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Aclara Announces Filing and Results of Pre-Feasibility Study for Its Flagship Carina Project

06.11.2025  |  ACCESS Newswire

After-tax NPV8 of US$1.1B based on Mineral Reserves

TORONTO, November 6, 2025 - Aclara Resources Inc. ("Aclara" or the "Company") (TSX:ARA) is pleased to announce the filing and results of the pre-feasibility study (the "PFS") of the Company's flagship asset, the Carina Project ("Carina" or the "Project") based on Mineral Reserves. The PFS, titled "NI 43-101 Technical Report & Pre-feasiblity Study on the Carina Project, Goiás, Brazil" with an effective date of October 22, 2025, was prepared and consolidated in accordance with National Instrument 43-101 - Standards of Disclosure for Mineral Projects ("NI 43-101") by by Hatch Consultoria em Projetos Ltda. ("Hatch"). Other engineering companies that participated in the preparation of the PFS include L&M Geociencias SpA, Promet 101 Consulting Pty Ltd, Abelco Consulting SpA, LOM Consultoria em Mineração Ltda, F&Z Consultoria e Projetos, ERM Consultants Canada Ltd and Argus Media Ltd ("Argus Media").

There are no differences between the mineral resources described in the PFS and those previously disclosed in the Mineral Resource Statement press release issued by the Company on October 1, 2025. The terms "Mineral Resource," "Inferred Mineral Resource," "Indicated Mineral Resource," "Measured Mineral Resource," "Mineral Reserve," "Probable Mineral Reserve," and "Proven Mineral Reserve" referenced in this news release, have the meanings given to them in NI 43-101 by reference to the "Definition Standards for Mineral Resources and Mineral Reserves" (2014) of the Canadian Institute of Mining and Metallurgy.

The PFS has been filed and can be found under the Company's profile on SEDAR+ ( www.sedarplus.ca ) and on Aclara's website ( www.aclara-re.com ).

Aclara's COO, Hugh Broadhurst, commented:

"The results of this Pre-Feasibility Study mark a defining milestone for Aclara, we are the first company in the world to publish heavy rare earth Mineral Reserves from ionic clays in accordance with NI 43-101. The depth of data, quality of engineering, and validation through pilot-scale operations give us strong confidence as we move into the feasibility stage and prepare for early works in H1 2026. Carina's proven process, high-purity product, and sustainable design position us to deliver one of the most responsible and competitive sources of heavy rare earths globally, supporting Aclara's integrated mine-to-magnet proposal."

Highlights

Strong Economics

Significant Production of HREEs and Light Rare Earths (LREEs)

High Confidence in the Production Forecast, the Process Flowsheet and the Product Quality

Expedited Path to Early Production

Mine to Magnet Solution: Strong Bedrock for Integration with Aclara's Processing Hub in Louisiana

Strong Financial Backing

Key Project Parameters

Table 1 and Table 2 summarize the relevant parameters associated with the PFS operating and financial metrics:

Post-Tax Free Cash Flow

Figure 1 demonstrates the yearly and cumulative post-tax free cash flow generated through the LOM.

Sensitivity Analysis

A sensitivity analysis was undertaken to evaluate the impact on after-tax NPV, considering a variation of ±30% for five key input variables: MREC sale price, Separation Cost, Desorption Efficiency, OPEX and CAPEX (Figure 2).

The economic analysis of the estimated cashflows for the Project indicates the potential for an economic project across a broad range of input assumptions. The NPV calculated at an 8% discount rate is positive, and the Internal Rate of Return calculated for the project is within a favourable range.

The primary commercial risks include:

Mineral Resource Statement

  1. Notes:

  2. Mass is expressed in million tonnes (dry, metric).

  3. TREO means total rare earth oxides (La2O3, CeO2, Pr6O11, Nd2O3, Sm2O3, Eu2O3, Gd2O3, Tb4O7, Dy2O3, Ho2O3, Er2O3, Tm2O3, Yb2O3, Lu2O3, and Y2O3).

  4. NdPr means neodymium and praseodymium (Nd2O3 and Pr6O11).

  5. Dy means dysprosium (Dy2O3) and Tb means terbium (Tb4O7).

  6. Mineral Resources were reported at a Net Smelter Return (NSR) cut-off of 10.0 US$/t, constrained within a conceptual pit shell using average long term metal prices and metallurgical recoveries, both outlined in Chapter 14.

  7. Mineral Resources that are not Mineral Reserves do not have demonstrated economic viability. Mineral Resources are reported inclusive of Mineral Reserves. The estimate of Mineral Resources may be materially affected by environmental, permitting, legal, title, taxation, socio-political, marketing or other relevant issues.

  8. The PFS Mineral Resource estimate was prepared by Andres Beluzan, Member of Chilean Mining Commission, an independent Qualified Person as defined by NI 43-101.

  9. Totals may not be balanced due to rounding of figures.

Mineral Reserves Statement

Mineral Reserves, which include the identified economic portion of the Indicated Mineral Resources, were estimated by LOM Consultoria em Mineração Ltda ("LOMC") for the Project as part of the PFS. At this stage, Measured Mineral Resources are not classified in the resource model.

To convert Mineral Resources to Mineral Reserves, consideration was given to forecasts and estimates of REE prices, metallurgical recovery, mining dilution and ore loss factors, royalties and costs associated with mining, processing, overheads, and logistics. These parameters were used to derive economic cut-offs and create a feasible pit design based on geotechnical assumptions, a production schedule and a financial model. It is LOMC's opinion that the Mineral Reserve estimation is compliant with NI 43-101.

Notes

  1. The REE prices assumed are: US$96.00/kg Pr oxide, US$96.00/kg Nd oxide, US$3,056.00/kg Tb oxide, US$829.00/kg Dy oxide.

  2. An exchange rate of R$5.75 to US$1.00 is assumed.

  3. Mineral Reserves are based on Indicated Mineral Resources only. At this stage, Measured Mineral Resources are not classified in the model.

  4. The economic cut-off was calculated cell-by-cell as ore/waste mining costs vary with haul distances. For equal haul distance, the economic NSR cut-off is US$9.27/t.

  5. 2% dilution and 98% mining recovery factors were applied to grades and tonnages, respectively.

  6. The mineral Reserve is included in the mineral Resource.

The economic model demonstrates that, under the metal prices assumed for the pit optimization, the Project provides a positive NPV which confirms the economic viability of the Mineral Reserves.

Project Description

The Project is based on standard open pit extraction techniques using 95-tonne hydraulic excavators and 75-tonne payload haulage trucks to extract and deliver the clays to the process plant. The process plant has been located close to the center of mass of the mining operation to minimize the total haulage distance over the LOM. Given the friable nature of the clays and the shallow depth of the extraction zones, no aggressive nor energy-intensive techniques such as drilling and blasting are required to extract the clays from the pits.

Once the clay is delivered to the process plant, it will be washed using an ammonium sulfate solution to extract the REEs from the clay surfaces. No crushing, grinding nor milling is needed to free the REEs from the clays as they are extracted through a non-invasive ion-exchange process whereby ammonium sulfate ions replace REE ions on the surface of the clay thereby liberating the REEs into solution. The REEs in solution are then isolated through a pH-adjusted precipitation process and then passed through a high-pressure filter to remove any remaining liquids. This results in the production of a high-purity REE carbonate ready for shipment to our separation facility in Louisiana. The process plant will have an average production rate [1] of 4,265 t/year of REO within the MREC at 90% availability.

Any unwanted impurities such as aluminum and calcium extracted from the clays during the ion exchange process are removed through a precipitation process and subsequently recombined with the washed clays before being transported to a deposition zone which is a filter-stack storage facility.

An integrated water recovery system cleans and regenerates the remaining process liquors so they can be reintroduced into the feed. The treated water is recycled in a closed circuit to reduce water consumption. This allows the process plant to operate with minimum make-up water and for the main reagents to be regenerated and reused within the process plant.

Before the clays exit the process plant, they are washed with clean water within standard plate-and-frame membrane filter presses. The wash removes any residual ammonium sulfate from the clays before they are returned to the deposition zone or used to back-fill the extraction zones for revegetation. Table 5 lists the key process design criteria used in the mass balance calculations.

The Project includes the necessary infrastructure to provide make-up water for the process plant, supply power to the site, and provide a road network to service the operation, amongst others.

Electrical power for the processing plant, truck shop, administration offices, and other facilities will be supplied by a dedicated transmission line designed to ensure stable and efficient energy delivery. This line operates at a nominal voltage of 230 kV and is fed from a sub-station located approximately 100 km from the project site.

Work on environmental and social studies will continue to assist in further defining mitigations which will be integrated into the Project engineering design and throughout life of mine. The studies underway are consistent with Brazilian regulations and International leading sustainability principles. Engagement with local communities and residents in the vicinity of the Project is underway to establish working relationships and to collaboratively understand local conditions which will inform the development and implementation of programs and mitigations.

REE Market Outlook and Pricing (Source: Argus Media)

Based on the work of Argus Media [1] , vehicle electrification and the transition to renewable energy will continue to drive the REE market in terms of volume and (especially) value. Demand will increase for the REEs used in permanent magnets (REE PMs): neodymium (Nd), praseodymium (Pr), dysprosium (Dy), and terbium (Tb) oxides. When growth in the electric vehicle and renewable energy industries begins to plateau, the industrial and humanoid robotics sector and drone technology are likely to continue boosting REE PM demand in the long term.

The supply of the LREEs, Nd (primarily) and Pr (to a lesser extent), from existing producers and new projects appears to be sufficient to satisfy demand until at least the end of the decade. However, the supply of the HREEs, Dy and Tb, as well as the HREEs gadolinium (Gd) and yttrium (Y) is more problematic as far fewer projects target HREE deposits. The market will likely have to rely on China and Myanmar/Laos in the short to medium term for supply of HREE feedstocks, although production of ion-adsorption REE ores in southern China is declining.

In early April, China extended its export control scheme to include Dy, Tb, Gd, Y, lutetium (Lu), samarium (Sm), and scandium (Sc), likely in retaliation against the reciprocal tariffs announced by the United States president on April 2, 2025. The effect on European REE prices was immediate: Argus Media's European assessments for Dy, Tb, and Y prices rose to nearly 3, 2.5, and 7 times higher than Chinese prices, respectively. At the end of July 2025, Dy prices had reached US$750-860/kg (compared to US$225/kg in China), and Tb prices were US$2,800-3,500/kg (compared to US$985/kg in China). Y prices soared to US$60/kg-nearly 9 times higher than domestic Chinese prices.

Nd prices in Europe have continued to track the Chinese free on board (FOB [2] ) prices because Nd was not a product subject to export controls. However, the 10-year Nd floor price of US$110/kg agreed between the United States Department of War (DOW; formerly the Department of Defense) and the American REE producer MP Materials is likely to raise European Nd prices to these levels as the European Union Critical Rare Materials Act begins to take effect towards the end of the decade. REE prices in Europe are likely to remain high, at least in the short term, given the uncertainty surrounding Chinese exports.

Argus Media has assessed European prices for Nd and Ce oxides and metals since 2012 and Dy, Tb, and Er oxides since 2015. In July 2025, it introduced prices for Pr and NdPr oxides to complete the suite of REE PM materials. Historically, European prices have tracked Chinese FOB prices (with the addition of shipping to reflect the CIF [3] Rotterdam assessment) because most of the material traded in Europe would be of Chinese origin. In the future, it is likely that European prices will decouple from Chinese prices as the supply chains not reliant on China are created and are based on the costs curve for non-Chinese production of REEs. Figure 3 shows the comparison between Chinese FOB prices and European CIF prices for Dy and Tb.

Targeted Development Timeline

The permitting process is currently underway and the technical development is in progress with a feasibility study scheduled to be delivered in Q2 2026 and commencement of operations projected to begin at the end of 2028 (Table 6). The Company is evaluating the possibility to expedite the production schedule to begin by mid-2028.

Proposed Next Steps

Data Verification

Data verification was conducted both internally by Aclara and externally by an independent Qualified Person ("QP"), in accordance with NI 43-101 standards, as described in the PFS.

Qualified Persons

All QPs are independent of Aclara. The scientific and technical information included in this news release and pertaining to the following chapters and sections of the PFS has been reviewed and approved as follows:

About Aclara

Aclara Resources Inc. (TSX: ARA), a Toronto Stock Exchange listed company, is focused on building a vertically integrated supply chain for rare earths alloys used in permanent magnets. This strategy is supported by Aclara's development of rare earth mineral resources hosted in ionic clay deposits, which contain high concentrations of the scarce heavy rare earths, providing the Company with a long-term, reliable source of these critical materials. The Company's rare earth mineral resource development projects include the Carina Project in the State of Goiás, Brazil as its flagship project and the Penco Module in the Biobío Region of Chile. Both projects feature Aclara's patented technology named Circular Mineral Harvesting, which offers a sustainable and energy-efficient extraction process for rare earths from ionic clay deposits. The Circular Mineral Harvesting process has been designed to minimize the water consumption and overall environmental impact through recycling and circular economy principles. Through its wholly-owned subsidiary, Aclara Technologies Inc., the Company is further enhancing its product value by developing a rare earths separation plant in the United States. This facility will process mixed rare earth carbonates sourced from Aclara's mineral resource projects, separating them into pure individual rare earth oxides. Additionally, Aclara through a joint venture with CAP, is advancing its alloy-making capabilities to convert these refined oxides into the alloys needed for fabricating permanent magnets. This joint venture leverages CAP's extensive expertise in metal refining and special ferro-alloyed steels. Beyond the Carina Project and the Penco Module, Aclara is committed to expanding its mineral resource portfolio by exploring greenfield opportunities and further developing projects within its existing concessions in Brazil, and Chile, aiming to increase future production of heavy rare earths.

Forward-Looking Statements

This news release contains "forward-looking information" within the meaning of applicable securities legislation, which reflects the Company's current expectations regarding future events, including statements with regard to: mineral continuity, grade, metallurgical recoveries, methodology, production timing and upside at the Project, the Company's exploration plan, drilling campaigns and activities in Brazil and the expectations of the Company's management as to the timing, cost, scope and results of such exploration works and drilling activities in Brazil, the timing and obtaining of environmental and other Project licenses, the timing and planning of construction works and production schedules, the results and interpretation of the PFS, the expected timing of the filing of a feasibility study for the Project, management's expectations as to production forecasts and product quality for the Project, the continued support and investment of the Company's shareholders and other strategic partnerships, management of the Company's expectations as to market outlook and pricing for REE, the expected timing of approval of the EIA and the expected timing and approval process of the permitting process of the Project. Forward-looking information is based on a number of assumptions and is subject to a number of risks and uncertainties, many of which are beyond the Company's control. Such risks and uncertainties include, but are not limited to risks related to operating in a foreign jurisdiction, including political and economic problems in Brazil; risks related to changes to mining laws and regulations and the termination or non-renewal of mining rights by governmental authorities; risks related to failure to comply with the law or obtain necessary permits and licenses or renew them; compliance with environmental regulations can be costly; actual production, capital and operating costs may be different than those anticipated; the Company may be not able to successfully complete the development, construction and start-up of mines and new development projects; risks related to mining operations; and dependence on the Carina Project. Aclara cautions that the foregoing list of factors is not exhaustive. For a detailed discussion of the foregoing factors, among others, please refer to the risk factors discussed under "Risk Factors" in the Company's annual information form dated as of March 20, 2025, filed on the Company's SEDAR+ profile. Actual results and timing could differ materially from those projected herein. Unless otherwise noted or the context otherwise indicates, the forward-looking information contained in this press release is provided as of the date of this press release and the Company does not undertake any obligation to update such forward-looking information, whether as a result of new information, future events or otherwise, except as expressly required under applicable securities laws.

For further information, please contact:

Ramón Barúa Costa
Chief Executive Officer
investorrelations@aclara-re.com


[1] Annual average does not consider the first year of ramp-up and the last year of ramp-down.

[2] Estimate of China's official production of Dy and Tb in 2024 based on quotas published that year by the Ministry of Industry and Information Technology of the People's Republic of China

[3] Purity is expressed as REO equivalent.

[4] China has reached to an agreement with the United States to remove export restriction on all REE for one year until November 2026.

[5] Annual average does not consider the first year of ramp-up and the last year of ramp-down.

[6] Argus Media is an independent price reporting agency and market intelligence provider specializing in energy and critical minerals. With over 15 years of rare earths market, Argus Media delivers transparent benchmark pricing, supply-demand analysis, and long-term forecasts. Argus Media' independent data and expertise support accurate market assessments for project evaluations.

[7] Free on board (FOB) prices are associated with a seller who is responsible for the goods until they are loaded onto the ship or other transport vehicle at a specific location.

[8] Cost, Insurance, Freight (CIF): Under CIF terms, the seller arranges and pays for the cost of transporting the goods to the named port of destination, including insurance and freight charges. However, the risk of loss or damage to the goods transfers from the seller to the buyer once the goods are loaded onto the vessel at the port of shipment.

SOURCE: Aclara Resources Inc.



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