Enhancing Tailings Management Through Optimised In-Situ Dewatering and Consolidation
- johncastiblanco
- Jul 23
- 3 min read
Updated: Oct 7
Brisbane, Australia — As tailings management continues to top the priority list for mine operators worldwide, Phibion is proud to present its latest white paper at the upcoming Life of Mine Conference (LOM 2025). "Enhancing Tailings Management Through Optimised In-Situ Dewatering and Consolidation", this new study introduces a practical, data-driven framework that could reshape how the industry tackles stability, storage, and sustainability challenges in Tailings Storage Facilities (TSFs).*
The Importance of In-Situ Dewatering
Tailings are the slurry-like byproducts of mineral extraction. They present significant environmental and geotechnical challenges for the mining industry. As global tailings volumes continue to rise, the demand for reliable, scalable, and affordable solutions to strengthen stored material, recover water, and reduce risk has never been greater.
Traditional methods, such as filtration and dry stacking, are effective. However, they can be expensive and difficult to scale, particularly for legacy facilities. Phibion’s AMC™ (Accelerated Mechanical Consolidation) offers a cost-effective alternative. This innovative approach dramatically improves tailings strength and reduces consolidation time without requiring additional infrastructure.
Overview of the White Paper
The white paper, co-authored by Dr. Oscar Santiago, Rodrigo Menezes, and Will McAdam, outlines a structured methodology. It combines in-situ dewatering and mechanical consolidation to convert weak, saturated tailings into dense, trafficable material. The process employs an amphibious vehicle (Amphirol) to apply controlled, cyclic mechanical loading across the tailings surface. This accelerates water removal and increases shear strength.
Key Outcomes from the Study
Some of the headline outcomes include:
Strength Increase: From <5 kPa to >30 kPa in under 60 days.
Storage Recovery: Over 300,000 m³ of tailings volume recovered at a copper TSF over four months.
Strength at Closure: Exceeding 50 kPa, enabling safe access for civil machinery.
Settlement Time Reduced: Up to 60 weeks saved compared to natural consolidation.
Real-World Validation of AMC
Field trials at large-scale copper and zinc operations in Chile and Australia have confirmed that AMC delivers consistent, measurable improvements across various tailings types. These range from low-plasticity copper silts to clay-rich zinc residues.
At a copper mine processing 180,000 tonnes/day, AMC recovered 6,692 m³/Ha of storage space and increased surface shear strength to >50 kPa.
At a zinc facility with inactive deposition for 7 years, the method achieved significant water removal and improved surface strength across 27 Ha, demonstrating its suitability for legacy impoundments.
Smarter Tailings Management Begins Here
What makes AMC® compelling is not just the machinery; it is the operational model. By aligning the AMC® process with tailings discharge plans and site-specific geotechnical conditions, operators can:
Decrease their capital and OPEX footprint.
Reduce facility heights and construction frequency.
Improve water recovery for reuse.
Minimise environmental risks and crust formation.
Extend the functional life of TSFs.
Moreover, AMC® supports real-time monitoring through LiDAR and in-situ testing. This provides engineers with dynamic insights into compaction, drainage, and material performance.
Beyond Compliance — Towards Resilience
This white paper supports the growing global movement toward safer, more sustainable tailings practices. It echoes commitments under the ICMM’s Global Industry Standard on Tailings Management. By strengthening residue, reducing seepage, and enabling earlier capping, AMC simplifies closure planning. This is a major cost centre for mines nearing end-of-life.
Join Us at LOM 2025
If you're attending the Life of Mine Conference in Brisbane, don’t miss the opportunity to speak with our authors and see the data first-hand. The Phibion team will be on-site to walk you through the results and answer your questions about implementation, integration, and future development of AMC.
Ready to rethink how your site manages tailings?
Get in touch with our team or download the full white paper.
Conclusion
In conclusion, the management of tailings is a critical aspect of mining operations. The innovative approach presented in the white paper can significantly enhance the sustainability and safety of tailings management. By adopting AMC, mining companies can address the pressing challenges of tailings storage while aligning with environmental and social responsibilities. This commitment not only benefits current operations but also ensures a safer and more sustainable future for generations to come.
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