XXXI International Mineral Processing Congress 2024 Proceedings/Washington, DC/Sep 29–Oct 3 733
more pronounced at large-scale throughputs, making filtra-
tion of the tailings either not possible, too expensive, and/
or simply too risky for an ongoing operation.
TNS™ TECHNOLOGY—BACKGROUND
AND INDUSTRY TAILINGS CHALLENGES
Challenges to the Filtration of Tailings
The increase in existing operational mine throughputs has
surpassed the progress in dewatering equipment develop-
ment in both throughput and advanced technology. The
present evolution of equipment has primarily been organic,
leading to dewatering plants presently characterized by
high capital and operational intensity and costs.
• The cost of dewatering is a new challenge to an
industry that traditionally operates on narrow profit
margins and is susceptible to market price cyclicality.
• Moreover, not all tailings can be dewatered with
existing technology. High concentrations of ultra-
fine and fine particles can hinder the dewatering
process. Additionally, certain minerals, particularly
surface-active clays, pose challenges to dewatering,
making filtration either impractical or prohibitively
expensive, especially if their presence is extensive.
• The variability in ore composition frequently exac-
erbates the challenge. While it’s feasible to design a
plant to accommodate a specific level of clay in the
feed, addressing significant fluctuations in clay con-
tent within the source ore and consequently in the
resulting tailings is a different and more complex
matter that requires new more robust treatments and
technologies.
TNS™ Technology
Historic Perspective
Extrakt Process Solutions LLC (EPS) has created an inno-
vative method for tailings dewatering called TNS ™. This
new chemistry and its application are similar to conven-
tional polymer technology. However, the effectiveness of
this cuttingedge technology significantly surpasses that of
traditional dewatering techniques.
TNS™ Dewatering Technology
Extrakt Process Solutions has introduced TNS ™, a simple
yet powerful technological solution -a novel and highly
efficient high-rate dewatering technology driven by propri-
etary chemistry. This cutting-edge technology showcases its
ability to handle streams with high clay content, including
particles smaller than 20 microns and slimes. TNS ™ rap-
idly and effectively dewaters tailings, producing a stackable
material, while simultaneously generating a clear recyclable
supernatant stream. This dewatering innovation represents
a straightforward yet robust advancement in swiftly and
efficiently extracting water from tailings.
The technology represents the fusion of a novel chem-
istry with an innovative process configuration designed for
dewatering tailings, utilizing conventional onsite equip-
ment readily available through existing industry supply
chains. Application of this chemistry is akin to conven-
tional polymer technology, yet its effectiveness sets it apart
significantly from this traditional approach.
In a preceding paper [Florman et al., 2021], EPS exam-
ined the most pressing challenges facing the current tailings
industry. They identified up to six (6) critical aspects, some
of these challenges are outlined below.
1. Increment in water demand.
2. Larger tailings storage facilities.
3. Challenges for the solid-liquid separation processes
(Thickener and Filtration).
EPS has introduced the engineered tailings concept, where
the tailings flowsheet is meticulously designed to improve
tailings characteristics via dewatering using this innovative
technology. Furthermore, this technology is well-equipped
to manage significant variations in tailings composition,
making it feasible to handle feedstock with high clay
content.
COPPER TAILINGS DEWATERING WITH
TNS™ TECHNOLOGY
Background
Two copper tailings samples were tested using this new
technology: one labelled as Sample from Producer #1 and
the other as Sample from Producer #2. Both samples were
taken from flotation tailings before flocculation, specifically
as thickener feed. Samples from Producer #1 and Producer
#2, originated from different sites within a similar mining
region.
Each sample was decanted and combined into a single
high solids concentration slurry, suitable for shearing and
more reliable sub-sampling. The decanted water was also
combined into one process water sample, to be used for
dilution as needed during the test program.
Methodology
Semi-Dynamic Cylinder Batch Settling and
Consolidation Test
The settling and consolidation tests were carried out
using a standard 2-litre raked cylinder test rig. This is a
batch test. The semi-dynamic cylinder batch settling and
more pronounced at large-scale throughputs, making filtra-
tion of the tailings either not possible, too expensive, and/
or simply too risky for an ongoing operation.
TNS™ TECHNOLOGY—BACKGROUND
AND INDUSTRY TAILINGS CHALLENGES
Challenges to the Filtration of Tailings
The increase in existing operational mine throughputs has
surpassed the progress in dewatering equipment develop-
ment in both throughput and advanced technology. The
present evolution of equipment has primarily been organic,
leading to dewatering plants presently characterized by
high capital and operational intensity and costs.
• The cost of dewatering is a new challenge to an
industry that traditionally operates on narrow profit
margins and is susceptible to market price cyclicality.
• Moreover, not all tailings can be dewatered with
existing technology. High concentrations of ultra-
fine and fine particles can hinder the dewatering
process. Additionally, certain minerals, particularly
surface-active clays, pose challenges to dewatering,
making filtration either impractical or prohibitively
expensive, especially if their presence is extensive.
• The variability in ore composition frequently exac-
erbates the challenge. While it’s feasible to design a
plant to accommodate a specific level of clay in the
feed, addressing significant fluctuations in clay con-
tent within the source ore and consequently in the
resulting tailings is a different and more complex
matter that requires new more robust treatments and
technologies.
TNS™ Technology
Historic Perspective
Extrakt Process Solutions LLC (EPS) has created an inno-
vative method for tailings dewatering called TNS ™. This
new chemistry and its application are similar to conven-
tional polymer technology. However, the effectiveness of
this cuttingedge technology significantly surpasses that of
traditional dewatering techniques.
TNS™ Dewatering Technology
Extrakt Process Solutions has introduced TNS ™, a simple
yet powerful technological solution -a novel and highly
efficient high-rate dewatering technology driven by propri-
etary chemistry. This cutting-edge technology showcases its
ability to handle streams with high clay content, including
particles smaller than 20 microns and slimes. TNS ™ rap-
idly and effectively dewaters tailings, producing a stackable
material, while simultaneously generating a clear recyclable
supernatant stream. This dewatering innovation represents
a straightforward yet robust advancement in swiftly and
efficiently extracting water from tailings.
The technology represents the fusion of a novel chem-
istry with an innovative process configuration designed for
dewatering tailings, utilizing conventional onsite equip-
ment readily available through existing industry supply
chains. Application of this chemistry is akin to conven-
tional polymer technology, yet its effectiveness sets it apart
significantly from this traditional approach.
In a preceding paper [Florman et al., 2021], EPS exam-
ined the most pressing challenges facing the current tailings
industry. They identified up to six (6) critical aspects, some
of these challenges are outlined below.
1. Increment in water demand.
2. Larger tailings storage facilities.
3. Challenges for the solid-liquid separation processes
(Thickener and Filtration).
EPS has introduced the engineered tailings concept, where
the tailings flowsheet is meticulously designed to improve
tailings characteristics via dewatering using this innovative
technology. Furthermore, this technology is well-equipped
to manage significant variations in tailings composition,
making it feasible to handle feedstock with high clay
content.
COPPER TAILINGS DEWATERING WITH
TNS™ TECHNOLOGY
Background
Two copper tailings samples were tested using this new
technology: one labelled as Sample from Producer #1 and
the other as Sample from Producer #2. Both samples were
taken from flotation tailings before flocculation, specifically
as thickener feed. Samples from Producer #1 and Producer
#2, originated from different sites within a similar mining
region.
Each sample was decanted and combined into a single
high solids concentration slurry, suitable for shearing and
more reliable sub-sampling. The decanted water was also
combined into one process water sample, to be used for
dilution as needed during the test program.
Methodology
Semi-Dynamic Cylinder Batch Settling and
Consolidation Test
The settling and consolidation tests were carried out
using a standard 2-litre raked cylinder test rig. This is a
batch test. The semi-dynamic cylinder batch settling and