Let’s be honest: most surge bins underperform. They struggle with inconsistent discharge, density fluctuations, and operational inefficiencies that ripple through the entire process. The mtLYONS is engineered to do the opposite - delivering stability, precision, and performance where it matters most.

At a glance: ±1% underflow density variation, 65–70% solids by weight, and still fully pumpable - delivering consistent, efficient control in real operation.

Within the mtLYONS, the dense bed and upward wash create natural classification:

• By particle size – fine material preferentially reports to overflow, coarse particles settle.
• By mineral density – lighter gangue (e.g. clays, silicates) tends to overflow; heavier valuable minerals (e.g. ilmenite, zircon, magnetite) remain in the bed and discharge to underflow.

This passive effect upgrades the feed before it reaches the separation circuit, acting as both a feed stabiliser and a combined density/size classifier.

Where water is scarce or tailings transport and storage costs dominate, the LFCU transforms tailings management from a dilute pumping problem into a controlled densification step:

1. High-density tailings discharge
2. Tailings settle and consolidate in the cone section. Base water injection gently re-mobilises the compacted solids, allowing discharge at very high solids concentration while remaining pumpable. Water content can be reduced by up to ~48%, shrinking pumping and storage volumes.
3. Recycled overflow water
4. As solids compact, clarified water rises and exits via the overflow. This water is clean enough to be recycled to upstream process steps, improving water efficiency and lowering make-up demand.
5. Reduced equipment and environmental footprint
6. A dense, pumpable underflow can often be sent directly to tailings lines or further handling, reducing or eliminating boom stackers, cyclones or secondary thickening. That means fewer pieces of equipment, less mobile plant use, and a smaller tailings and water footprint.

Many operators are unsure if a feed control system will work for their specific ore type. The LFCU is engineered for versatility. Whether your project involves heavy-duty extraction or fine beneficiation, the unit adapts to your specific challenges:

• Iron Ore: Essential for processing hematite and magnetite fines where slime management is critical.
• Magnetite: Provides the necessary density stability to ensure efficient magnetic separation.
• Mineral Sands: Effective in handling heavy mineral concentrates and separating fine clay from valuable ilmenite or rutile.
• Copper/Gold (Sulphides): Utilized in flotation circuits to ensure a stable feed density for optimal chemical reactions.

The LFCU is a universal tool for plant engineers looking to standardise their process inputs.