Outstanding cost efficiency in filtration with the Larox® FFP3716

The reliable and optimized Larox® FFP filters family 

At Metso, we bring nearly a century of expertise in filtration equipment and services, making us a leader in providing the most comprehensive filtration solutions available today. Our focus on smart, sustainable dewatering technologies serves a wide range of mining applications, including concentrates, tailings, and filtration. With experience from over 100 large-scale hole-less cloth filters installed around the world and continuous innovation; we aim to address the most pressing challenges faced by our customers. 

The Larox® FFP filter family stands out for its ability to handle high-volume processing across various applications. Utilizing advanced technology and a design focused on reliability and easy maintenance, the Larox® FFP filters not only optimize dewatering processes but also contribute to significant long-term savings, making them an invaluable asset for any mining operation.  

“The Larox FFP filters used in tailings have been seen as technically viable and effective solution, even in difficult processes”, praises Tomi Ravattinen, Product Director, Tailings Filtration.   

Choosing a Larox® FFP filter offers numerous advantages that make it a standout solution in filtration technology. With filtration areas ranging from 108m² to 1980m² per unit and chamber volumes from 1.9m³ to 44m³, the Larox® FFP provides high capacity and a quick technical time of just 3 to 4.5 minutes. Its design ensures high availability, featuring easy and quick maintenance for filter cloths, plates, and membranes, all tailored to meet the rigorous demands of heavy mining applications. The integrated perimeter protection adheres to health and safety requirements, while the modular design not only reduces installation costs but also simplifies maintenance. 

The filter operates fully automatically with a Programmable Logic Controllers (PLC) system, allowing for automatic adjustments to process changes and enabling pre-defined recipes for different slurry conditions. Seamless communication with the Distributed Control System (DCS) enhances operational efficiency. Additionally, the rapid operation is facilitated by a horizontal plate pack with vertically hanging filter plates, interconnected via linking mechanisms and crafted from tough, aging-resistant polypropylene material. Low flow velocities in large channels help minimize erosion risks whilst permitting fast filling of the chambers, while elastomer filling shoes ensure reliable sealing and reduced wear. 

“The hole-less cloth and simple plate design were carefully developed to enhance the filter’s reliability and reduce downtime by addressing key operational challenges”, explains Sergio Calil, Senior Manager, Tailings Filtration. “This innovative solution significantly extends cloth life by reducing wear and tear, with some sites exceeding 6000 cycles per cloth; while minimizing operational disruptions by eliminating potential points of failure, such as fabric tears around feed holes. Additionally, the hole-less design increases the effective filtration area of each plate, improving overall system efficiency.” 

“For the key wearing components, our design of the filter cloth is simple for easy manufacturing and installation. There is no need to manually install feed shoes, and it is easy to change 10 cloths at once”, Tomi says. 

Designed for built-in performance with minimal downtime, the Larox® FFP features double-sided filtration capability and elastomer membranes that enhance cake pressing efficiency. Its large feed channels support high slurry volume flows, effective air drying of cakes, and simplified removal and installation of cloth and filter plates, making it an exceptional choice for any mining operation. 

“These design decisions ensure a robust, efficient, and low-maintenance filtration system that maximizes operational uptime while minimizing costs”, Sergio concludes. 

Larox® FFP3716: the reliable and cost-efficient long-term solution for tailings handling 

Metso’s advanced membrane technology ensures consistent performance despite significant variations in feed slurry, making the Larox® FFP3716 suitable for difficult tailings applications. “The Larox® FFP 3716 is designed to help mining operators achieve their sustainability goals, particularly in tailings management, by incorporating features that drive efficiency and help minimize environmental impacts”, Sergio comments. “With membrane technology, we are able to shorten the cycle time to a minimal. Also, our accurate measuring of the feed enables to actively control the needed process time”, Tomi describes. “For achieving lowest total cost, we considered latest technologies and an adequate filter size for the optimal result.” 

The simple plate design features a hole-less cloth, leading to low maintenance costs, while planned operational practices allow for daily shutdowns of just 30 minutes. Larger maintenance tasks can be scheduled during planned plant shutdowns, supported by advanced data collection and diagnostics that enhance operational efficiency. Operational costs are impressively low, reaching as little as $0.7 per ton of dry solid produced in tailings operations, depending on local factors such as electricity, water, and labor costs.  

“Our clients are highly attuned to the running costs of their operations. They seek solutions that not only meet technical requirements but also enhance overall efficiency. The Larox® FFP 3716 provides reliable, consistent performance in managing tailings, allowing operators to allocate resources more effectively to other critical areas of the plant”, Sergio explains. 

“Moreover, the system’s proven reliability offers peace of mind, reducing the need for frequent interventions and ensuring uninterrupted operation. This combination of cost-efficiency, reliability, and operational simplicity makes the Larox® FFP 3716 an invaluable asset for operators aiming to streamline their processes while maintaining high standards of safety and sustainability.” 

Metso offers local support in all major mining countries, ensuring reliable service and assistance. 

“Drawing on our past experience with FFPs and incorporating the most effective filtration technology and size, we have designed this product to achieve the best total cost of ownership (TCO). We are happy and proud to present this as the right solution for tailings challenges”, Tomi concludes. 

Get the most out of your filters with Metso’s Life Cycle services portfolio 

At Metso, we strive to deliver the best possible quality, availability, performance, and financial solutions for our beneficiation and dewatering customers. We are committed to a long-term partnership throughout the equipment's life cycle, ensuring your targets are reached and creating win-win relationships for all stakeholders. Our comprehensive service portfolio is supported by deep technical knowledge, experienced people, and specialized tools to maximize your profitability. By combining our quality products and expertise, we closely partner with our end users to provide reliable, innovative, and sustainable solutions to mitigate environmental risk. 

“Service and operations are local, in the installation country of the customer. Metso has a wide local service network with approximately 1000 certified field services experts in over 30 countries, supported with global resources to ramp up operations in any corner of the world”, Tomi highlights. 

Reshaping the future of tailings 

Constant innovation in tailings management is required to meet the industry’s changing business environment. As the demand for sustainability rises, environmental regulations become stricter and modern mineral processing methods are required to improve, Metso paves the way with extensive know-how on tackling the challenges.  

“Filtration technology is poised to play an increasingly pivotal role in the mining industry in the coming years, driven by evolving tailings management practices and heightened awareness of environmental and social impacts”, Sergio says, continuing: “In recent years, the industry has witnessed significant changes in how tailings are handled, largely due to growing public scrutiny and the inherent risks associated with wet tailings dams. This has accelerated the adoption of filtration systems across mining operations globally.” 

Our cutting-edge technology solutions fit any tailings management needs, while reducing water use, environmental impact, risks and costs. The risk of tailings dam failure could be minimized by dewatering and dry stacking the tailings, helping to recover process water from the filtrate and erase the needs for raising existing dams’ height. Based on the studies conducted by Metso, this is also the best long-term solution from the economical perspective. At Metso, our goal is to provide holistic tailings management solution by bringing a step change in the way we view, handle, and manage tailings. Backed by proven technology and industrial knowledge, our efficient dewatering solutions help in maximizing water recovery and reuse. 

When asked about the evolving of filtration technology in the future, Tomi describes the ways in which Metso is preparing for such changes with its products: “The mining industry is going through a challenge to gain access to sustainable solutions that help minimize environmental impacts, and better for the economy and society long-term. The FFP 3716 answers these questions as a simple and well-designed product that can be scaled up to 100kptd size customer sites. Metso is also continuously leading R&D activities for repurposing tailings and eventually aiming for use of this most significant side stream of non-metallic minerals.” 

Metso innovation provides a more sustainable filtration solution, and our Larox® FFP filters exemplify our dedication to advance in the mining industry. Larox® FFP is part of the Metso Plus portfolio, indicating distinctive sustainability benefits. Metso Plus products represent our commitment to go beyond and exceed expectations by continuously enhancing our technologies and providing additional sustainability benefits for both our customers and the environment.   

Welcome to see our Larox FFP filters in operation or in our factory for detailed discussions! Please reach out for more information: 

Sergio Calil, Senior Manager, Tailings Filtration, Metso, email: sergio.calil(at)metso.com

Tomi Ravattinen, Product Director, Tailings Filtration & Business Development, Metso, email: tomi.ravattinen(at)metso.com