Reprocessing tailings at Worsley Alumina to unlock value

Tailings at Worlsey

Phibion has played a critical role in enabling Worsley Alumina to achieve innovative and sustainable outcomes in tailings management, significantly enhancing the efficiency of its operations.

At Worsley Alumina, bauxite residue—the waste generated during the alumina production process—is deposited in tailings storage facilities (TSFs) on-site. Worsley manages three active TSFs, which require annual embankment raises of five metres from October to May to accommodate additional bauxite residue disposal.

Traditionally, clay has been the primary material used for raising TSF embankments. However, in FY24, following comprehensive studies, successful trials, and Phibion's expert guidance, Worsley implemented a groundbreaking solution: reprocessing bauxite residue within the TSFs to construct embankments. This approach resulted in bauxite residue constituting approximately 40% of the material used for embankment raising.

This innovation offers numerous benefits. By reprocessing bauxite residue, the material no longer requires storage in the TSFs, freeing up significant space. Each cubic metre of storage space recovered adds an estimated A$3 in value. Over the next decade, it’s projected that this approach will unlock over 3.3 million cubic metres of storage space, generating significant value for Worsley Alumina.

In addition to creating more storage capacity, reprocessing bauxite residue addresses another critical issue: the limited on-site supply of clay. Worsley's clay reserves are expected to be depleted within the next 20 years. By reducing clay usage through residue reprocessing, it’s estimated that Worsley will conserve approximately 1.8 million cubic metres of clay over the next decade, yielding potential savings of around A$50 million.

Phibion’s advanced expertise and innovative solutions have been instrumental in driving this sustainable transformation. By leveraging their cutting-edge technologies and tailored strategies, Phibion has enabled Worsley to implement an efficient, cost-effective, and environmentally sustainable approach to managing tailings and embankment construction.

This collaboration not only highlights Worsley Alumina’s commitment to operational excellence but also demonstrates the value of innovation and partnership in addressing resource constraints and unlocking long-term value in the mining and alumina production industry.

Reference: Reprocessing tailings at Worsley Alumina to unlock value