Sovereign Metals’ Kasiya Rutile Project is rapidly emerging as one of Africa’s most important mineral assets. Located just outside Malawi’s capital, Lilongwe, the deposit combines large-scale resources, high-grade mineralisation, and ready access to infrastructure, giving it the potential to reshape the nation’s economy while strengthening global titanium supply chains.
The project benefits from exceptional location advantages. Road and rail links provide a direct route to Mozambique’s Nacala deep-water port, while existing power supply and water resources reduce development hurdles. These features stand in contrast to many other African projects that require heavy upfront infrastructure spending before operations can even begin.
Global markets are already feeling the impact of tightening rutile supply, with output falling sharply over the last decade while demand for titanium continues to accelerate. Aerospace, defence, medical, and industrial sectors rely on titanium with little room for substitution, making security of supply a growing priority for Western economies. Against this backdrop, Kasiya’s emergence in a stable and strategically aligned jurisdiction is attracting international attention.
The resource itself is remarkable. Current estimates show over 2.1 billion tonnes of ore containing more than 21 million tonnes of rutile and 28 million tonnes of graphite. This scale places Kasiya on track to become the largest natural rutile operation in the world, with expected annual production of 222,000 tonnes of rutile—around 12% of global supply—plus 188,000 tonnes of graphite concentrate. The soft, free-dig ore and simple gravity-based processing deliver a high-purity product suited to premium applications, from pigment to aerospace-grade titanium metal.
Economic modelling underscores the project’s strength. Studies forecast a pre-tax NPV of US$2.3 billion, a post-tax IRR of 28.3%, and operating margins above 60%. With projected annual EBITDA of US$415 million and a payback period under three years, Kasiya ranks among the most attractive mining developments globally. The inclusion of graphite revenues adds another layer of resilience, creating a dual-commodity profile that reduces reliance on rutile prices alone.
Sustainability and community development are built into the project’s design. With no chemicals required in the main processing circuit, reduced carbon transport through rail, and progressive land rehabilitation, Kasiya aligns with international ESG expectations. Sovereign Metals has also prioritised local benefit through initiatives in healthcare, education, agriculture, and employment, ensuring surrounding communities share in the long-term value created.
A strategic partnership with Rio Tinto has provided additional momentum. The global miner brings technical expertise, financial support, and market reach, significantly de-risking development and accelerating progress. A definitive feasibility study is due in 2025, with production targeted for 2028–2029, positioning Kasiya to come online during a period of tightening global supply.
Kasiya is more than a resource project—it is a catalyst for national transformation. By diversifying Malawi’s economy beyond agriculture and establishing it as a critical supplier to global titanium and graphite markets, the project represents both an economic and strategic breakthrough. With its unmatched scale, premium product quality, and world-class partnerships, Kasiya is set to become a defining force in the future of critical minerals.
