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Mining filtration

Maximise efficiency and performance in mining filtration

Boost recovery and maximise throughput with FLS’s advanced filtration solutions. Our filters are designed to optimise cake recovery and filtrate quality, while standing up to the toughest operating conditions. With low maintenance and user-friendly operation, our filtration equipment sets the industry standard.

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Key benefits of mining filters

  • High efficiency and productivity

    With efficient solid/liquid separation and larger filter area, our filtration equipment is designed for high throughput and improved operational performance.

  • Reduced operating and maintenance costs

    Engineered for low maintenance and minimal operator intervention, our filtration solutions are designed to be low cost. We limit consumables, reduce power consumption where possible and simplify filter design to help reduce operating and maintenance expenses.

  • Optimised cake recovery and filtrate quality

    Our filter press and vacuum filters prioritise efficient cake formation and recovery, resulting in dry filter cakes with low moisture content, to enhance overall process efficiency and quality.

Pressure filters

Automatic Filter Press

The FLS automatic filter presses (AFPs) are pressure filters designed for large-scale liquid liquid solid separations with heavy duty rugged and reliable construction built to withstand the demands of the minerals processing industry.  Customisable with recess chamber plates, or membrane plates when required, pressures up to 16 bar are utilised to optimise production and minimise cake moisture. Filter plates are available in 900, 1200, 1500, 2000 and 2500 mm square sizes.

AFP 2500

With thousands of total installations, FLS filter presses have reliably provided solutions for customers in industries ranging from fine chemicals to mining and minerals processing, including hundreds of concentrate and tailings filter applications. We deliver decades of experience across all applications, from testing to operation, furthering our commitment to developing the best possible filter solutions.

Benefits include:

  • Lowest cost per tonne
  • Highest availability – averaging 93% in the field
  • Ultra-effective automatic cake discharge
  • Reliable cloth flood wash system
  • ICool cloth rejuvenation maintenance station
  • Robust design is built to last
  • Efficient operation with lower power usage
  • Optimised water recovery and lower environmental impact

The AFP2500 filter press uses high pressure and fast cycling to achieve significantly larger single-machine capacities compared to other filter types. Able to recover more than 200 m3 of water per hour, the filter is specifically designed to optimise large-scale filtered tailings dewatering. This means that in a typical mine operating at over 21,000 tonnes a day, a filter installation will recover enough process water to fill six Olympic swimming pools every 24 hours.

Some of the key features of the AFP include push closure-cylinders mounted at centerline of press, rolling cross head for plate stacks longer than 50 chambers, automatic cloth washing apparatus, and drip trays for liquid containment. Filter media is also available in a variety of materials and weave patterns to optimise the process for your specific application. The AFP is designed for quick open-close and cake discharge providing the industry’s lowest (or shortest) mechanical times allowing more production per unit filtration area.

Shriver® Filter Press

The Shriver® Filter Press is a critical player in optimising your dewatering process regardless of your industry. Fully customisable and highly efficient, this product’s cost effectiveness matches its rugged dependability.

Benefits include:

  • Over 100 years’ experience in process and design with over 30 000 installed units worldwide
  • U.S. technologies combined with local manufacturing, local service, and OEM spare parts support
  • Plate sizes up to 2000mmm x 2000mm
  • Recessed Chamber or Membrane Plates as required for your application
  • Easy operation and maintenance
  • Safe pneumatically or electrically operated controls
  • Minimum weight and space requirements
  • Maximum area and volume
  • Flexibility in design
  • Efficient cake washing
  • Food-grade construction (optional)
  • Complete corrosion resistance (optional)

Filter presses offer drier cakes at lower cost than other dewatering devices. They consist of two basic components: a skeleton frame and a filter plate stack. Regardless of the construction or methods of control and operation, filtration is achieved by clamping the plates together under hydraulic closing force and pumping slurry under pressure into the cavities formed between the closed plates. Filter media lines the chambers and captures solids while permitting clarified liquid to pass through. Filtration proceeds until a cake is formed in the chambers or a preset pressure is reached. By unclamping and shifting the plates, the cake drops from the chambers and the filter is ready to repeat the operation. Filtration rate is dependent on feed pressure, thickness of the cake, slurry temperature and viscosity, nature of the cake solids, and filter media.

Typical Shriver selection considerations

  • Filter model selection (automatic/semi-automated as required)
  • Filter Press Frame (pressure ratings; 8 or 16 bar)
  • Filter plate pack & cloth selection (application specific)
  • Hydraulic Power Unit (electrically or pneumatically operated)
  • Plate Shifting & Cloth Washing (manual or automatic discharge)
  • Membrane squeeze components (if required)
  • Process piping (manual or automated valves)
  • Cake discharge (drip trays, chutes, conveyors)
  • Controls & Instrumentation (for site specific requirements)
  • Ancillaries (pumps, compressors. etc.)

Maxa Filter Plate

The unique design of the Maxa Filter Plate resolves common issues related to filter plate performance, including area, volume, flow and durability, granting users as much as 10% more volume, improved filtration times and longer plate lifecycle for your AFP.

Benefits include:

  • 3 – 5% increase in filtration area and 15% more filtrate open area
  • 5 – 10% more volume, allowing for increased cake mass per cycle
  • Engineered port locations and size to promote filtrate flow and eliminate areas that fatigue filter media
  • Increased filtrate port area reduces velocity of filtrate and cake blow air, extending plate life

We improved the AFP filter plate’s physical characteristics to increase cloth life and maximise productivity.

Expanded filtration surface area

  • Optimised staybosses and sealing surface
  • Maximum energy transfer with pip pattern design
  • Expanded cake formation for greater cake volume
  • Streamlined filtrate path from edge to edge

Streamlined plate anatomy

  • Air for cake blow is introduced at a lower velocity to reduce abrasion
  • Modified interfaces between the plate and cloth provides greater support, minimising high stress areas on the filter cloth
  • Better pip design provides more consistent cloth support
  • Engineered port locations and size promote filtrate flow

Pneumapress® Filter

The Pneumapress Filter’s clean design creates highly efficient solid/liquid separation, greater availability, easier operating and simpler maintenance.

The Pneumapress Filter uses a remarkably simple filtration system that both dramatically improves solid and filtrate production and reduces costs. In a test measuring the production rates of automatic filter presses, it was shown that the Pneumapress can exceed production rates by more than 1000% that of the competitor.

Benefits include:

  • Isolatable plates deliver higher overall availability
  • High production rates require less filtration area
  • Low OPEX and long operating life
  • TCO on average 33% less than other tower press filters
  • Easy to use and maintain
  • Highly adaptable to processing requirements

Conventional filter presses can be complicated and come with a multitude of devices, piping and equipment. The Pneumapress design eliminates the need for these bulky parts of the product. It also eliminates consumable items such as diaphragms, elastomer impregnated filter media, carrier belts membrane squeeze pumps and other equipment.

Since the Pneumapress Filters are simple, versatile and use very few consumable items, they are compatible with many different applications. They even work well with specialised applications such as processing corrosive and/or high-temperature streams. Even under these circumstances, the filter produces dry and uniform solids and high-quality filtrate. The Pneumapress can produce a filter cake up to 96% solids, and unlike other filters, the filter cake thickness can vary by simply adjusting feed parameters.  Their design also makes them simple to maintain and operate.

Compatible applications

  • Mineral processing
  • Hydrometallurgy
  • Sludge dewatering
  • Chemical dewatering
  • Food processing
  • Concentrates

There have been rapid advances in media technology since the creation of the Pneumapress, which produces higher quality filter cakes and filtrate. The new filtration media influences producing a dry cake, effectively washing the cake, producing clean filtrate and for a long filter media life. The Pneumapress Filter is adaptable to the most efficient filter media suited for each application.

Vacuum filters

Horizontal Belt Filters

Horizontal Belt Filters provide you with high extraction efficiency, low cake moisture, increased production and reduced operating costs.  Our filters are suited for fast filtering materials, concentrates, and tailings, and can be configured for counter-current washing to maximise recovery while minimising water use.

Benefits include:

  • Optimised operation for the material and process requirements
  • Low maintenance, quick cloth changes, continuous filter washing
  • Minimal operation intervention required – usually just a periodic check
  • Low installation cost, can be shipped fully assembled

The most important component of the filter is the drainage belt. Drainage belts are uniquely designed for each application to suit the process and environment. Each one provides:

  • Uniform filtration
  • Mechanical strength
  • Chemical resistance

Counter Current Washing (CCW) Filters lower costs, increase circuit recovery and provide the operational simplicity and service reliability you demand. With more than 1500 units installed, FLS has more experience than any other manufacturer.

The better your filters, the more pure the cakes that come from Counter Current Washing (CCW). Our rollerdeck horizontal belt filter (HBF) design provides your operation with the best process performance at the lowest maintenance and power costs. Benefits include:

  • How CCW Filters can benefit your operation
  • Flexible operating range across a wide variety of applications
  • High product recovery and reduced cake moisture
  • Reduced operating and maintenance costs
  • Full and continuous service support
  • Capable of handling even the most corrosive applications

When recommending the best solution for your application, we consider particle size distribution, suspended solids distribution, wash ratio, number of thickeners or wash zones, wash liquor soluble metal concentration, and interstage mixing efficiency. We’ll carry out test work and careful planning to maximise wash efficiency and optimise product recovery.

Vacuum Disc Filter

The FLS Agi-Disc and E-Disc Filters deliver high dewatering efficiency and exceptional throughput for reliable, high-capacity filter cake production with low moisture content. Its advanced features include:

  • Improved process efficiency: Enhanced design for greater performance, including reduced maintenance, lower energy consumption, and optimised operational costs.
  • Durability and reliability: Key components like a trunnion bearing with grease lubrication and a robust, hard metric design ensure long-lasting performance and easy maintenance.
  • Adaptable design: Configurable to meet various industrial requirements, with options for different motor drives and high-capacity valve and bearing solutions, ensuring compatibility with your operations.
  • Cost savings: The advanced, cost-effective design reduces energy consumption and minimises maintenance needs, resulting in lower overall operational expenses.

Perfect for industries requiring high-quality paste backfill, our disc filters offer a reliable, adaptable, and cost-effective solution to optimise your production process.

Want to talk? Reach out to our experts.

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Additional filtration solutions

Granular media filtration is a cornerstone of effective liquid-solid separation, widely used across industries for removing suspended solids from water, wastewater, and various process liquids. At FLS, we’ve been leading the way in this technology for over 50 years, offering tailored solutions that meet the unique demands of your operations. Central to our granular media filters is the underdrain system, which ensures optimal filtration performance by managing backwash distribution, preventing media escape, and maintaining the integrity of the filter media. FLS has partnered with AWI, the global leader in underdrain technology, to offer a system that ensures accurate flow distribution, durability, and efficient cleaning — key to achieving long production runs and minimising maintenance.

For applications where large volumes need to be treated cost-effectively, the OTG™ (Open-Top Gravity) filter is the perfect choice. Designed with flexibility in mind, OTG filters can handle varying headlosses and feed water qualities while offering high filtration rates through deep, multi-media beds. Their versatile design can accommodate a range of backwash processes, including combined air and water, making them ideal for treating challenging feed streams or biological effluents. Available in circular and rectangular tank designs, OTG filters provide robust, low-maintenance filtration, with optional self-backwashing control systems for uninterrupted performance.

When pressurised feed streams are involved, the Vertical Pressure Filter (VPF) is your go-to solution. Built to handle deeper filter beds and higher solid loadings, the VPF is engineered for heavy-duty filtration and is ideal for applications where reliability and high capacity are a must. Featuring FLS's advanced AWI® stainless steel underdrains, the VPF provides exceptional flow distribution and efficient cleaning. These filters, fully shop-fabricated to meet ASME Boiler and Pressure Vessel Code standards, ensure superior durability, with multi-unit installations that offer self-backwashing capabilities for continuous, efficient operation.

Filters

Benefits, features, applications

Key benefits
Lowest cost per tonne. High availability (93%). Optimised water recovery. Efficient cake recovery. Robust, long-lasting design.
Easy operation and maintenance. Safe controls. Customizable design. Efficient cake washing. Corrosion-resistant options.
Features
Recess or membrane plates. Sizes: 900–2500 mm. High-pressure filtration. Low cycle times. Automatic cloth washing apparatus.
Pneumatic or electric controls. Membrane options. Lightweight design. Over 30,000 installations.
Applications
Mining (tailings, concentrate). Chemical industries.
General industry. Food-grade and corrosive applications.

Mining filtration add-ons

Frequently asked questions

FAQs for mining filtration

Mining filtration is the process of separating solids from liquids in the mining industry, primarily to extract valuable minerals from ores and manage waste materials. This process is crucial for enhancing the recovery of valuable minerals while minimising environmental impact. Mining filtration typically involves various techniques and equipment to dewater slurries, concentrate ores, and treat tailings. Effective filtration helps improve the overall efficiency of mining operations by optimising water use, reducing waste, and ensuring compliance with environmental regulations.

A filter press is a type of filtration equipment commonly used in mining to separate solids from liquids in slurry form. It consists of a series of filter plates that are stacked together and clamped, creating chambers that hold the slurry. The liquid is forced out through filter media while the solids remain trapped in the chambers, forming a filter cake. Filter presses are highly efficient and can achieve high solid content in the filter cake, making them ideal for applications such as tailings management, mineral concentrate dewatering, and wastewater treatment in mining processes. They are known for their ability to produce drier cakes, leading to reduced disposal costs and improved resource recovery.

In mineral processing, various types of filters are used, each suited for specific applications and operational needs. Here are some common types:

  • Filter Presses: Used for dewatering slurries, filter presses consist of multiple plates that trap solids, producing a dry filter cake. They are efficient for thickening and can handle a wide range of materials.
  • Vacuum Disc Filters: These filters use a vacuum to draw liquid through a porous medium on rotating discs, separating solids from liquids. They are ideal for processing fine particles and provide continuous operation with high dewatering efficiency, often used in mineral processing for large-scale operations.
  • Horizontal Belt Filters: A continuous filtration method that uses a moving belt to separate solids from liquids. They are suitable for applications requiring low cake moisture and multi-stage washing.
  • Rotary Drum Filters: These filters operate on a rotating drum that is partially submerged in a slurry. As the drum rotates, solids are deposited on the surface and subsequently washed and discharged.
  • Pneumapress (Pneumatic Filters): These filters utilise gas pressure to assist in the separation of solids from liquids. They are typically employed in processes where high moisture content is present, offering effective dewatering and low energy consumption. Pneumapress is especially useful in applications requiring efficient handling of high-volume slurries with moderate moisture levels.
  • Continuous Vacuum Drum Filters: Designed for continuous operation, these filters have a rotating drum and can provide efficient solid-liquid separation, commonly used in mineral processing.