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Black Canyon Limited (ASX:BCA), an Australian manganese explorer and developer, has reported successful pilot scale Dense Media Separation (DMS) beneficiation testwork at its 100%-owned Wandanya Project. The testwork produced high-grade manganese concentrates with grades of 41.0% Mn and 38.5% Mn from blended feed composites, achieving manganese recoveries of 82% and 80% respectively. This milestone advances the company’s development strategy for the Wandanya manganese deposit located in Western Australia.
Key Points
- Black Canyon Limited (ASX:BCA) is focused on manganese exploration and development at the Wandanya Project in Western Australia.
- Stage 4 pilot scale DMS testwork upgraded manganese products to 41.0% Mn (Blend 1) and 38.5% Mn (Blend 2) with recoveries of 82% and 80%, respectively.
- Two 100kg blended composites were processed using a 2.8 g/cm dense media density, consistent with industry standards at Australian manganese mines.
- Reverse circulation drilling is planned to commence in August 2026 to expand the Wandanya resource.
- Results will feed into an upcoming Scoping Study evaluating a dual commodity operation combining direct ship ore (DSO) and beneficiated manganese products.
- The testwork follows prior screen/assay, heavy liquid separation (HLS), and blend feed testing on PQ3 diamond drill core composites.
Wandanya Project Demonstrates Multi-Product Manganese Beneficiation Pathway
Black Canyon Limited’s recent update confirms that the Wandanya Project in Western Australia has successfully demonstrated its manganese mineralisation’s capacity to produce multiple marketable products. The beneficiation program progressed through four stages, with the latest pilot scale DMS testwork validating the commercial viability of upgrading lower-grade feed to specification-quality concentrates. Identified product streams include direct ship ore (DSO) manganese products grading 42% to 44% Mn, blended feed concentrates at 38.5% Mn, and combined low, medium, and high-grade feeds yielding a 41.0% Mn concentrate. These products feature low impurities and high recoveries, positioning Wandanya for potential multi-product development.
Black Canyon’s Managing Director Brendan Cummins highlighted that the larger scale DMS trial on blended feedstocks reinforces confidence in the manganese oxide mineralisation’s ability to upgrade to highly marketable products. The use of processing technology aligned with established mining operations supports the company’s development approach and advances preparations for the Scoping Study with improved technical and economic certainty.
Dense Media Separation Outcomes for Blend 1 and Blend 2
The Stage 4 pilot scale DMS testwork processed two blended 100kg composites reflecting the geometallurgical profile of the Wandanya deposit. Blend 1 combined low, medium, and high-grade manganese composites at 20%, 60%, and 20%, respectively, while Blend 2 mixed low and medium-grade composites in a 25% to 75% ratio. Both blends were crushed to 10mm and screened at 1mm to remove fines, which were included in recovery calculations. Initial head grades were 32.4% Mn for Blend 1 and 29.3% Mn for Blend 2.
Processing with a 2.8 g/cm dense media upgraded manganese grades to 41.0% Mn and 38.5% Mn for Blend 1 and Blend 2, respectively, representing grade increases of 8.6 and 9.2 percentage points. Manganese recoveries ranged from 80% to 82%, confirming consistent performance and validating the DMS approach. The dense media density matches parameters used at Woodie Woodie and Groote Eylandt manganese mines, demonstrating industry-standard processing. The beneficiated concentrates met specification requirements with low penalty elements, supporting commercial marketability.
Four-Stage Metallurgical Program Integrates Earlier Testwork
The pilot scale DMS results culminate a four-stage metallurgical testwork program initiated on PQ3 diamond core samples collected in November 2025. Stage 1 involved preparing representative master composite samples across three grade categories: Low Grade MnO (24.4% Mn), Medium Grade MnO (30.9% Mn), and High Grade MnO (45.0% Mn). Stage 2 applied heavy liquid separation (HLS) to these composites to assess potential beneficiation grades and recoveries. Stage 3 evaluated blended feedstock grade and recovery characteristics, informing the formulation of the two blends tested in Stage 4. This staged methodology reduced technical uncertainty and enhanced confidence for scale-up.
Diamond Core Sampling and Head Grade Analysis
The metallurgical samples originated from the PQ3 diamond drilling campaign comprising 298m of core from 22 holes completed in November 2025. The drilling twinned earlier reverse circulation holes and targeted representative mineralisation within the 3km base case zone. Sampling focused on mineralisation type, geology, grade, and spatial distribution to ensure composites reflected deposit variability.
Head grade assays showed the Low Grade MnO composite contained 24.4% Mn, 6.09% Fe, 3.13% Al, and 14.4% Si with 11.03% LOI. Medium Grade MnO assayed 30.9% Mn, 6.85% Fe, 3.15% Al, and 9.9% Si with 12.15% LOI. High Grade MnO graded 45.0% Mn, 3.15% Fe, 1.3% Al, and 3.6% Si with 13.65% LOI. These variations informed beneficiation parameter selection for each feed and blended scenario.
Recovery Rates and Penalty Element Control in Upgraded Products
The pilot scale DMS testwork achieved manganese recoveries of 82% for Blend 1 and 80% for Blend 2, confirming dense media separation as an effective beneficiation method for Wandanya feeds. High recoveries are critical for project economics by maximizing marketable manganese extraction and influencing operating costs and revenues.
The beneficiated concentrates exhibited low penalty element levels, meeting customer specifications and enabling price premiums in global manganese markets. The 2.8 g/cm dense media effectively separated manganese minerals from waste and iron oxides, producing concentrates exceeding industry standards. Black Canyon noted potential to improve recoveries further by processing fines, indicating ongoing optimization beyond the current validated baseline.
Dual Commodity Strategy: Combining Direct Ship Ore and Beneficiated Manganese
Testwork outcomes have shaped Black Canyon’s strategy to pursue a dual commodity operation at Wandanya, integrating direct ship ore (DSO) iron, DSO manganese, and beneficiated manganese concentrates. This approach leverages the deposit’s geology and market demands, offering DSO manganese products grading 42% to 44% Mn that reduce processing costs and meet specifications. Beneficiated concentrates (38.5% to 41.0% Mn) target customers requiring specification-grade material or blending options. The inclusion of a direct ship iron stream captures additional value from iron oxides separated during beneficiation.
By developing multiple product streams, Black Canyon aims to optimize project flexibility and adapt to market conditions, selecting product mixes that maximize returns. Managing Director Brendan Cummins stated the metallurgical results enable application of grade and recovery data in the upcoming Scoping Study, which will rigorously evaluate the dual commodity operation’s feasibility.
Resource Expansion Drilling Set for August 2026
Following the pilot scale testwork success, Black Canyon plans to mobilize a reverse circulation (RC) drill rig to the Wandanya site in August 2026 to advance resource expansion. The program targets extensions of known manganese mineralisation north and south of the current 3km base case zone, aiming to increase the mineral resource estimate and support long-term development. This drilling marks a shift from metallurgical core drilling to production-scale resource definition.
The timing aligns with the company’s development schedule, occurring after metallurgical feasibility is confirmed but prior to integrating updated resource data into the Scoping Study. Results from this drilling will directly inform economic assumptions and development plans, enhancing the quality of pre-feasibility assessments.
Industry-Standard Dense Media Processing Validates Metallurgical Approach
A key highlight is the use of a 2.8 g/cm dense media density in the Stage 4 DMS testwork, consistent with parameters at established Australian manganese mines such as Woodie Woodie and Groote Eylandt. This alignment validates Black Canyon’s processing methodology as proven technology, reducing technical risk associated with scale-up and operational execution.
Benchmarking against these operations confirms the commercial viability of the beneficiation approach. Managing Director Brendan Cummins emphasized the successful application of processing technology comparable to existing mining operations, underscoring the technical soundness and risk mitigation underpinning the company’s development strategy. This industry consistency should reassure investors and stakeholders regarding the project’s prospects.
Scoping Study to Define Development Pathway and Timeline
Black Canyon’s next major milestone is completing a Scoping Study that will integrate metallurgical results, resource expansion drilling data, and economic assumptions into a pre-feasibility evaluation of the dual commodity operation. The study will assess capital and operating costs, revenue forecasts, and project returns based on the integrated technical and economic parameters. Completion is expected in late 2026 or early 2027, following the August 2026 RC drilling and resource estimation.
The Scoping Study will guide project development strategy, target production rates, and commercialization timelines for bringing the Wandanya Project into production, leveraging the robust data generated through the comprehensive testwork and exploration programs.
