Last updated: April 2026 | Reading time: 10 minutes
Project Background
Location: Kazakhstan, Central Asia
Customer: Large-scale mining operation with decades of accumulated tailings
Material: Gold mine tailings, accumulated over 20+ years, naturally hardened and cemented
Feed Size: Up to 500mm maximum, with the majority in the 200-400mm range
Required Product Sizes: 0-5mm, 5-10mm, 10-20mm, 20-40mm (four specifications)
SUHMAN Solution: Crawler-mounted mobile jaw crusher + crawler-mounted mobile cone crusher + crawler-mounted mobile screening plant, all operated via wireless remote control
The Tailings Challenge
Problem 1: Hardened and Cemented Material
The gold tailings had been accumulating for over two decades. During this time, natural weathering, moisture exposure, and chemical reactions caused the fine tailings particles to cement together, forming hard clumps ranging from 200mm to 500mm in size.
Why this matters: Standard screening equipment cannot handle material this large. The clumps must be crushed before any size separation can occur. According to the United Nations Environment Programme (UNEP), tailings management is one of the most critical challenges in the global mining industry, with over 3,500 known tailings storage facilities worldwide.
Problem 2: Variable Feed Size
Unlike a controlled quarry feed, tailings are unpredictable. The material varied from fine powder (already at target size) to large hardened clumps (500mm). This variability creates challenges for:
- Feeder design — must handle both fines and large clumps simultaneously
- Crusher selection — must accept 500mm feed while producing fine output
- Screen efficiency — fines must be removed before crushing to avoid over-crushing and wasted energy
Problem 3: Site Access and Relocation
The tailings storage facility covered a large area. The crushing operation needed to:
- Access different sections of the tailings pond
- Relocate as each section was fully processed
- Operate on uneven, soft ground (tailings surface is inherently unstable)
A fixed plant would require extensive site preparation, concrete foundations, and could not relocate between processing zones — making it impractical for this application.
Problem 4: Environmental and Economic Pressure
The accumulated tailings represented both a liability and an opportunity:
- Environmental liability — Unmanaged tailings pose dust emissions and potential water contamination risks
- Economic opportunity — Modern processing can recover residual valuable minerals and produce saleable construction aggregate from the waste material
The International Council on Mining and Metals (ICMM) emphasizes that responsible tailings management is essential for sustainable mining operations.
Material Analysis
Tailings Composition
| Parameter | Value |
| Origin | Gold mine processing residue |
| Accumulation period | 20+ years |
| Feed size range | 0-500mm (majority 200-400mm) |
| Hardness | Medium-hard (weathered and cemented) |
| Moisture content | Variable (surface dry, deeper layers moist) |
| Residual mineral content | Low (primary gold extraction already completed) |
Processing Objectives
The customer’s goals were clear:
- Reduce clumped material to manageable sizes for further processing
- Produce four size fractions: 0-5mm, 5-10mm, 10-20mm, 20-40mm
- Enable aggregate sales — recycled tailings aggregate for local construction use
- Clear the tailings pond — reclaim land and reduce environmental liability
For reference on tailings recycling standards, see the Global Industry Standard on Tailings Management.
SUHMAN Solution: Complete Crushing Circuit
Recommended Configuration
After analyzing the material characteristics and production requirements, SUHMAN recommended a three-stage mobile crushing circuit:
Tailings Clumps (0-500mm)
↓
[Stage 1:Mobile Jaw Crusher] → Reduces 500mm clumps to 80-150mm
↓
[Stage 2: Mobile Cone Crusher] → Reduces to 10-50mm
↓
[Stage 3: Mobile Screening Plant] → Separates into 0-5mm, 5-10mm, 10-20mm, 20-40mm
Why Jaw Crusher + Cone Crusher (Not Impact Crusher)?
| Crusher Type | Suitable for Tailings? | Reason |
| Jaw Crusher | Yes | Handles 500mm feed, compression crushing ideal for cemented material |
| Cone Crusher | Yes | Produces fine sizes (10-20mm), handles medium-hard material efficiently |
| Impact Crushe | Not recommended | Blow bars would wear faster with cemented tailings; better suited for soft rock |
The jaw + cone combination is the industry standard for tailings recycling — it handles the large, hardened feed and produces the fine, multi-size output required for aggregate sales.
For more information on crusher selection principles, see PowderPro’s crushing equipment guide.
Equipment Configuration
Stage 1: Mobile Jaw Crusher (Primary Crushing)
Role: Accept 500mm tailings clumps and reduce to 80-150mm.
Key features for this application:
- Heavy-duty frame designed for cemented, hard material
- Large feed opening (accepts 500mm clumps without bridging)
- Hydraulic CSS (Closed Side Setting) adjustment for quick output size changes
- Crawler-mounted chassis for easy repositioning on soft tailings surface
Stage 2: Mobile Cone Crusher (Secondary Crushing)
Role: Reduce 80-150mm material to 10-50mm for final aggregate production.
Key features for this application:
- Short-head crushing chamber for fine output sizing
- Hydraulic CSS adjustment and automatic clearing
- Robust construction for continuous heavy-duty operation
- Crawler-mounted for mobility across the tailings pond
SUHMAN Model:SY-HP400 Mobile Cone Crusher
Stage 3: Mobile Screening Plant (Product Sizing)
Role: Separate crushed material into four precise size fractions: 0-5mm, 5-10mm, 10-20mm, 20-40mm.
Key features for this application:
- Multi-deck screen (3-4 decks for four distinct size fractions)
- Heavy-duty construction to handle abrasive recycled material
- Crawler-mounted for mobility alongside the crushing circuit
SUHMAN Model:SS-7018 Mobile Screening Plant
Installation and Operation
Simple Installation — Drive and Start
One of the customer’s biggest concerns was installation complexity. Traditional fixed plants require:
- Concrete foundations (2-4 weeks curing time)
- Conveyor system installation and alignment
- Electrical infrastructure setup (transformers, cables, switchgear)
- Professional installation team on-site for weeks
With SUHMAN crawler mobile crushers:
- Drive to the tailings site under their own power
- Unfold the conveyors (hydraulic operation, no tools needed)
- Start the diesel engine (no external power needed)
- Begin feeding material
Total setup time: 2-4 hours from arrival to production.
Wireless Remote Control Operation
All three machines are operated via wireless remote control:
- Start/stop each machine remotely from a safe distance
- Adjust CSS (closed side setting) remotely to fine-tune output sizes
- Monitor operation — watch the entire circuit from an optimal viewing position
- Drive and steer the crawler chassis remotely for repositioning
Benefits:
- Operator stays in a safe, comfortable location away from dust and noise
- Better visibility of the entire crushing circuit
- Reduced exposure to hazardous conditions
- Faster response to operational issues or blockages
Easy Relocation
As each section of the tailings pond was processed, the entire crushing circuit was relocated to the next section:
- Drive all three machines to the new position under remote control
- Reposition conveyors for the new layout
- Resume crushing within 30 minutes
No dismantling, no transport vehicles, no new foundation work.
Results and Customer Feedback
Production Results
| Parameter | Target | Actual |
| Feed size | 0-500mm | 0-500mm (as expected) |
| Capacity | 200 tph | 220 tph (exceeded target by 10%) |
| Product sizes | 0-5, 5-10, 10-20, 20-40mm | All four sizes produced to specification |
| Setup time | < 4 hours | < 4 hours |
| Relocation time | < 1 hour | 30 minutes |
Customer Feedback
The customer reported high satisfaction with the SUHMAN solution across all key areas:
- Performance — The jaw + cone configuration handled the hardened tailings clumps without issue. The 500mm feed size was processed efficiently, and all four product sizes met specification requirements.
- Mobility — The crawler-mounted design allowed easy relocation across the tailings pond surface. The wireless remote control made repositioning simple and safe.
- Installation — The “drive and start” simplicity eliminated the weeks of foundation and installation work required by fixed plants.
- Value — As a direct manufacturer operating from a former China Ordnance Factory (military factory), SUHMAN provided competitive pricing without compromising quality. The 1-year warranty provided additional confidence in the investment.
Why Mobile Crushers for Tailings Recycling
1. No Foundation Required
Tailings ponds are soft, unstable surfaces. Building concrete foundations would be expensive, time-consuming, and impractical. Mobile crushers sit on crawler tracks that distribute weight evenly across a large surface area, similar to how excavators operate on soft ground.
2. Relocation Capability
Tailings recycling requires processing material across a large area over time. Mobile crushers can relocate in 30 minutes, compared to 2-4 weeks for dismantling, transporting, and reinstalling a fixed plant.
3. Self-Contained Power
Most tailings facilities lack grid electricity. Diesel-powered mobile crushers operate independently without any external power infrastructure, making them ideal for remote mining sites.
4. Fast Deployment
Time is money in tailings recycling. Every day of delay is a day of continued environmental liability and missed revenue. Mobile crushers start producing in hours, not weeks.
5. Resale Value
After the tailings are fully processed, the mobile crushers can be sold or redeployed to another project. Fixed plants have zero resale value since they are site-specific installations.
SUHMAN Advantages
1. Military-Grade Quality (Former China Ordnance Factory)
SUHMAN operates from a former China Ordnance Factory located in the Feixi County Economic Development Zone, Hefei City, Anhui Province. This military manufacturing heritage means:
- Higher quality standards — Military-grade steel, welding procedures, and assembly processes
- Better durability — Equipment built to withstand extreme operating conditions
- Consistent quality — Military quality control protocols applied to every machine produced
For more about our manufacturing capabilities, visit our About Us page.
2. Direct Factory Pricing
As a direct manufacturer (not a trading company or distributor), SUHMAN offers:
- No middleman markup — Save 15-30% compared to purchasing through trading companies
- Transparent pricing — Clear specification-to-price mapping with no hidden costs
- Factory-direct support — Direct access to engineering and technical teams
3. 1-Year Warranty
All SUHMAN equipment comes with a comprehensive 1-year warranty covering:
- Main frame and structural components
- Crushing components (jaw plates, cone liners)
- Hydraulic and electrical systems
- Crawler track system
4. Fast Spare Parts Delivery
SUHMAN maintains a complete spare parts inventory at the factory:
- Common wear parts shipped within 1-7 working days worldwide
- Free spare parts included with every order
- International shipping available to all countries
5. Complete Crushing Circuit Expertise
SUHMAN doesn’t just sell individual crushers — we design and supply complete crushing circuits:
- Material analysis — We analyze your material and recommend the optimal configuration
- Circuit design — We design the best jaw + cone + screen combination for your needs
- Installation support — We provide on-site guidance and comprehensive operator training
- After-sales service — We stand behind our equipment with warranty coverage and rapid spare parts delivery
FAQ
Q: Can mobile crushers handle hardened tailings clumps?
A: Yes. Mobile jaw crushers are specifically designed to handle large, hard feed material. The jaw crusher’s compression crushing mechanism is ideal for breaking down cemented and hardened tailings clumps. The SE-1060 can accept feed up to 700mm and reduce it to 80-150mm for further processing.
Q: What crusher configuration is best for tailings recycling?
A: For tailings with feed sizes over 200mm, the recommended configuration is: Jaw Crusher (primary crushing) → Cone Crusher (secondary crushing) → Screen (product sizing). This combination handles large feed efficiently and produces multiple fine product sizes suitable for aggregate sales.
Q: How do mobile crushers operate on soft tailings surfaces?
A: Crawler-mounted crushers distribute their weight across large crawler tracks, similar to excavators or bulldozers. This allows them to operate on soft, uneven surfaces without sinking. The crawler chassis also provides self-propelled mobility for easy repositioning.
Q: Do I need grid electricity for mobile crushers?
A: No. SUHMAN mobile crushers are diesel-powered as standard, with electric and diesel-electric hybrid options also available. They operate completely independently without any external power infrastructure.
Q: What is the typical production capacity for tailings recycling?
A: A standard SUHMAN jaw + cone + screen configuration processes 200-350 tph of tailings material, depending on material hardness, moisture content, and feed size distribution. The Kazakhstan project achieved 220 tph with hardened tailings clumps.
Summary
This Kazakhstan gold tailings recycling project demonstrates the effectiveness of SUHMAN crawler mobile crushers for tailings processing:
The challenge: 20+ years of accumulated, hardened tailings clumps (up to 500mm) requiring crushing to four fine product sizes (0-5mm, 5-10mm, 10-20mm, 20-40mm).
The solution: Crawler-mounted mobile jaw crusher + crawler-mounted mobile cone crusher + crawler-mounted mobile screening plant, all operated via wireless remote control.
The results:
- 220 tph capacity (exceeded 200 tph target by 10%)
- All four product sizes produced to specification
- 3-hour setup time (vs. weeks for a fixed plant)
- 30-minute relocation time between processing zones
- High customer satisfaction across all performance metrics
SUHMAN advantages: Military-grade quality from a former China Ordnance Factory, direct factory pricing (no middleman markup), 1-year warranty, fast spare parts delivery (1-7 working days), and complete crushing circuit design expertise.
Looking for a tailings recycling solution? Contact SUHMAN for a free consultation and customized crushing circuit design tailored to your specific material and production requirements.
Contact SUHMAN for a Free Tailings Recycling Quote
This case study is based on a real SUHMAN installation in Kazakhstan. All performance data is from actual customer operation. For more information on tailings management best practices, see the Global Tailings Review and ICMM Tailings Management Guidelines.
