Tailings management starts with the right cyclone Multotec’s cyclone specialists, Blane Pillai, Ernst Bekker and Erick Herbs discuss the use of cyclones for tailings management and the importance of matching each cyclone choice to the specific onsite factors that influence their performance.
management. No two TSFs are the same; each requires a tailored cyclone solution. “Tailings deposition is far more complex than people think, which is where correctly specified cyclones make the difference,” explains Ernst Bekker, process specialist for cyclones at Multotec. “When chosen and applied correctly, cyclones are more than just classification devices. They directly impact how efficiently tailings are deposited in a TSF, the stability of the TSF structure, and the effectiveness of water recovery for reuse in the plant. This means that the right cyclone can transform tailings management from a costly necessity into a driver of best practice standards for sustainable tailings management.” Selecting the appropriate cyclone for tailings management is therefore not a one- size-fits-all exercise, and several factors must be weighed carefully. Durability: Harsh operating conditions, abrasive material and considerable pressure spikes during start-up demand equipment that lasts. Multotec’s GV Cyclones were introduced after earlier polyurethane units frequently failed on TSFs due to fluctuating start-up pressures. Multotec engineered a spin-cast steel shell with a 12 mm bonded rub- ber lining to combine strength with longevity, while keeping the weight manageable. Cyclones designed with wear-resistant lin-
ings, durable composite construction materi- als and simplified maintenance requirements not only extend service life but also reduce downtime and operating costs. Erick Herbst, applications manager at Multotec, says, “cyclones may look simple, but we have put a lot of thought into durabil- ity, usability and maintenance because these are the factors that determine long-term performance in harsh tailings environments.” Ease of handling: A lightweight cyclone is faster to install and easier to move around on- site, facilitating quick modifications, upgrades and ore replacements without downtime. This is particularly important in tailings-dam environments, where cyclone relocation is done by hand. A 250 mm cyclone size has emerged as the most economical compromise, small enough to be easily handled, but large enough to reduce the number of units needed. A lightweight cyclone also requires a smaller tailings contractor team for operation and maintenance. The quick-release screw spigot couplings on Multotec’s GV Cyclones allow for easy spigot changeouts, which is vital because spigot wear directly affects underflow den - sity, wall stability, and overall TSF safety. Flexibility: The ability to alter the combi- nation of the cone angle, spigot and vortex finder of a cyclone to meet the specific op - erational parameters, material characteristics
T ailings management is a significant challenge for the mining industry and is under greater scrutiny than ever, as global industry standards call for safer, more sustainable practices. The rising demand for minerals and metals means that modern mines must raise throughput, control costs, and reduce their environmental footprint, all while responsibly managing their Tailings Storage Facilities (TSFs). Meeting these demands starts with a technology that is often overlooked but essential: the cyclone. Mining companies carry a long-term responsibility to manage tailings and waste material left behind after ore is processed and valuable minerals and metals extracted, from operation through to closure and even post-closure. This management is critical for preventing catastrophic failures, protecting human safety, and minimising environmental impacts. Responsibly managed TSFs are charac- terised by knowledgeable mine owners and tailings contractors who implement good engineering practices and use technologies that support safety, compliance, and ef- ficiency. While several factors influence cyclone selection, choosing the right one is crucial to ensuring efficient, cost-effective, and environmentally responsible tailings Multotec’s cyclone specialists, Blane Pillai, applications engineer, Ernst Bekker, process specialist for cyclones and Erick Herbst, applications manager.
Their lightweight, durable design, simple spigot change system, and adaptable components make Multotec's GV Cyclones an operator-friendly and technically reliable solution for tailings dams.
12 ¦ MechChem Africa • May-June 2026
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