High-Pressure Filtration Leads To Better Tailings Management in Mining Sites

High-Pressure Filtration Leads to Better Tailings Management in Mining Sites

Many mining operations rely on tailings dams to store byproducts from ore processing. However, these dams can fail, posing serious risks to people, the environment, and a company’s bottom line. In recent years, events like the Brumadinho dam collapse have demonstrated the dangers of relying on outdated tailings management strategies. As regulatory pressure intensifies, the industry needs safer, more efficient alternatives—such as high-pressure filter presses—to handle tailings responsibly.

What Are Tailings in Mining?

When minerals like gold or iron are extracted from ore, the leftover material—known as tailings—contains fine mineral particles mixed with water. This slurry can be large in volume; for example, every ton of hard coal mined can produce about half a ton of waste. Tailings can be challenging to store and stabilize, especially since leftover metals and minerals may generate acids when exposed to air or water.

Because tailings can contaminate local water sources, proper handling and treatment are essential. Regulators and communities alike expect mining operations to manage these waste materials without endangering ecosystems or nearby populations.

Why Are Tailings Dangerous?

Tailings dams are a common storage solution, but their failure rate is higher than many other dam types. Common causes include:

• Liquefaction: Earthquakes and natural disasters that destabilize the dam structure
• Risky Upstream Constructions: Adding new “steps” on top of tailings, which can be unpredictable building materials
• Structural Weaknesses: Uneven ground or poor-quality control during construction
• Bad Designs: Flawed engineering leading to drainage problems and waterlogged sediments

When a tailings dam collapses, it can unleash massive amounts of toxic slurry, causing environmental devastation and loss of life. The ramifications for mining companies include hefty fines, legal action, and reputational damage.

How Can We Reduce Mining Tailings?

A safer, more sustainable approach involves reducing or eliminating the need for tailings dams. Mechanical filtration and proper wastewater treatment help achieve this goal. Several technologies exist, but some are more efficient than others.

1. Hydrocyclones

   • Cost-effective for removing large volumes of solids
   • Use centrifugal forces, requiring no additional chemicals
   • Cannot remove ultra-fine particles, making secondary filtration necessary

2. Belt Filters

   • Compact and initially less expensive
   • Require high doses of chemical flocculants
   • Belt wear leads to frequent maintenance and downtime

3. Filter Presses

   • Among the oldest, most trusted dewatering solutions
   • Pump slurry through filter plates, separating liquids from solids
   • High-pressure filter presses outperform low-pressure units by handling tougher slurries with greater efficiency

The Power of High-Pressure Filter Presses

High-pressure Matec® filter presses from ChemREADY introduce a game-changing solution for tailings management. They operate at 16 to 21 bar to tackle even the most challenging mining slurries.

Key Advantages:

• Less Chemical Use: Lower consumption of flocculants compared to other equipment
• Reduced Maintenance: Engineered for minimal downtime
• Highly Stable Cakes: Dewatered solids are easy to stack, transport, or dispose of safely
• Advanced Features: Automatic washing, remote monitoring, and gasser shakers for easy cake discharge

Better Tailings Management with ChemREADY

At ChemREADY, we help mining operations move beyond tailings dams to safer, more efficient practices. Our team performs comprehensive wastewater analyses, selecting the right blend of chemical treatments—such as flocculants—and mechanical solutions, including ultrafine recovery and clarifiers. High-pressure Matec® filter presses can then finalize the dewatering process, producing stable, stackable cakes and reclaiming clean water.

Benefits of ChemREADY’s Tailings Solutions:

• Eliminate or drastically reduce tailings pond usage
• Reduce environmental risk and regulatory concerns
• Improve workplace safety and operational efficiency
• Lower overall treatment costs over the long term

Ready to upgrade your tailings management?
Contact ChemREADY today or request a quote and brochure to learn how high-pressure filtration can revolutionize your mining operations. With the right combination of chemicals and filter press technology, you can enhance safety, protect the environment, and operate more sustainably.