In an industry where declining ore grades and rising costs are squeezing margins, conventional processing methods often hit a wall: ores below certain thresholds become technically challenging or economically unfeasible to process.
At MET63, we’ve fundamentally reimagined the leaching process with our Fluidised Leach oxidation Reactors (FLeXoR) technology – a hydrometallurgical breakthrough that’s turning previously sub-economic materials into profitable assets.
This isn’t incremental improvement. FLeXoR represents a step-change in mineral processing that’s redefining technical and economic boundaries for mining operations worldwide.
The Evolution of FLeXoR Technology
FLeXoR was born from a fundamental question: How can we extract maximum value from low-grade ores and tailings whilst minimising capital expenditure and environmental impact? Conventional processing methods often struggle with these materials, requiring either substantial capital investment or accepting lower recovery rates.
Our engineering team approached this challenge by reimagining the leaching process from first principles. The result is a continuous vat leaching system that optimises fluid dynamics and mass transfer kinetics, delivering enhanced metal recovery with significantly reduced capital intensity.
Technical Differentiation: How FLeXoR Works
At its core, FLeXoR technology represents a sophisticated engineering approach to hydrometallurgical processing:
1. Optimised Fluid Dynamics
FLeXoR utilises specially designed reactors that maintain ideal solid-liquid interaction through controlled fluidisation. This approach maximises mass transfer coefficients and ensures optimal reagent contact with mineral surfaces, even with coarse particle sizes up to 10mm (depending on liberation characteristics).
2. Precision Process Control
Each FLeXoR reactor allows independent control of critical processing parameters:
- Eh/pH conditions
- Dissolved oxygen levels
- Reagent concentrations
- Residence time
This level of control creates optimal leaching conditions for specific mineralogical profiles, allowing for customised extraction protocols for different ore types.
3. True Counter-Current Design
FLeXoR implements genuine counter-current leaching and washing circuits, maximising reagent utilisation efficiency and reducing operating costs whilst improving overall recovery rates.
4. Enhanced Containment
The system utilises low-cost lined vats with internal barrier protection and sophisticated leak detection systems, ensuring environmental integrity whilst keeping capital costs manageable.
Validated Performance: One of MET63’s FLeXoR Success Stories
MET63 has successfully constructed, commissioned and operated multiple FLeXoR plants that definitively establish the technology’s commercial viability. Among these successes, our gold demonstration plant provides compelling performance data confirming the technology’s capabilities. This is just one example of how MET63 regularly implements FLeXoR technology to solve complex processing challenges:
Technical Performance Metrics
- Recovery Efficiency: The demonstration plant achieved recovery rates comparable to and in some cases exceeding conventional heap leaching methodologies
- Processing Flexibility: Successfully handled material with gold grades of 0.5-1.5 g/t that would typically be considered marginal or sub-economic
- Capital Intensity: Achieved approximately 30-45% reduction in capital intensity ($/tpa) compared to conventional processing circuits
- Implementation Timeline: Demonstrated significantly accelerated commissioning timeline—typically 40-60% faster than alternative technologies
The demonstration plant not only validated the technical feasibility of FLeXoR but also confirmed its economic viability for processing low-grade gold ores that might otherwise remain unutilised.
Versatility Across Metals: Multiple FLeXoR Applications
MET63 has successfully implemented FLeXoR technology across a diverse range of mineral processing applications. While gold processing demonstrates one successful application, the technology has been equally effective in processing various other metals and minerals.
Most notably, FLeXoR has delivered exceptional results in copper processing operations, where it provides a cost-effective alternative to traditional processing methods for low-grade copper ores. These implementations highlight one of FLeXoR’s key strengths: versatility. With strategic adaptations, the same core technology is successfully optimised for different mineral compositions, ore characteristics, and target metals.
This proven adaptability makes FLeXoR particularly valuable for mining operations with complex or variable mineralogy, allowing for controlled processing across changing feed materials while maintaining optimal recovery rates.
Economic Implications: The FLeXoR Advantage
The economic case for FLeXoR becomes particularly compelling when considering previously sub-economic resources:
1. Unlocking Stranded Value
For mining operations with accumulated low-grade stockpiles or tailings, FLeXoR provides a pathway to extract additional value from materials previously considered waste or uneconomic.
2. Reduced Capital Requirements
With capital intensity reductions of 30-45% compared to conventional processing circuits, FLeXoR enables projects to proceed that might otherwise fail economic feasibility assessments.
3. Operational Flexibility
The technology’s ability to process variable feed grades and characteristics provides operations with strategic flexibility, allowing for more dynamic mine planning and resource utilisation.
4. Environmental and Footprint Advantages
FLeXoR’s significantly smaller footprint (65-80% reduced compared to equivalent heap leaching circuits) not only reduces environmental impact but also minimises water management challenges, particularly in regions
with high precipitation.
Implementation Methodology
For operations considering FLeXoR technology, MET63 employs a structured implementation approach:
Phase 1: Technical Assessment
Our metallurgical engineers conduct comprehensive mineralogical analysis, leachability studies, and process modelling to quantify FLeXoR’s technical viability for your specific material.
Phase 2: Pilot-Scale Validation
We execute controlled test campaigns to validate kinetic models, optimise process parameters, and generate scale-up design criteria tailored to your operation.
Phase 3: Engineering & Commissioning
Our technical team designs, develops, and commissions a customised FLeXoR circuit with instrumentation for real-time process control and performance monitoring.
Phase 4: Operational Optimisation
Once operational, we work with your team to achieve superior recovery kinetics, reduced specific energy consumption, and optimised reagent utilisation.
The Future of Mineral Processing
As the mining industry continues to evolve, technologies like FLeXoR represent the future of efficient, sustainable mineral processing. The ability to economically extract value from lower-grade materials isn’t just a competitive advantage—it’s increasingly becoming a necessity for long-term viability.
The development and successful implementation of FLeXoR demonstrates MET63’s commitment to solving complex processing challenges through innovative approaches and deep technical expertise. It represents our philosophy of finding simplicity through first principles and delivering practical solutions to real-world mining challenges.
Take the Next Step with FLeXoR Technology
If your operation is facing challenges with low-grade ore processing, accumulated tailings, or you’re seeking more efficient alternatives to conventional processing methods, FLeXoR technology may provide the solution you’ve been looking for.
Our team of metallurgical and process engineering experts is ready to evaluate the potential application of FLeXoR technology for your specific materials and requirements
Ready to explore how FLeXoR can transform your processing economics?
Contact Tamsyn Grewar, Proposal and Studies Manager (Pr. Sci. Nat., MSc), directly at tamsyngrewar@met63.com or call our technical team at +27 10 600 2140 / 2141 to arrange a consultation.
MET63: Engineering the impossible through innovation, expertise, and a commitment to client success.
