933 Figure 68 Figure 6 depicts Larox FFP filters Metso’s global experience indicates that these new systems can operate safely and economically at capacities previously considered impractical for large copper and iron-ore operations. The adoption of automated, fast-cycle filters has been a “game changer,” enabling operators to reconsider filtration even in lower-grade, high-tonnage environments where energy and cost sensitivity is high. The “Addressing the Barriers to the Implementation of Filtered Tailings”(Calil, Palmer, Paste2026) paper further emphasizes that improvements in filter design, hydraulic control, and throughput efficiency directly reduce both technical and economic risk, helping to close the gap between feasibility-level assumptions and real operational performance. 5.2 Modularization of Filtration Plants and Dry-Stack Infrastructure Traditional filtration plants were often large, complex facilities requiring extensive civil works. Modern designs increasingly embrace modular concepts, which offer the following benefits: • reduced construction time, • predictable capital deployment, • easier expansion of installed capacity, • simplified logistics during installation, • standardized maintenance and spares. Modular designs are a key enabler for improving the viability of filtration at scale, particularly in remote or space-limited sites. Modularization reduces risk in early project stages by creating scalable building blocks that can be aligned with mine development increments. This modular approach is echoed in large-scale feasibility work, which demonstrates how multi-train filter plants—each based on modular process units—can produce 85-90% water recovery while maintaining high process availability. Figure 7 shows a Typical modular plant solution Figure 69
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