Modular containerised flocculant systems: a fast-track and cost-effective solution for tailings treatment

Authors: Bonnier, J; Gathier, F Download Paper Open access courtesy of:

DOI https://doi.org/10.36487/ACG_repo/2655_59

Cite As:
Bonnier, J & Gathier, F 2026, 'Modular containerised flocculant systems: a fast-track and cost-effective solution for tailings treatment', in AB Fourie, M Horta, M Oliveira & S Wilson (eds), Paste 2026: Proceedings of the 28th International Conference on Paste, Thickened and Filtered Tailings, Australian Centre for Geomechanics, Perth, pp. 1-16, https://doi.org/10.36487/ACG_repo/2655_59



Abstract:
This paper presents recent operational insights and technological advances in the application of modular and containerised systems for flocculant preparation and dosing in tailings treatment. While the mining industry has increasingly adopted containerised units, our work introduces design refinements, integration of innovative equipment, optimised automation strategies, and deployment methodologies that elevate their performance, adaptability, and sustainability. To support continuous and large-scale operations, the paper presents innovative containerised storage solutions for flocculant in powder form. These systems address logistical and operational challenges in remote or high-throughput mining environments through bulk handling features, and compact enclosures that preserve product integrity. Their modular design allows for scalable capacity and rapid deployment, ensuring reliable supply and seamless integration with preparation and dosing units. This paper will also show how enhanced mixing technologies accelerate polymer dissolution, delivering more uniform and stable solutions that improve treatment consistency. These are complemented by integrated digital monitoring that further strengthens system reliability. Real-time tracking of dissolution and dosing parameters, as well as equipment behaviours, enables predictive maintenance and centralised oversight. Remote access tools reduce unplanned downtime and enhance responsiveness across dispersed mine sites. Beyond pure technical performance, containerised systems offer strategic deployment advantages. Their plug-and-pump design reduces installation timelines and capex, while modularity supports phased expansion and rapid relocation. Case studies illustrate benefits including optimised capex and opex, minimised site work, improved maintainability, and resilient operation under challenging climates. By combining operational efficiency with practical implementation, containerised flocculant systems are positioned as a transformative technology for tailings management and other flocculant usage in mining applications. The innovations described here demonstrate measurable gains in sustainability and operational resilience, underscoring their role in supporting the mining industry’s shift toward safer and more sustainable tailings practices.

Keywords: flocculant, modular, tailings treatment, containerised, polymer

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