732 XXXI International Mineral Processing Congress 2024 Proceedings/Washington, DC/Sep 29–Oct 3
contributing to the escalating demand for water. This
surge in water demand can be attributed to the significant
expansion of existing mines and the development of new
projects. Furthermore, there is a significant increase in cop-
per, gold and iron extraction and production due to the
diminishing grades at established mines. As grades decline,
more ore must be processed to yield the same amount of
metal. Since water usage is directly proportional to the
processed ore volume, it follows that a greater amount of
water is required to produce the same quantity when grades
are on the decline. The exploitation of extensive ore depos-
its with decreasing grades has prompted the utilization of
large, efficient equipment for ore milling and processing.
These enhance production rates, concurrently leading to an
increased demand for water in these metallurgical processes
[Cacciuttolo and Scognamillo, 2014].
Inadequate containment of mine tailings can lead to
catastrophic consequences, and errors in their storage and
management are the primary cause of severe global impacts
on the public [Bowker and Chambers, 2017]. Water
plays a crucial role in influencing the behavior of tailings.
Therefore, recovering water from tailings impoundments is
a common strategy to promote water reuse and mitigate the
risks associated with tailings dams, particularly in regions
facing water scarcity [Ritcey, 2005].
For most operational and planned mines worldwide,
traditional tailings impoundments continue to be the pri-
mary choice. These facilities are typically constructed using
tailings slurries, which constitute the final waste prod-
uct of the milling process. A typical tailings storage facil-
ity comprises a dam, a beach formed by the discharge of
tailings slurry, and fine sand to silt and clay slimes posi-
tioned farthest from the dam in a layer that is sufficiently
impermeable to maintain an overlying pond [Kempton et
al., 2010l]. Despite requiring a high percentage of water,
approximately 70%, this method is chosen for its cost-
effectiveness [Adiansyah et al., 2015]. The construction
and ongoing maintenance of these impoundments are vital
for ensuring the structural integrity of the retention struc-
tures and the storage and management of large volumes of
water. Once these facilities have been in operation, clos-
ing these impoundments can present significant challenges
during reclamation and for long-term geotechnical stability
considerations.
Conventional slurry tailings, when deposited in spe-
cifically designed impoundments, necessitate considerable
water usage and pose various challenges regarding engi-
neering, operations, environmental considerations, and the
complexities of long-term closure. Innovative dewatering
methods, such as paste and thickened tailings, characterized
by higher solids content ranging from 60% to 70%, have
been successfully applied in specific operations, even when
deposited in a saturated state. [Cacciuttolo and Valenzuela,
2022].
In conclusion, traditional slurry tailings present sub-
stantial challenges related to water usage, engineering,
operations, and environmental considerations. Enhanced
dewatering approaches like paste and thickened tailings
have been innovatively developed to tackle these challenges,
providing more sustainable solutions for effective tailings
management.
Enhanced dewatering approaches like paste and thick-
ened tailings, featuring higher solids content, have shown
successful application in certain operations, although
deposited while saturated. Nonetheless, in numerous sce-
narios, storing tailings in a partially saturated condition,
often called dry stacking, offers several advantages com-
pared to conventional saturated slurry tailings. Filtered
tailings and dry stacking have consequently garnered con-
siderable interest, owing to recent advancements in filtra-
tion technology, water scarcity, regulatory demands, and
the acknowledgment of life cycle cost benefits.
Recent incidents involving the failure of tailings facilities
that used conventional slurry deposition have heightened
the urgency to explore tailings filtration and dry stacking to
enhance safety and mitigate risks. Unfortunately, there are
significant knowledge gaps in the engineering design and
operation of large-scale filtered tailings and geo-stable dry
stacks because case records of their operations are limited.
Thickened tailings (TT) and filtered tailings (FT)
reduce the water content of tailings but are considered
energy-intensive and, consequently, more expensive.
Nevertheless, implementing these technologies can lead to
reduced costs at mine closure [Fourie, 2012], and [Franks
et al., 2011]. Various studies suggest that emerging tech-
nologies like TT and FT represent a significant advance-
ment in the mining industry as they rely more heavily on
recycled water, thereby reducing freshwater consumption
[Moolman and Vietti, 2012]. Additional advantages of TT
and FT, compared to conventional tailings disposal, include
a smaller environmental footprint, diminished potential
for acid mine drainage, decreased risk of dam failure, and
higher reagent recovery [Boger, 2013].
The current best available practice to reduce the poten-
tial liquefaction of tailings, which can lead to dam failures
and potentially devastating runout consequences, is to
dewater the tailings via filtration. Filtration is a well-devel-
oped technology with mixed results when filtering tailings.
Its effectiveness can be adversely impacted by high clay con-
centrations in the tailings. The adverse results can be even
contributing to the escalating demand for water. This
surge in water demand can be attributed to the significant
expansion of existing mines and the development of new
projects. Furthermore, there is a significant increase in cop-
per, gold and iron extraction and production due to the
diminishing grades at established mines. As grades decline,
more ore must be processed to yield the same amount of
metal. Since water usage is directly proportional to the
processed ore volume, it follows that a greater amount of
water is required to produce the same quantity when grades
are on the decline. The exploitation of extensive ore depos-
its with decreasing grades has prompted the utilization of
large, efficient equipment for ore milling and processing.
These enhance production rates, concurrently leading to an
increased demand for water in these metallurgical processes
[Cacciuttolo and Scognamillo, 2014].
Inadequate containment of mine tailings can lead to
catastrophic consequences, and errors in their storage and
management are the primary cause of severe global impacts
on the public [Bowker and Chambers, 2017]. Water
plays a crucial role in influencing the behavior of tailings.
Therefore, recovering water from tailings impoundments is
a common strategy to promote water reuse and mitigate the
risks associated with tailings dams, particularly in regions
facing water scarcity [Ritcey, 2005].
For most operational and planned mines worldwide,
traditional tailings impoundments continue to be the pri-
mary choice. These facilities are typically constructed using
tailings slurries, which constitute the final waste prod-
uct of the milling process. A typical tailings storage facil-
ity comprises a dam, a beach formed by the discharge of
tailings slurry, and fine sand to silt and clay slimes posi-
tioned farthest from the dam in a layer that is sufficiently
impermeable to maintain an overlying pond [Kempton et
al., 2010l]. Despite requiring a high percentage of water,
approximately 70%, this method is chosen for its cost-
effectiveness [Adiansyah et al., 2015]. The construction
and ongoing maintenance of these impoundments are vital
for ensuring the structural integrity of the retention struc-
tures and the storage and management of large volumes of
water. Once these facilities have been in operation, clos-
ing these impoundments can present significant challenges
during reclamation and for long-term geotechnical stability
considerations.
Conventional slurry tailings, when deposited in spe-
cifically designed impoundments, necessitate considerable
water usage and pose various challenges regarding engi-
neering, operations, environmental considerations, and the
complexities of long-term closure. Innovative dewatering
methods, such as paste and thickened tailings, characterized
by higher solids content ranging from 60% to 70%, have
been successfully applied in specific operations, even when
deposited in a saturated state. [Cacciuttolo and Valenzuela,
2022].
In conclusion, traditional slurry tailings present sub-
stantial challenges related to water usage, engineering,
operations, and environmental considerations. Enhanced
dewatering approaches like paste and thickened tailings
have been innovatively developed to tackle these challenges,
providing more sustainable solutions for effective tailings
management.
Enhanced dewatering approaches like paste and thick-
ened tailings, featuring higher solids content, have shown
successful application in certain operations, although
deposited while saturated. Nonetheless, in numerous sce-
narios, storing tailings in a partially saturated condition,
often called dry stacking, offers several advantages com-
pared to conventional saturated slurry tailings. Filtered
tailings and dry stacking have consequently garnered con-
siderable interest, owing to recent advancements in filtra-
tion technology, water scarcity, regulatory demands, and
the acknowledgment of life cycle cost benefits.
Recent incidents involving the failure of tailings facilities
that used conventional slurry deposition have heightened
the urgency to explore tailings filtration and dry stacking to
enhance safety and mitigate risks. Unfortunately, there are
significant knowledge gaps in the engineering design and
operation of large-scale filtered tailings and geo-stable dry
stacks because case records of their operations are limited.
Thickened tailings (TT) and filtered tailings (FT)
reduce the water content of tailings but are considered
energy-intensive and, consequently, more expensive.
Nevertheless, implementing these technologies can lead to
reduced costs at mine closure [Fourie, 2012], and [Franks
et al., 2011]. Various studies suggest that emerging tech-
nologies like TT and FT represent a significant advance-
ment in the mining industry as they rely more heavily on
recycled water, thereby reducing freshwater consumption
[Moolman and Vietti, 2012]. Additional advantages of TT
and FT, compared to conventional tailings disposal, include
a smaller environmental footprint, diminished potential
for acid mine drainage, decreased risk of dam failure, and
higher reagent recovery [Boger, 2013].
The current best available practice to reduce the poten-
tial liquefaction of tailings, which can lead to dam failures
and potentially devastating runout consequences, is to
dewater the tailings via filtration. Filtration is a well-devel-
oped technology with mixed results when filtering tailings.
Its effectiveness can be adversely impacted by high clay con-
centrations in the tailings. The adverse results can be even