Optimizing Tailings Management of large TSFs with the implementation of mechanical consolidation and dewatering

Oscar Santiago1*, Rafael Menezes2 and William McAdam3

1. Global Tailings Principal, Tailings Technology, Phibion, Australia

2. AMC Tailings Specialist, Tailings Technology, Phibion, Chile

3. AMC Tailings Specialist, Tailings Technology, Phibion, Australia

ABSTRACT

The responsible extraction of critical minerals is essential to support the global transition toward

decarbonisation. The International Council on Mining and Metals (ICMM) introduced guidelines

promoting responsible tailings and water management. This study presents the outcomes of a large-

scale industrial trial designed to evaluate the effectiveness of mechanical consolidation in improving

water recovery and tailings deposition efficiency within a conventional tailings storage facility (TSF).

The trial was conducted at an active TSF located in a geologically complex and topographically

constrained region.

A significant operational challenge at this site involved the accumulation of large

volumes of water in upstream valleys with limited drainage toward the decant pond, disconnected

areas reduced reclaim water availability and increased reliance on fresh water. An Accelerated

Mechanical Consolidation (AMC) strategy was deployed across selected upstream zones. AMC

applied controlled mechanical effort to tailings to consolidate material, displace interstitial water,

and improve surface drainage conditions.

The 14-month monitoring period included bathymetric and topographic surveys, remote sensing,

weather data, and continuous operational tracking. As a result of the intervention, a total of 569,000 m³

of water was liberated and redirected to the decant pond, supporting stable reclaim supply for ore

processing. A reduction of nearly 400,000 m³ in upstream ponded volume, indicating improved

hydraulic connectivity and drainage performance. Concurrently, the surface elevation of tailings in

upstream valleys increased by over 2 metres, even in water-covered zones, demonstrating the ability

of AMC to promote deposition under submerged conditions. Cross-sectional analysis of the beach

profile showed a progressive smoothing of the surface and restoration of the hydraulic gradient

toward the decant pond. This improved the flow path for surface water and reduced the likelihood

of isolated pond formation, particularly during periods of high slurry discharge.

The trial also enhanced tailings storage efficiency by converting non-productive ponded areas into

functional deposition zones while minimising water retention near structural components.

Mechanical consolidation proved to be a scalable, cost-effective method for improving tailings

performance and water recovery in a conventional large TSF. These results reinforce the solution as

a viable alternative to capital-intensive tailings systems, especially in existing or constrained sites

where retrofit options are limited.

The full White paper will be published after the oral presentation at Gecamin Chile