In a significant development for the mining sector, Fulcrum Metals has deployed Extrakt Process Solution’s non-cyanide solid-liquid separation and leaching technology, known as TNS, to advance tailings reprocessing in Canada’s gold-rich Timmins and Kirkland Lake regions. This innovative technology is set to challenge conventional cyanide-based methods, potentially reshaping the future of mineral processing.
Fulcrum Metals CEO Ryan Mee explains that the TNS technology replaces traditional cyanide leaching and gravity separation with a faster, cleaner, and more versatile system. “Unlike gravity separation, which depends on the density of minerals, Fulcrum’s method chemically mobilises gold and other metals for recovery, even from complex or finely disseminated ores,” Mee states. Initial tests have shown high gold recovery rates, with further testing planned for silver, gallium, and tellurium at the company’s Kirkland projects.
The absence of cyanide in the TNS technology marks a major shift in reprocessing standards. Traditional cyanide-based methods often require up to 48 hours for leaching and can result in lower recovery rates. In contrast, Fulcrum’s alternative delivers results in just three to six hours while improving recovery rates and reducing the environmental footprint. The TNS technology also integrates filtration to optimise yield without pre-treatment or energy-intensive regrinding.
Efficiency gains have been notable at Fulcrum’s Teck-Hughes and Sylvanite projects in the Kirkland Lake gold region. At Teck-Hughes, gold recovery of up to 59.4% has been achieved in high-level Phase 1 tests—nearly double the efficiency of legacy systems, according to Mee. Leach times of three hours represent an over 80% reduction in time. At Sylvanite, recoveries improved by 63% over 2008 cyanide leach test results, with leach durations similarly reduced by over 90%.
The economic implications are substantial. Mee illustrates that, at a 59.4% recovery rate and a gold price of $2,899/oz, the Teck-Hughes project has a pretax net present value (NPV) of $33 million, with a 21.4% internal rate of return and an estimated three-year payback. Increasing the recovery rate by 25% boosts the NPV to $75.5 million. These economics make lower-grade tailings economically viable and create new opportunities from old waste.
Extrakt developed the technology and is commercialising it globally through an alliance with Bechtel Energy Technologies and Solutions. Fulcrum has conducted on-site validation at its tailings projects in real-world conditions, confirming efficiency and scalability. The company is currently in Phase 3 of its roll-out, focused on optimisation and modular scale-up. While no major bottlenecks have emerged, optimising the process to variable tailings compositions and packaging it into field-ready systems remains an ongoing task, notes Mee.
From an environmental perspective, the benefits are clear. By eliminating cyanide, reducing leach time and energy use, and operating without excavation or regrinding, the process limits dust, contamination, and water consumption. Consequently, the process lowers the risks typically associated with tailings reprocessing. The system also supports future land rehabilitation by reducing untreated waste and recovering a wider range of metals, potentially turning previously impacted sites into green spaces or agricultural land, especially benefiting First Nations communities in Canada.
“The goal is to reach zero-waste processing. This not only improves environmental, social, and governance credentials but also positions the company to unlock further value from secondary metals,” Mee says. The model lends itself to replication. While Fulcrum’s agreement with Extrakt covers legacy tailings in Timmins and Kirkland Lake, the company is open to expanding its footprint. With around 70 historic gold mines in the region and countless others globally, the potential to scale is considerable.
Mee adds that the company sees its approach as a blueprint for the future of gold mining. This development could spur a broader industry shift towards more sustainable and efficient mineral processing technologies, potentially unlocking value from previously uneconomical tailings and reducing the environmental impact of mining operations. As the technology is further validated and scaled, it may set a new standard for the sector, driving innovation and reshaping the future of mining.