Throughout the long history of mining development, tailings treatment has consistently been a critical and highly regarded aspect. How to process tailings efficiently and environmentally, maximize resource utilization, and minimize environmental impact has become a persistent challenge for numerous mining enterprises and related technology companies.

I. The Importance and Challenges of Tailings Treatment

   The mining process inevitably generates substantial amounts of tailings. According to statistics, China produces approximately 110 million tons of iron tailings annually, with an average grade of around 11%. If these iron tailings undergo re milling of ores (reprocessing), yielding iron concentrate with a grade of 60% and a recovery rate of 2%–3%, an additional 3–4 million tons of iron concentrate could be obtained each year—equivalent to the output of a large iron ore processing plant (data cited from the Mine Solid Waste Think Tank). Improper handling of these tailings not only consumes significant land resources but also poses serious risks of soil, water, and ecological contamination, as well as safety hazards such as tailings dam failures. Moreover, tailings contain valuable recoverable mineral resources; their direct disposal would undoubtedly represent a waste of these resources.

   Traditional tailings treatment methods exhibit certain limitations in terms of efficiency, environmental sustainability, and resource recovery. To address these challenges, there is an urgent need for more advanced and scientifically sound technologies and equipment to enhance tailings processing. The introduction of Honghe Technology’s dewatering screening system has undoubtedly brought new hope to the entire industry.

II. Efficient dehydration for double the result with half the effort

   The primary advantage of Honghe Technology’s dewatering screen in tailings treatment lies in its exceptional dewatering capability. Tailings typically contain high moisture content, which not only complicates subsequent processing and transportation but also hinders their storage and reuse. The dewatering screen developed by Honghe Technology employs advanced screening and dewatering technologies to rapidly and accurately remove moisture from tailings, achieving the desired moisture content standard.

   Through its unique vibration system and meticulously designed screen structure, the tailings are evenly distributed across the screen surface. Under high-frequency vibrations, moisture rapidly passes through the screen and is discharged, while solid particles remain on the screen surface, achieving efficient separation of tailings from water. Compared to traditional dewatering equipment, this system significantly reduces dewatering time, enhances processing efficiency, and saves valuable time and costs throughout the entire tailings treatment process.

III. Stable and durable, reducing costs

   In the complex and high-intensity operating environment of mining, the stability and durability of equipment are paramount. Recognizing this, Honghe Technology employs high-quality wear-resistant materials in the production of dewatering screens. Every component—from the screen frame to the screen mesh—is subjected to rigorous quality inspections and process optimization, ensuring long-term stable performance and minimizing downtime, maintenance time, and associated costs caused by equipment failures.

   Moreover, its rational structural design reduces the equipment’s energy consumption, ensuring efficient tailings treatment while significantly cutting energy costs for the company. From a long-term operational perspective, this is undoubtedly a highly cost-effective investment that enables mining enterprises to achieve both economic and environmental benefits in their tailings management processes.

Tailing treatment methods

Iron Tailings Treatment – Tailings Remilling of ores

Currently, China produces approximately 110 million tons of iron tailings annually, with an average grade of around 11%. If the iron tailings undergo remilling of ores, the recovered iron concentrate—with a grade of 60% and a yield of 2% to 3%—could yield an additional 3 to 4 million tons of iron concentrate per year, equivalent to the output of a large iron ore processing plant.

Under current technological conditions, mineral composition analysis of iron tailings is conducted based on their specific properties. Subsequently, valuable minerals are recovered and reprocessed using magnetic separation, gravity separation, flotation, or combined processes, transforming waste into resources. This approach not only contributes to environmental protection but also positively impacts the long-term development of enterprises.

1. Iron Tailings Treatment – Dry Discharge of Tailings

The disposal methods for iron tailings are categorized into wet discharge and dry discharge. Wet discharge is a relatively traditional method that carries numerous potential risks and imposes stringent requirements on tailings ponds. In contrast, the dry discharge method is significantly more efficient. Dry tailings disposal involves concentrating and dehydrating tailings to produce material with a moisture content (mass percentage) of 10%±2%, which is then transported to tailings ponds or stockpiles for storage or reuse. The dry tailings disposal system primarily consists of slurry pumps, hydraulic cyclones, high-efficiency modified thickeners, high-frequency high-efficiency dewatering screens, chamber filter presses, and mineral slurry conveying equipment. Tailings are pumped by slurry pumps to hydraulic cyclones for concentration and classification; the sediment settled in the cyclones is sent to the high-frequency high-efficiency dewatering screens for dehydration, while the overflow flows into the high-efficiency modified thickeners for further concentration. Coarse-grained tailings processed by the screens are transported via belt conveyors to storage yards. Tailings concentrated by the high-efficiency modified thickeners are then pumped by slurry pumps to chamber filter presses for filtration, with the filter cakes discharged onto belt conveyors, while fine-grained tailings are stored in designated yards.

The dry tailings discharge method alleviates pressure on tailings ponds and reduces safety risks, while significantly lowering technical system investments and energy consumption. Its notable economic benefits lay the foundation for realizing the vision of zero-tailings mining and green mining practices.