Optimizing dewatering with Metso’s Filtration Plant Units: a simplified, systems-level approach

As global mining operations face increased pressure to improve water recovery, reduce tailings volume, and enhance environmental performance, filtration technologies have emerged as a key enabler. At the heart of these efforts lies a critical component – filtration plant units. Far beyond just filters, these integrated systems form the backbone of high-performance dewatering processes in modern mines.

Tailings filtration at scale

The evolution of tailings filtration now enables plants to handle throughputs of up to 100 kt/d, a key development as more sites adopt dry stacking to mitigate the long-term risks of conventional tailings storage. However, scaling filtration capacity is not solely a matter of equipment; it is closely linked to plant design, auxiliary systems, and execution strategies.

Filtration plants require a well-orchestrated combination of mechanical, structural, and control systems. The design choices made at the early stages, such as filter selection, flowsheet, layout, and sizing, can significantly influence the capital and operational expenditures (CAPEX and OPEX) of the entire plant. Testing feed materials early in the process is essential to ensure proper sizing and system compatibility. Notably, early testing remains one of the most cost-effective methods to mitigate risk.

Plant design: beyond equipment procurement

Industry experience shows that evaluating a filtration solution based solely on the filter unit can lead to unexpected costs down the line. While filter performance is fundamental, its efficiency is heavily influenced by supporting systems such as pumps, tanks, steel structures, process control, and EIA systems.

Plant-level costs do not scale linearly with equipment costs, and different filtration technologies may differ considerably in their cost distributions. Thus, a more accurate evaluation must account for the entire plant configuration, enabling comparisons based on total investment and life cycle costs rather than unit price alone.

Integrated Filtration Plant Units

Recognizing the need for a systems approach, Metso has developed modular Filtration Plant Units that integrate filters, feed systems, auxiliary equipment, and automation in a compact, scalable layout. These units are designed specifically for demanding dewatering applications, including concentrates, tailings, and industrial applications.

Metso’s two core offerings, the Larox® PF and Larox® FFP Filter Plant Units, are tailored for high-volume processing. The Larox® PF is optimized for concentrates, while the Larox® FFP excels in tailings filtration. Both units leverage design optimizations such as reduced elevation, efficient pump and piping layouts, and improved maintenance access. This results in enhanced reliability, improved safety, and increased availability.

The Larox® FFP 3716, in particular, is engineered for large-scale tailings filtration, capable of handling up to 14,000 t/day of coarse tailings and 10,000 t/day of fine tailings. The use of hole-less filter cloths eliminates the need for filling shoes, reducing air consumption and simplifying maintenance. This design leads to higher uptime and consistently low cake moisture, crucial for dry stacking efficiency.

Engineering support and Life Cycle Services

Designing a filtration plant is a complex task that requires deep expertise in both filtration and process integration. Metso’s Filtration Plant Units are supported by engineers with decades of experience in plant configurations and diverse filtration technologies. Backed by a comprehensive filtration portfolio and the unique world-class Dewatering Technology Center (DTC) in Finland, Metso provides end-to-end solutions – from bench-scale testing to commissioning and life cycle optimization.

The plant units are designed to integrate seamlessly into broader process flows, reducing the risk of operational mismatches and improving project execution timelines. The offering can be tailored from equipment-only delivery to full turnkey solutions, depending on the project’s scope and customer needs.

Streamlining tailings dewatering with an end-to-end solution

For mining operations seeking to enhance tailings management, water recovery, and overall efficiency, Metso’s Filtration Plant Units present a practical and technically robust solution. By shifting from isolated equipment procurement to a systems-level approach, operations can achieve higher reliability, improved cost predictability, and long-term sustainability.

In an industry where filtration capacity, cost optimization, and environmental responsibility are more critical than ever, engineering the right filtration plant is no longer just a good practice; it’s essential.