Optimising Safety with Advanced Tailings Management

Mining operations generate significant volumes of waste material known as tailings. Managing these tailings safely and sustainably is critical to protecting the environment, ensuring operational continuity, and meeting regulatory requirements. Over recent years, advances in technology and engineering have enabled the development of more effective tailings strategies that reduce risks and improve overall safety. This article explores key approaches to optimising safety in tailings storage and disposal, providing practical insights for mining companies and operators.

Understanding the Importance of Effective Tailings Strategies

Tailings are the finely ground rock and process effluents left after valuable minerals have been extracted. These materials often contain residual chemicals and heavy metals, making their management a complex challenge. Poorly managed tailings can lead to catastrophic failures, environmental contamination, and significant financial and reputational damage.

Effective tailings strategies focus on minimising the volume of tailings produced, improving the stability of storage facilities, and reducing the environmental footprint. These strategies are essential for:

• Preventing dam failures that can cause loss of life and environmental disasters.

• Complying with increasingly stringent regulations on waste disposal.

• Reducing water usage and contamination through improved processing and recycling.

• Enhancing community trust by demonstrating responsible environmental stewardship.

  
  

Implementing these strategies requires a combination of engineering expertise, technological innovation, and ongoing monitoring.

Tailings storage facility showing containment structures

Key Components of Effective Tailings Strategies

Developing and implementing effective tailings strategies involves several critical components. Each element contributes to the overall safety and sustainability of tailings management.

1. Tailings Characterisation and Risk Assessment

Understanding the physical and chemical properties of tailings is the foundation of any management plan. This includes particle size distribution, moisture content, chemical composition, and potential for acid generation. Comprehensive risk assessments evaluate the likelihood and consequences of dam failure or seepage.

2. Design and Construction of Tailings Storage Facilities

Modern tailings storage facilities (TSFs) are designed with safety as a priority. This includes:

• Selecting appropriate dam construction methods (e.g., upstream, downstream, or centerline).

• Incorporating engineered liners and seepage control systems.

• Designing for seismic and extreme weather events.

  
  

Regular inspections and maintenance are essential to ensure structural integrity over the facility’s lifespan.

3. Water Management and Recycling

Water is a critical resource in mining operations. Effective tailings strategies aim to reduce water consumption by:

• Recycling process water within the plant.

• Using thickened or paste tailings to reduce free water content.

• Implementing drainage and seepage control systems to prevent contamination.

  
  

4. Monitoring and Early Warning Systems

Continuous monitoring of tailings facilities using sensors, drones, and satellite imagery helps detect potential issues early. Parameters such as pore water pressure, slope stability, and seepage rates are tracked to trigger timely interventions.

5. Progressive Rehabilitation and Closure Planning

Planning for the eventual closure of tailings facilities is vital. Progressive rehabilitation involves stabilising and revegetating tailings areas during operations to reduce long-term risks and environmental impacts.

Monitoring equipment installed at a tailings dam for safety

What Should Be Done with Tailings?

The question of how to manage tailings effectively is central to improving safety and sustainability. Several approaches are currently employed or under development:

Dry Stacking

Dry stacking involves dewatering tailings to create a solid, stackable material. This method reduces the risk of dam failure and water contamination. It is particularly suitable for arid regions where water conservation is critical.

Paste and Thickened Tailings

By increasing the solids content, paste and thickened tailings reduce the volume of water stored in the facility. This improves stability and reduces seepage risks. These methods require specialised equipment but offer significant safety benefits.

Backfilling

Tailings can be used as backfill material in underground mines, reducing surface storage requirements. This approach also helps stabilise underground workings and minimises waste footprint.

Reprocessing and Resource Recovery

Advances in mineral processing allow for the recovery of additional valuable minerals from tailings. This reduces waste volume and generates additional revenue streams.

Innovative Technologies

Emerging technologies such as geopolymers and tailings solidification offer new ways to immobilise contaminants and improve structural stability.

Thickened tailings deposition to reduce water content and improve stability

Implementing Advanced Tailings Management Solutions

To optimise safety, mining operations should adopt a holistic approach to tailings management. This includes:

• Engaging experts in geotechnical engineering, hydrology, and environmental science.

• Utilising digital tools for real-time monitoring and data analysis.

• Investing in research and development to adopt innovative tailings treatment methods.

• Collaborating with regulators and communities to ensure transparency and compliance.

• Developing emergency response plans tailored to specific site conditions.

  
  

Phibion offers advanced solutions to make tailings dams smaller and more secure. Their approach aligns with environmental and social responsibilities, helping mining companies manage mine waste more sustainably and safely. For more information on their offerings, visit Phibion's tailings management page.

Future Directions in Tailings Safety

The mining industry is moving towards more sustainable and safer tailings practices. Future trends include:

• Increased automation and AI for predictive maintenance and risk management.

• Greater use of renewable energy in tailings processing.

• Enhanced community engagement to address social concerns.

• Stricter global standards are driving innovation and accountability.

  
  

By adopting these trends, mining operations can reduce environmental impacts and improve safety outcomes.

Optimising safety with effective tailings strategies is a continuous process that requires commitment, innovation, and collaboration. By integrating advanced engineering, technology, and responsible practices, mining companies can protect people and the environment while maintaining operational efficiency.