Managing tailings safely and sustainably remains one of the mining industry’s biggest challeng es. For operations where above-ground deposition in a Tailings Storage Facility (TSF) is the only option, finding equipment that balances operational efficiency, safety, and environmental responsibility is critical. Yet, many conventional deposition methods struggle to keep pace with stricter regulations, sustainable water use targets, and the need to effectively manage both the rate of rise and long-term TSF stability.  

Multotec’s GV Cyclone has been designed specifically for tailings dam applications, and engineered with these priorities in mind, delivering durability, flexibility, simple maintenance, and process efficiency. Its lightweight spin-cast steel shell is lined with bonded rubber, ensuring it can withstand pressure fluctuations while remaining easy for operators to move on-site.

“By improving material distribution, Multotec’s GV Cyclones help mining operations reduce their environmental impact while maintaining safe and efficient tailings deposition,” says Ernst Bekker, Cyclone Product Specialist at Multotec.

Supporting clients with tailored solutions 

A leading South African gold producer, committed to reducing the environmental impact of its tailings deposition, sought a more efficient solution for slurry management. With strict operational and environmental performance standards in place, the safety and reliability of its tailings infrastructure were non-negotiable. 

Multotec had already built a long-standing relationship with the client through its work on other TSFs and gold processing plants, where it extended equipment wear life, optimised cyclone performance, and supplied fit-for-purpose solutions such as screening media, automated mechanical samplers, and mill liners. This track record made Multotec the natural partner for the new TSF order.

Overcoming operational challenges

The mine’s focus on leveraging modern technology to enhance operational performance while reducing environmental impact placed high demands on cyclone durability, flexibility, and efficiency. 

Handling large tailings volumes under tough conditions had placed pressure on the existing deposition equipment, highlighting the need for a more reliable and operator-friendly solution. Earlier deployments of Multotec cyclones had already proven their performance advantage over competing systems, encouraging the decision to order the GV Cyclones for the new facility.

Innovative cyclone design for optimal performance

To configure the GV Cyclones, Multotec conducted both in-house simulations and test work, supported by on-site comparative equipment trials. These trials evaluated material behaviour, confirmed achievable recoveries, and provided accurate tailings samples for further testing. To ensure reliability, Multotec engineers oversaw sampling procedures to eliminate bias, giving the client confidence in the final configuration. 

The cyclone’s performance depends on factors such as length, cone angle, spigot size, and vortex finder selection. Multotec’s GV Cyclones can be supplied with either a 10° or 20° cone angle, allowing operators to balance ease of handling with fine performance control.

For this project, Multotec customised the inlet head size and overflow elbow flange to integrate seamlessly with the client’s existing pipework. This removed the need for auxiliary adaptor equipment and reduced the weight of the cyclone, demonstrating Multotec’s commitment to delivering fit-for-purpose solutions that add real value on site.

“The GV Cyclones were designed with operators in mind. Features like the lightweight body, interchangeable cone angles, and quick-release spigots make day-to-day management easier and safer, while still delivering the durability needed for harsh conditions,” explains Blane Pillai, Applications Engineer at Multotec.

The GV Cyclones are engineered to deliver the optimal volumetric split between overflow and underflow to meet TSF rate-of-rise requirements. Their configuration can be adjusted as deposition conditions evolve, ensuring consistent performance even if the characteristics of the ore entering the processing plant change. 

Built to absorb pressure spikes during start-up, the cyclones offer stability under demanding conditions, while the quick-release spigot system simplifies adjustments and minimises downtime.

Key design features included:

• Lightweight construction: Weighing just 44.6 kg, the cyclone can be easily manoeuvred by operators for installation, handling and maintenance.
• Durable build: A steel rubber-lined inlet head and cone, with a 15 mm replaceable liner ensure wear resistance and a long service life.
• Quick-change spigot system: A lightweight, tool-free screw coupling enables operators to replace spigot rapidly without shutdowns. Since spigot diameter directly influences product quality and deposition accuracy, this feature is critical to TSF stability.
• Flexible operation: Interchangeable spigots, vortex finders, and cone angle options (10° and 20°) give operators control across different stages of TSF development.
• Optional movable stands/skids: Improve cyclone relocation efficiency while reducing labour requirements.

Earlier in 2025, Multotec received an order for upwards off 200 GV250 Cyclones, for one of the client’s existing TSFs. Manufacturing is underway, with delivery scheduled before the end of 2025, and the field service team will provide on-site installation support and training to ensure a reliable performance from day one.

Delivering results: efficiency, safety, sustainability

Although the GV Cyclones are yet to be commissioned, installations at other sites already highlight their benefits. 

“Cyclones enable a faster, more controlled rate of rise compared to traditional open spigot deposition, reducing labour intensity, lowering operational costs, and giving operators precise control over dam wall height,” says Erick Herbst, Territory Sales Manager - Capital at Multotec.

By ensuring even material distribution, the GV Cyclones improve water recovery, and aid in the correct material characteristics depositing on the TSF wall, contributing to safer and more sustainable long-term TSF management. 

With their balance of durability, lightweight handling, and operator-friendly features, Multotec’s GV Cyclones are setting a new benchmark for safer, more sustainable tailings management.