation concentrate assessing a number of
different separation processes.

 

Key results to date include:

·    Fine fraction "rougher" flotation on a TOM SAP sample has achieved
67- 77% TiO(2) recovery and up to 19% TiO(2) concentrate grade. Similar
recovery performance was achieved on a COS WS sample fines fraction with a
"rougher" flotation recovery of 68%.

·    Cleaner tests on rougher concentrate from the TOM SAP rougher
flotation test achieved a 90% stage recovery at 32%TiO(2) concentrate grade.
This equates to an overall float recovery of circa 70%.

·    Bulk scrubber testwork on TOM SAP sample resulted in 51% of the mass
and 72% of the contained TiO(2) to the fines fraction, using a hydro cyclone.
Similar results were seen on a smaller scale scrubber test using drillcore
material, with 53% of the mass and 66% of the TiO(2) reporting to the fines
fraction, using a 38µm screen.

 

 

Figure 3.  (L-R): Bulk Scrubber test in progress at AML, Batch slimes fraction rougher flotation test at ALS.

 

Elemental Extraction and Product Finishing

A wide range of concepts are being explored for extraction of titanium from
the mineral concentrate.  These range from conventional processes, already
applied in the titanium industry or other comparable industries, to more novel
processes that have been developed through laboratory research and pilot scale
testing.

 

A base case of sulphuric acid bake water leach, followed by titanium
hydrolysis and calcination has been tested by Empire. This is based on the
conventional sulphate route for TiO(2) pigment production, which is usually
applied to ilmenite concentrates.  A range of other lixiviants and
decomposition and leach conditions have been identified and are planned to be
tested as part of the ongoing development programme.

 

Product finishing testwork aims to take titanium from the leach solutions and
produce a final product. It is closely tied to the elemental extraction, so in
some cases is being tested as part of that testwork programme. There is a
range of product options: separate research testwork is being undertaken to
develop and understanding of the various TiO(2) pigments and Ti chemicals that
Pitfield can produce and the markets in which these products are required.

Around 15 leach tests have been completed to date, including five product
finishing tests. A number of product process options are as yet untested:
further testwork is budgeted and is currently in the planning stage.

 

Elemental extraction results achieved to date include:

 

·    Acid bake water leach tests on rougher flotation concentrate have
achieved 98% TiO(2) extraction to the liquor phase.

·    Titanium hydrolysis and calcination has been successfully applied to
the leach liquor after iron conversion, producing a low-impurity TiO(2)
product containing 99.25% TiO(2).

·    Recovery in the hydrolysis stage requires further testwork as the
conditions applied in the tests and has not yet been optimised. Hydrolysis is
a standard process used in sulphate pigment industry, and high recoveries
(greater than 95%) are achieved on a commercial scale.

 

Figure 4.   Elemental Extraction testwork (L-R): Acid-Concentrate mixing
pre-acid bake, Acid bake product, initial stages of water leach, water leach
residue and filtrate.

 

Product Potential

A fast-tracked separate work programme was undertaken to determine whether an
impurity-free high grade product could be made from samples taken at Pitfield.
The sample was processed through scrubbing, gravity separation, flotation,
acid bake/water leach, impurity removal, titanium hydrolysis and calcination.
The flowsheet used and conditions selected were based on industrial examples
and literature. This work achieved a product grade of 99.25% TiO(2): impurity
levels, particularly colorformers which impact negatively on pigment quality,
were below detection limits or very low. (Announcement "Exceptional
High-Purity TiO(2) Product Achievement" 9 June 2025).

 

Further work is ongoing to understand the TiO(2) pigment market, optimise the
test conditions and also understand the alternative product options, such as
TiCl(4) (the feedstock for making titanium sponge metal) or other titanium
chemicals.

 

Figure 5.  Purification and Product finishing testwork (L-R): titanyl
sulphate solution from leaching stage, hydrated TiO2 produced from hydrolysis,
and the calcined TiO 2 product

 

Future metallurgical testwork

Empire has committed significant resources to enable the process flowsheet
development programme to continue to proceed at pace. This includes not only
the allocation of several full time Empire technical staff but also the use of
various industry specialists who support the Empire team in managing the
necessary metallurgical testwork and research programmes.

 

Over the coming months the Company will focus on optimising the mineral
separation stages to further improve the flotation and gravity concentrate
grades and recovery. Bulk metallurgical testwork has commenced, utilising
large scale scrubbing, gravity and flotation test equipment at local mineral
processing laboratories. This testwork will produce significant quantities of
titanium mineral concentrates: allowing the testing of multiple downstream
beneficiation options aimed at defining the optimal hydrometallurgical
processing route.

 

Finished product optimisation, through research and laboratory testwork, is
continuing and is aimed at further refining the +99% titanium product already
achieved to date, looking at alternative titanium products for marketing
purposes.

 

The next steps for the mineral separation flowsheet development will be
further optimisation of the chemistry and conditions, larger scale batch
testwork and then continuous piloting can be undertaken at a laboratory scale.
Testwork to date has shown the Pitfield weathered ores amenability to
conventional mineral separation, beneficiation and refining techniques, and
this avoids the need to build a bespoke, demonstration plant. A simpler and
lower cost continuous pilot plant operation can be established, utilising
local, internationally accredited commercial metallurgical laboratories.

 

The Company aims to complete the bench and large scale batch metallurgical
testwork phase by Q1 2026, which is when it expects to move toward continuous
piloting of the process in order to provide the critical technical information
for the development of a commercial process flowsheet and to enable the supply
of bulk product samples to prospective end users.

 

The Pitfield Titanium Project

Located within the Mid-West region of Western Australia, near the northern
wheatbelt town of Three Springs, the Pitfield titanium project lies 313km
north of Perth and 156km southeast of Geraldton, the Mid West region's capital
and major port. Western Australia is a Tier 1 mining jurisdiction, with
mining-friendly policies, stable government, transparency, and advanced
technology expertise. Pitfield has existing connections to port (both road
& rail), HV power substations, and is nearby to natural gas pipelines as
well as a green energy hydrogen fuel hub, which is under planning and
development (refer Figure 3).

Figure 3. Pitfield Project Location showing the Mid-West Region Infrastructure
and Services

 

Competent Person Statement

The scientific and technical information in this report that relates to
process metallurgy is based on information reviewed by Ms Narelle Marriott, an
employee of Empire Metals Australia Pty Ltd, a wholly owned subsidiary of
Empire. Ms Marriott is a member of the AusIMM and has sufficient experience
relevant to the style of mineralisation and type of deposit under
consideration and to the activity being undertaken to qualify as a Competent
Person as defined in the JORC Code 2012. Ms. Marriott consents to the
inclusion in this announcement of the matters based on their information in
the form and context in which it appears.

 

The technical information in this report that relates to the Pitfield Project
has been compiled by Mr Andrew Faragher, an employee of Empire Metals
Australia Pty Ltd, a wholly owned subsidiary of Empire. Mr Faragher is a
Member of the Australian Institute of Mining and Metallurgy. Mr Faragher has
sufficient experience that is relevant to the style of mineralisation and type
of deposit under consideration and to the activity being undertaken to qualify
as a Competent Person as defined in the 2012 Edition of the 'Australasian Code
for Reporting of Exploration Results, Mineral Resources and Ore Reserves'. Mr
Faragher consents to the inclusion in this release of the matters based on his
information in the form and context in which it appears.

 

Market Abuse Regulation (MAR) Disclosure

Certain information contained in this announcement would have been deemed
inside information for the purposes of Article 7 of Regulation (EU) No
596/2014, as incorporated into UK law by the European Union (Withdrawal) Act
2018, until the release of this announcement.

 

**ENDS**

 

For further information please visit www.empiremetals.co.uk
(http://www.empiremetals.co.uk) or contact:

 Empire Metals Ltd

 Shaun Bunn / Greg Kuenzel / Arabella Burwell                                            Tel: 020 4583 1440
 S. P. Angel Corporate Finance LLP (Nomad & Broker)                                      Tel: 020 3470 0470

 Ewan Leggat / Adam Cowl
 Shard Capital Partners LLP (Joint Broker)                                               Tel: 020 7186 9950

 Damon Heath / Erik Woolgar
 St Brides Partners Ltd (Financial                                                       Tel: 020 7236 1177
 PR)

 Susie Geliher / Charlotte Page

 

About Empire Metals Limited

Empire Metals is an AIM-listed and OTCQB-traded exploration and resource
development company (LON: EEE) with a primary focus on developing Pitfield, an
emerging giant titanium project in Western Australia.

 

The high-grade titanium discovery at Pitfield is of unprecedented scale, with
airborne surveys identifying a massive, coincident gravity and magnetics
anomaly extending over 40km by 8km by 5km deep. Drill results have indicated
excellent continuity in grades and consistency of the mineralised beds and
confirm that the sandstone beds hold the higher-grade titanium dioxide
(TiO₂) values within the interbedded succession of sandstones, siltstones
and conglomerates. The Company is focused on two key prospects (Cosgrove and
Thomas), which have been identified as having thick, high-grade, near-surface,
bedded TiO₂ mineralisation, each being over 7km in strike length.

 

An Exploration Target* for Pitfield was declared in 2024, covering the Thomas
and Cosgrove mineral prospects, and was estimated to contain between 26.4 to
32.2 billion tonnes with a grade range of 4.5 to 5.5% TiO(2).  Included
within the total Exploration Target* is a subset that covers the weathered
sandstone zone, which extends from surface to an average vertical depth of 30m
to 40m and is estimated to contain between 4.0 to 4.9 billion tonnes with a
grade range of 4.8 to 5.9% TiO(2).

 

The Exploration Target* covers an area less than 20% of the overall mineral
system at Pitfield which demonstrates the potential for significant further
upside.

 

Empire is now accelerating the economic development of Pitfield, with a vision
to produce a high-value titanium metal or pigment quality product at Pitfield,
to realise the full value potential of this exceptional deposit.

 

The Company also has two further exploration projects in Australia; the
Eclipse Project and the Walton Project in Western Australia, in addition to
three precious metals projects located in a historically high-grade gold
producing region of Austria.

*The potential quantity and grade of the Exploration Target is conceptual in
nature. There has been insufficient exploration to estimate a Mineral Resource
and it is uncertain if further exploration will result in the estimation of a
Mineral Resource.

 

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