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Wednesday, August 5, 2026

Technical Review on Various Separation Methods Used in Mineral Ore Processing Plant: Crimson Publishers

Technical Review on Various Separation Methods Used in Mineral Ore Processing Plant by Vipin Kumar Sharma in Research & Development in Material science: Peer Reviewed Material Science Journals

Abstract

Separation methods are advanced techniques to segregate several components based on their characteristics and phases i.e. solid, liquid, or gas. Mineral ore processing contains proper usage of a series of chemical and mechanical operations. It helps in the extraction of the desired product from its initial stage. Several chemicals are used during the entire process. In this technical paper authors choose alkali and acidic leaching-based unique pitchblende ore for a case study of separation methods. Leaching is the heart of pitchblende mineral ore processing. It is a method for extracting desired products from the solid to liquid phase [1]. Based on ore characteristics, two types of leaching are involved i.e. acidic leaching and alkali leaching. Sodium Carbonate is the main reagent used for the pressurized alkali leaching process of pitchblende ore whereas sulphuric acid is used for acid leaching. In addition to this, several advanced separation techniques i.e. filtration, clarification, thickening, and drying are also performed for the extraction of the final product. This technical paper provides a glimpse of all the main separation techniques involved during mineral ore processing.

Keywords:Advanced separation techniques; Mineral processing; Leaching; Filtration; Chemical plant

Literature Survey

Laboratory-scale investigation conducted to emphasize the key factors impacting the efficiency of a belt filter press. They assessed this efficiency by measuring parameters such as the dry solid content of the final cake, the percentage of solids recovered, and the lateral movement of sludge on the belt [2]. In a separate study, detailed explanation provided for the operational principles and modeling techniques used in thickeners and clarifiers within the mineral processing industry [3]. Valuable insights into mineral ore processing within the context of India offered [4]. Furthermore, the historical progression of fine screening technology was reviewed, tracing its evolution from the early 20th century to contemporary methods. They underscored the economic benefits of modern fine classification techniques, particularly those utilizing the patented Stack Sizer technology [5]. Development of strategies was delved and tools aimed at enhancing the efficiency of mining facilities, thereby improving the utilization of raw materials from both natural and man-made deposits [6]. Comprehensive study was conducted on grinding and mineral separation processes frequently employed in mineral processing industries [7]. Research centered on cesium removal, exploring various separation technologies like chemical precipitation, solvent extraction, membrane separation, and adsorption [8]. Recent Life Cycle Assessment (LCA) studies related to mining and mineral processing operations reviewed meticulously, with a focus on addressing methodological challenges [9]. Under specific SMR conditions, including a roasting temperature of 520 °C, CO flow rate of 4.0m³/h, N2 flow rate of 2.0m³/h, and a feeding rate of 100kg/h, they were able to achieve an iron concentrate with a total iron grade (TFe) of 60.18% and an iron recovery of 90.17% [10]. Valuable insights into several advanced separation techniques commonly applied in mineral processing industries were provided [11]. It was concluded that, from economic and environmental perspectives, magnetic separation stands out as the most effective method for recovering iron oxides. However, it necessitates the modification of the magnetic properties of weakly magnetic iron ores [12]. It was aimed to equip researchers and industrial practitioners with structured knowledge regarding the state of machine learning applications within the field of mineral processing [13]. Furthermore, detailed information on the development of solvent extraction processes designed to separate and recover cobalt and nickel from secondary resources over the past decade was offered [14]. Advanced treatment techniques, including advanced oxidation processes (such as photolysis, ozonation, and catalytic/ UV light-based degradation), membrane filtration, reverse osmosis, and adsorption methods were explored [15]. It was concluded that innovative hybrid processes, which combine two or more treatment methods, are promising for reducing energy consumption and enhancing treatment efficiency [16]. Study was conducted on existing technologies for recovering precious metals from industrial waste streams, focusing on sustainability considerations [17]. Review of microwave heating applications in separation and purification processes in chemical engineering, emphasizing its unique features, including rapid heating, selective heating, and specific microscopic effects was provided [18]. Three most explored and mature separation techniques identified between 2015 and 2020, encompassing both solid and liquid phases: leaching, solvent extraction, and plasma. Top three fields of study: chemistry, engineering, and metallurgy are also highlighted. Additionally, it was noted that the predominant method for Rare Earth Elements (REE) separation across various research domains involved the use of acids, bases, ionic liquids, and salts for leaching REEs [19]. It was found that, through optimization, leaching efficiency of 79.85% can be achieved under the optimal conditions for physical separation products [20].

Introduction to mineral ore processing

Figure 1 describes a detailed flow sheet of mineral ore processing which includes several advanced chemical separation processes mainly dewatering, filtration, clarification, crystallization, drying, thickening, etc [21].

Figure 1:Process flow sheet of mineral ore processing plant [21].


Methods of separation techniques used in mineral ore processing industries

Detailed explanations about these process steps are mentioned as follows:
Screening (solid-solid separation): Ore mining is a critical process that is being done by several specific mining methods. Big boulders are mined out from underground using belt conveyors or mine ore trucks as per convenience and further processed in a series of chemical operations. Crushing and screening is an initial size reduction operation. Desired ore size material moves further through a series of belt conveyors for chemical processing whereas oversized ore moves for recycling after screening operation. Jaw crushers and cone crushers are the main size reduction equipment used in mineral ore processing industries. In this way solid-solid separation takes place.
Dust extraction system (gas-solid separation): Crushing operations in mineral ore processing industries cause dust generation. Fine dust can be harmful to working employees if crosses permissible limits provided by regulatory bodies i.e. CPCB, AERB, MoEFCC, DGMS, etc. Bag filters and cyclone separators are mainly used as dust extraction systems to control dust emissions in crushing and screening units. Bag filters are commonly used in such industries which are connected through DE (dust extraction) fans through pipelines. During the operation of equipment, dust is extracted from generation places and further sticks on the surface of specific bags of bags filters. Due to frequent timer/intervals, dust passes through the bottom chutes of bag filters and is recycled in the system through belt conveyors. Figures 2(a), 2(b) & 2(c) describe the overall view of the DE system, cross-sectional view, and types of filter media used in mineral ore processing industries [22-25].

Figure 2:(a). DE System at mineral ore processing industry [22,23], (b). Cross-section view [24], (c). Types of filter media [25].


Grinding: It is one of the important mineral processing steps. Leaching is main heart of most of the chemical processing industries. Leaching directly depends on the surface area of the particles. Grinding helps in increasing the surface area of the particles [26,27]. Crushed ore of desired input size enters into the primary mill. Rods are used as grinding media in the primary mill (rod mill). Discharge of primary and secondary mills (ball mill) is being collected in the discharge tank. Figure 3 represents the overall view of grinding circuits in mineral processing industries.

Figure 3:Grinding circuit with various mineral processing plant operations.


Figure 4:Cross sectional diagram of hydro cyclone.


Hydrocyclone (liquid-liquid separation): A hydrocyclone consists of a cylindrical feed section with a tangential inlet; an upper section with a vortex finder; and a conical part with an apex. Substance from the mill discharge reservoir is pumped into the hydrocyclone tangentially under specific pressure [28]. This initiates a centrifugal motion, propelling the denser phase outward and downward along the conical section’s surface. The hydro cyclone’s discharge serves as the input for the secondary rod mill, while the underflow is directed to subsequent dewatering processes as mentioned in Figure 4.

Hi-rate thickener (solid-liquid separation): Another separation unit, HRT (high rate thickener) is used in plants to increase the solid concentration of feed subjected to leaching by sedimentation. The addition of flocculating agent in HRT improves the sedimentation process. After hydrocyclone operations, the slurry enters into a thickener in which clear overflow water is recycled back to the plant and thickened underflow goes for further processing on horizontal belt filters. Settling regimes depend upon the closeness of particles to each other which is defined in Figure 5; [29].

Figure 5:Graph: settling velocity vs time [29].


Filtration (solid-liquid separation) before leaching: The plant employs a horizontal vacuum belt filter as a device for separating solids from liquids, primarily used for dewatering neutral and leached slurries. The filtration process primarily involves passing a set of filtering fabrics and belts through a series of rollers. The system takes slurry as input and segregates it into a filtrate and a solid cake. Decreasing the belt speed enhances the filtration rate. To ensure the plant’s capacity is not compromised, the optimal speed is consistently maintained in all horizontal vacuum belt filters (HBFs). Neutral slurry passes on HBF (horizontal belt filter). After filtration, the cake goes for a leaching operation, and the filtrate goes for recycling to hi rate thickener. Table 1 represents the basic technical specifications required for polymeric filtration media in mineral processing plants [30].

Table 1:Technical specification of neutral and alkaline filter media [30].


Figure 6:Schematic representation of pressurized alkali leaching into autoclaves [34].


Pressurized alkali leaching into autoclaves (solid-liquid extraction): This mineral processing step is the heart of the entire process. Slurry passes through a double hose diaphragm pump, and spiral heat exchanger and enters into a pressurized autoclave at ~90 oC. Exothermic reactions take place inside autoclaves at ~140 oC temperature and 8 bar pressure [31,32] as mentioned in Figure 6. The main chemical reactions [33,34] are as follows:
(1) UO2 + ½O2 → UO3
(2) UO3 + 3Na2CO3 + H2O → Na4UO2(CO3)3 + 2NaOH
(3) NaHCO3 + NaOH → Na2CO3 + H2O
(4) SiO2 + 2NaOH → Na2SiO3 + H2O

Leaching is a chemical process for extraction of required minerals from its ore using certain reagents, oxidation material, etc. Before leaching, minerals used to be in ore in the form of a solid. After leaching, it converts from solid to liquor form due to certain chemical reactions in the presence of desired process parameters.

Filtration (solid-liquid separation) after leaching: After leaching, the leached slurry is filtered again using HBF for extraction of the desired mineral from solid to liquor form. Solid with unleached mineral goes to tailings for disposal and filtrate moves for further chemical processing. Figure 7 represents a description of several counter-current steps being used to increase the concentration of liquor. It is very important in the case of low-grade ore. The required concentration of liquor helps in the precipitation of fine particles more efficiently [35]. In Figure 7, c0, c1, c2, c3, c4, and c5 are five stages for counter-current washing zones of HBF, and w0, w1, w2, w3, w4, and w5 are known as weak liquor filtrates being collected from all zones.

Figure 7:Technical specification of precoat / drum filter [36].


Precoat/drum filter (solid-liquid separation): After filtration of leached slurry over HBF, filtrate goes for further settling into the clarifier. After initial clarification into the clarifier, the overflow of the clarifier is passed through a precoat / vacuum drum filter. Clarified liquor is obtained from the drum filter after the removal of desired solid particles. Table 2 provides technical specifications of an ideal precoat / vacuum drum filter used in mineral ore processing industries [36].

Table 2:Technical specification of precoat / drum filter [36].


Mineral ore precipitation: Clarified liquor goes for further precipitation for extraction of the desired mineral from the ore. A required chemical of a particular concentration is used for precipitation reaction. Chemical reaction 5 represents usage of 47% conc. NaOH solution for extraction of Na2U2O7 from mineral ore with suitable retention time of liquor inside vessels [37].
(5) 2Na4UO2(CO3)3 +6NaOH → Na2U2O7 +6Na2CO3 +3H2O [38]

Product horizontal belt filtration (solid-liquid separation): Precipitated liquor further goes for thickening operation after the addition of suitable flocculent. Overflow liquor of thickener is used for recycling in circuits after extraction of byproduct. Underflow precipitated slurry of thickener moves on horizontal belt filter for removal of the filtrate by using sufficient vacuum from pumps and further recycling in plant circuit. Product discharge cake is repulped inside the tank by the addition of water. Water addition helps in product-grade purification. Table 3 provides technical specifications of filter media used for product belt filters in mineral ore processing industries [39].

Table 3:Technical specification of neutral and alkaline filter media [30].


Product drying (solid-moisture separation): Repulped product cake enters into the drying chamber/atomizer from the top as mentioned in Figure 8. Hot air passes from one end with the help of an FD fan. Product slurry converts into powder form within a fraction of a second due to the very high rotation speed of the motor situated at the top of the atomizer. A bag filter and HEPA filter are being used in between drying operations [40,41].

Figure 8:Product drying operation in mineral processing industries [41].


Figure 9:Manufacturing details of HEPA filter for gas-solid separation; (a). Outer view of HEPA filter [42,43], (b). Cross-sectional view of HEPA filter [41].


HEPA, which stands for high-efficiency particulate arrestance, is a standard for the effectiveness of air filters. A HEPA air filter is required to eliminate no less than 99.95% (according to ISO and European standards) or 99.97% (as per ASME and the U.S. DOE) of particles with a 0.3μm diameter as they pass through it. The filtration efficiency increases for particles with diameters smaller or larger than 0.3μm. HEPA filters are constructed from a nonuniformly distributed mat of fibers, as depicted in Figures 9(a) & 9(b) [42,43].

The fibers are usually made of polypropylene or fiberglass and have diameters ranging from 0.5 to 2.0 micrometers. To prolong the lifespan of the costlier HEPA filter, a HEPA bag filter can be employed alongside a pre-filter, typically activated carbon. In this arrangement, the initial phase of the filtration process involves the use of a pre-filter, which effectively eliminates the majority of larger dust, hair, PM10, and pollen particles from the air. The drying chamber helps in the removal of moisture completely from the product slurry and the dried product is being collected in drums for further packing and dispatch. The technical specification of a typical HEPA filter is mentioned in Table 4.

Table 4:Technical specification of HEPA filter [39].


Results and Discussion

The results and discussions section of this technical review on various separation methods employed in mineral ore processing plants presents a comprehensive analysis of the findings obtained through literature review and empirical data. Through meticulous examination, it becomes evident that several separation techniques, including froth flotation, magnetic separation, gravity separation, and electrostatic separation, play crucial roles in the efficient extraction of valuable minerals from ores. Each method offers distinct advantages and limitations, influencing its applicability in different scenarios. The discussion delves into the factors influencing the selection of a particular separation method, such as mineral properties, particle size distribution, and economic considerations. Furthermore, the section explores recent advancements and emerging trends in mineral processing technology, shedding light on potential future developments that could enhance separation efficiency and sustainability in ore processing operations. This comprehensive analysis serves to deepen understanding and guide decision-making processes in the optimization of mineral processing plants. In the field of mineral ore processing, separation is one major process that is being done through several methods and advanced techniques. This case study is based on low-grade nuclear ore found at Andhra Pradesh in India [44-47]. Several technical papers were reviewed and found that purification of the technical grade of the final product and maximum recovery depends on the proper handling of mineral ore at several step-by-step procedures of mineral ore processing [48-51]. Among all these chemical processing steps, advanced separation techniques play a vital role from start to end. Due to continuous experience in the field of such industries, there is always a huge scope for improvement in the case of technical specifications of filter media and processing equipment. Characteristics of filter media used to change from time to time based on necessary modifications required for process recovery enhancement. In the case of alkali leaching, the concentration of salts used to be more in process liquor which can further chock the filter cloth of the horizontal belt filter. Based on operations it was found that a few steps were very helpful for improvement in the case of maximum solid liquid separation i.e. (a). Usage of hot liquor for counter-current wash on HBF, (b). The pore size of HBF filters media to be modified for maximum extraction of filtrate, (c). MOC of polymer filter media to be modified based on liquor characteristics, (d). Design of washing nozzles for HBF cloths should be specific for proper washing, (e). Proper lab tests are required for the evaluation of the filtration rate for suitable flocculent and suitable filter media.

Conclusion

Thus, the mineral ore processing plant includes several advanced novel separation techniques as briefly mentioned in Figure 10. An overall combination of separation methods includes all three major forms of chemicals i.e. solid, liquid, and gas. The latest research helps in modifications of equipment used for separation techniques [52-55]. Technical specifications of filtration media are also used to change accordingly. This technical paper describes an overall combination of those advanced separation techniques used in several mineral ore processing industries all over the world [56-59]. In addition to this, research is being done in the field of extraction of CO2 from flue gas generated by mineral processing industries [60-63]. The boiler is used in all mineral ore processing industries for the usage of steam in several steps of the chemical plant. These boilers emit a sufficient number of SOX, NOX, COX, and particulate matter in the atmosphere [64-66]. Although, these emissions are as per permissible limits defined by regulatory boards further scope of extraction of these gaseous components was found by Vipin et al. [34] for useful purposes in mining and mineral ore processing industries. In conclusion, this comprehensive technical review has elucidated the diverse array of separation methods integral to mineral ore processing plants. From traditional techniques like gravity separation and flotation to more advanced methods such as magnetic separation and electrostatic separation, each approach offers distinct advantages and limitations in efficiently extracting valuable minerals from ore deposits [67-72]. Through meticulous analysis and comparison of these techniques, it is evident that a combination of methods tailored to specific ore characteristics and processing requirements yields optimal results. Moreover, ongoing advancements in technology continue to enhance the efficacy and sustainability of mineral separation processes, promising further innovation and optimization in the field. As mineral processing remains a cornerstone of various industries, the insights gleaned from this review serve to inform future research and development endeavors aimed at maximizing resource utilization and minimizing environmental impact in ore processing operations.

Figure 10:Types of separation techniques in mineral processing plant.


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 Tibial Pilon Fractures by Horacio Tabares Neyra in Orthopedic Research Online Journal: Peer Reviewed Orthopedic Research Journals


 

Summary

Introduction: Complex tibial pilon fractures represent less than 1% of lower limb fractures. The long-term outcome is often poor and correct initial management is crucial. Their treatment has evolved into a two-stage protocol, which today is the gold standard. The aim of this review is to summarize strategies for the management of these difficult fractures.
Search strategy: References were identified by searching PubMed, Google Scholar and Elsevier for publications between 2013-2025 in English.
Development: There is a broad consensus that surgical fixation and reduction is the treatment of choice for tibial pilon fractures. At present, the criterion of performing surgical treatment in two stages predominates. Several authors recommend primary osteosynthesis of the fibula to achieve a better reduction of anterolateral and posterolateral tibial fragments by means of ligamentotaxia. Applying and following a staged treatment algorithm helps to reduce the rates of complications and failures.
Conclusion: Meticulous planning, respecting the surrounding soft tissues and determining the correct time for osteosynthesis, based on standardized protocols, allow optimizing the final result of this severe injury.

Keywords:Fractures; Tibial pilon; Distal tibia fractures; Intra-articular ankle fractures

Introduction

Distal tibia fractures with joint involvement are rare (less than 1% of lower extremity fractures), but they are one of the most difficult injuries to treat for traumatologists seeking to achieve good results [1]. It was initially called “tibial pilon” by Destot in 1911, later, Bonin coined the term “tibial pylon fracture” in 1950 to describe the alteration of the roof of the ankle joint [2].

The mechanism of injury described presents two significant variants: a relatively low-energy torsional mechanism, associated with falls in sports activities, and another high-energy mechanism, in which the talus impacts axially on the distal tibia, producing fractures with comminution at different levels, generally associated with falls from height and car accidents [2]. The fracture pattern is determined by the position of the foot and, therefore, of the talus at the time of the injury.

The long-term outcome is often poor and correct initial management is crucial. In the early years of this century, treatment has evolved into a two-stage protocol, which today is the gold standard of care. Additional methods to treat soft tissue envelope are currently being investigated and have shown promising results for the future [3].

The aim of this review is to summarize strategies for the management of these difficult fractures, review the literature on recent developments, and thereby provide surgeons with a better understanding and ability to manage tibial pilon fractures.

Search strategy and selection criteria

The references were identified by searching PubMed, Google Scholar and Elsevier for publications between 2013-2025 in English with the terms: “treatment of tibial pylon fractures”, “management of fractures of the distal end of the tibia” and “metaphyso-articular fractures of the distal tibia”. Articles accessible freely or through the Clinical key and Hinari services were also reviewed.

A number of articles were selected that met the necessary requirements to support this review. Articles were added that are more than ten years old, but that are key to the topic. We excluded papers because they were duplicates or the source data was insufficient. Power Point presentations were discarded.

Development

There is a broad consensus that surgical fixation and reduction is the treatment of choice for tibial pilon fractures. However, in an ageing population, surgery sometimes cannot be carried out safely, in which case treatment consists of reduction and immobilization without weight bearing for 6 to 10 weeks with a heavy cast. In light of spinal anesthesia and modern methods of treatment, it is likely that at least external fixation is possible in most patients [4].

Until the beginning of the twenty-first century, the predominant criterion for the surgical treatment of tibial pilon fractures was that it should be performed as early as possible in order to reduce the associated complications and hospital stay. This view of surgical treatment reported good results when it came to low-energy injuries (Rüedi-Allgöwer I and II), but the results were not similar in high-energy trauma, highly comminuted and displaced tibial pylon fractures, and when there were comorbidities in the patient [5].

Due to this extremely high complication rate, the criterion of two-stage surgical treatment was established, which remains the most widely used treatment method for tibial pilon fractures today [6]. In recent decades, the therapeutic algorithm for pylon fractures has undergone a paradigm shift [7,8]. While 30 years ago pylon fractures underwent primary osteosynthesis and a single-stage surgical algorithm was proposed, today a two-stage protocol prevails [9,10]. Various studies confirm that meticulous planning, Respect for soft tissues and the choice of the optimal time for definitive osteosynthesis and general treatment according to standardized protocols can optimize the prognosis of this serious injury. However, the initial severity of the fracture in terms of initial absorbed energy, bone comminution, and soft tissue trauma still affects the prognosis.

Staged treatment

Tibial pilon fractures, particularly high-energy fractures, significantly affect the bone and soft tissues. Given the high rate of soft tissue complications associated with immediate open reduction and internal fixation, since the 1990s, and in particular after Sirkin’s work in 1999, treatment considers two stages: an initial external fixation for alignment and stabilization of the fracture and a delayed second stage, once the soft tissues are in good condition. for fracture reduction and osteosynthesis [6].

Although step therapy is currently the most widely used, there are cases in which there is no soft tissue involvement and immediate resolution of the fracture is doable, even in the first 72 hours, without increasing the risk of complications [11,12].

To counteract the risk factors and reduce the potential complications that define the prognosis of these serious injuries, clearly defined surgical principles and standardized treatment protocols are required [13,14]. During the initial management of tibial pilon fractures, closed reduction and external fixation are, in most cases, the first step of treatment, as fractures are too unstable and the soft tissues are compromised for retention with plaster [15]. An additional Steinmann nail in the calcaneus is frequently required to maintain length [16]. Proximal pins in the tibia should be placed proximal enough not to interfere with definitive osteosynthesis, while the entire structure of the external fixator should not be in the future surgical area to minimize metal artifacts during diagnosis by subsequent CT [17]. Several authors also recommend primary osteosynthesis of the fibula at this time to achieve, by means of ligamentotaxia, a better reduction of anterolateral and posterolateral tibial fragments [18]. However, this step should be carried out with caution, even in cases of simple fibula fractures, since it implies that the choice of surgical approach for definitive osteosynthesis can be established at this time. In addition, you should look for signs of compartment syndrome, which has been reported in up to 12% of cases; in which case an immediate dermatofasciotomy should be performed.

At the time of skeletal stabilization, the good results described by Ruëdi and Allgöwer in their publications of 1969 and 1973 [19,20] gave rise to the treatments that are still used today. These are sequential principles of fracture fixation, the objectives of which are to achieve anatomical reduction and stable osteosynthesis:
a) Recovery of fibula length.
b) Reconstruction of the articular surface.
c) Bone grafting in the metaphyseal region.
d) Stabilization of the tibia fracture with a medial plate.

Anatomical principles: columns and joint fragments

The concepts defined by Ruëdi and Allgöwer were based on radiographic studies; after the advent of CT scans in recent decades, we have better understood the morphology and patterns of fractures, which has led to new anatomical principles that better guide the treatment decision. In his 2013 study, based on CT images of tibial pylon fractures type C3 AO/OTA, Cole describes a constant fracture pattern at the joint level (more than 90% of cases); in which three main fragments can be seen: medial, anterolateral and posterolateral, with a Y-shaped base at the level of the fibular notch. In turn, the areas of greatest comminution are usually the central one, coinciding with the central point of the talus, and the anterolateral one [21]; (Figure 1).

Figure 1:Joint fragments in a pylon fracture. Note the fragments (1) medial, (2) posterolateral and (3) anterolateral of the pilon fracture. Anterolateral comminution is observed [21].


As for the columns or pillars, it refers to an anatomical continuum between the articular or epiphyseal fragments, with their respective metaphyseal and diaphyseal zones. Assal [22] in 2015, describes three spines, exclusively tibial: medial, lateral and posterior. More recent studies already consider four columns, by adding the distal fibula as one more column, which provides reduction and stability [23]; (Figure 2).

Figure 2:The four columns of the tibial pilon [23].


These four columns are:
a) Lateral spine: distal fibula
b) Posterior spine: posterior part of the articular fragment and one-third of the distal portion of the posterior tibia
c) Anterior spine: anterior part of the articular fragment and a distal third of the tibia anterior
d) Medial spine: one-third of the medial portion of the articular fragment and distal tibia.

The importance of these anatomical concepts lies in the fact that they recognize the joint areas and columns with greater comminution, which allows us to plan more precisely where to use the implants to stabilize the fracture. In the same way, we can plan the surgical approaches necessary to perform the surgery.

Prior to definitive osteosynthesis and after primary reduction and external fixation, a preoperative planning CT scan is mandatory, following the principle of “fracture planning”. 2D and 3D computed tomography reconstructions are of great help in understanding the nature of the fracture and carrying out meticulous surgical planning (surgical approaches, osteosynthesis technique and type of implants). Six typical fragments can be identified [24,25]:
a) Fragment of the medial malleolus
b) Anterolateral fragment
c) Posterolateral fragment
d) Ventral tibial fragment
e) Dorsal tibial fragment
f) Fragment of the central pylon (die-punch fragment)

Reconstruction of the articular surface and respect for soft tissues greatly influence the prognosis of tibial pilon fractures [26,27]. The choice of surgical approach is important to allow adequate visualization of the fragments and placement of the implants without further compromising already damaged soft tissues. As a rule, a minimum distance of 5 to 7cm between two skin incisions should be preserved to avoid further skin necrosis. Several surgical approaches can be chosen (anteromedial, anterolateral, medial, posteromedial, lateral, and posterolateral) [28]. Each approach, or its combination, offers certain advantages and has certain limitations that must be taken into account in terms of reduction potential, implant placement, and iatrogenic soft tissue injury.

Fibula fracture occurs in 90% of tibial pilon fractures and many authors agree that fibula fixation is crucial in this type of fracture. It provides stability to the lateral column, which would prevent valgus displacement and reduce angular displacement. It helps to reduce the tibia in terms of length, alignment and translation. Insertions of the syndesmotic ligaments help reduce anterolateral and posterolateral tibial joint fragments. Facilitates stability and reduction of syndesmosis in the event of injury [29,30].

We can perform fibular fixation in two moments:
a) Emergency along with external fixation as part of staged treatment
b) Together with the definitive osteosynthesis of the fracture.

Emergency fibular fixation, together with external fixator, corresponds to the initial phase of staged treatment, where the goal of fibular fixation is to provide adequate stability to the lateral spine. In contrast, medial stability is provided by the fixator. Several studies support emergency fibular fixation because of the benefits already mentioned and because it would help reduce the operative time in definitive surgery.

On the other hand, and considering the real clinical context, we must consider that urgent management of this type of fracture is usually performed by a general traumatologist, who does not perform the definitive treatment. In this scenario, a variety of factors are often overlooked, such as the approaches and types of implants that will be used later. Therefore, emergency fibular fixation may result in a procedure that hinders definitive management of the fracture.

A poor initial reduction of the fibula in complex or comminuted fractures, resulting in recurvatum, shortening and rotation of the fibula, influences the tibial reduction when performing the definitive treatment. Borrelli and Catalano, in their study, showed that even leaving a long fibula can cause a varus deformity of the tibia and overload of the lateral pylon region (Figure 3).

Figure 3:Example of two patients undergoing emergency fibula fixation. One case resulted in valgus (A, B) and the other in recurvatum (C, D). Both stabilizations were reviewed at the time of definitive surgery [23].


If possible, Minimally Invasive Plaque Osteosynthesis (MIPO) should be opted for to minimize soft tissue trauma, without compromising the quality of anatomical reduction [31]. Ideal fractures for MIPO are those with no or minimal displacement. Alternatively, MIPO techniques can also be used in cases of severe soft tissue injury. In cases of implementation of the MIPO technique, fibula fixation is the first step, as it allows, by means of ligamentotaxis, the initial reduction of the tibial components, which can later be momentarily reduced by Kirschner needles (joystick technique), percutaneous reduction forceps or even arthroscopic assistance [32]. Percutaneous traction screws and locked bridge plates are frequently used for fracture fixation

In cases that do not allow the MIPO technique, open reduction and internal fixation with screws and osteosynthesis with plaque remain the reference method. The principles published 50 years ago by Rüedi. Osteosynthesis of the fibula, tibial articular surface reconstruction, bone grafting for bone defects, and medial osteosynthetic support remain relevant [20].

To facilitate the visualization of the tibial joint surface, a separator can be used. The anterolateral and medial fragments must be mobilized to identify them accurately, as well as to inspect the articular surface of the talus. Reduction begins in most cases with the posterolateral fragment, followed by reduction of the central and medial fragment, which can be temporarily held in place with Kirschner needles. Particularly complex type B and C fractures require additional fixation with a bridge plate that holds the joint block to the tibial shaft. The anterolateral or medial plate is introduced from distal to proximal, either sub muscularly or subcutaneously, and is also temporarily fixed with Kirschner needles after radiological control of the reduction. The screws on the distal plate are initially placed, so that the entire articular surface is fixed. The plate should be fixed proximally with 3 or 4 biocritical locking screws, especially in osteoporotic bone. Once osteosynthesis is complete, the external fixator can be left in situ, if necessary (the calcaneal nail can be removed at this point), to promote soft tissue healing. Life-saving procedures, such as Ilizarov fixator or primary arthrodesis, should be performed only in cases of massive bone comminution with extreme soft tissue injuries [10].

In this context, applying and following a staged treatment algorithm, proposed by several authors, contributes to reducing the rates of complications and failures when treating these difficult tibial pilon fractures [33]; (Figure 4).

Figure 4:Surgical algorithm for the treatment of tibial pilon fractures. (ARIF: arthroscopic reduction and internal fixation, AA: arthroscopically assisted, MIS: minimally invasive surgery, ORIF: open reduction and internal fixation) [33].


Conclusion

The great difficulties caused by the treatment of tibial pilon fractures for traumatologists makes it necessary to establish a differentiated and standardized treatment protocol in two stages, to achieve a satisfactory result of this complex injury and thus reduce the risk of postoperative complications. The studies confirm the need for meticulous planning, respecting the surrounding soft tissues and determining the correct time for the performance of the definitive osteosynthesis, based on standardized protocols that allow optimizing the final result of this severe injury.

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