Dry Stacking of Filtered Tailings for Large-Scale Production Rates over 100,000 Metric Tons per Day: Envisioning the Sustainable Future of Mine Tailings Storage Facilities

Abstract

Communities and authorities have been dismayed by globally recorded tailings storage facility (TSF) failures in recent years, which have negatively affected the safety of people and the integrity of the environment. In this context, obtaining the social and environmental license to operate TSFs has become a challenging process for mining companies. This has promoted the trend of using mine tailings dewatering technologies in the mining industry, with dry stacking of filtered mine tailings being recognized worldwide as one of the most acceptable, safe, and environmentally friendly solutions. This article presents a new paradigm in managing mine tailings, with disruptive and futuristic characteristics, considering the dry stacking of filtered mine tailings for large-scale industrial production rates over 100,000 metric tons per day (mtpd). Aspects of filtered tailings management are discussed, such as (i) dewatering process plant with thickening/filtering equipment, (ii) conveyance using fixed and movable conveyor belts, (iii) construction of dry stacking of filtered mine tailings facility, and (iv) implementation of Industry 4.0 technologies for automation of the mining processes. Finally, the article discusses how the large-scale filtered mine tailings solution is applied, considering the advances in the equipment’s performance and implementation of Industry 4.0 technologies as well as the experience gained worldwide in several mining operations. The future global trend is that mining operations with high daily production of mine tailings will apply dry stacking technology without dams to guarantee sustainability, promote continuity of the mining business, ensure the safety of communities, and conserve the environment.

Sensor Technologies for Safety Monitoring in Mine Tailings Storage Facilities: Solutions in the Industry 4.0 Era

“…Thus, mining monitoring systems that implement these technologies are transforming the productive activity of the real world into a virtual world that is also known as the metaverse, where the collection of large-volume data in real time and their processing permits better holistic and prospective decision-making [38][39][40][41]. These technological improvements are driving changes in how mine tailings governance occurs; for example, sensors are gradually changing from mostly analog to mostly digital [13]. Similarly, the implementation of the Internet of Things (IoT) allows different sensors to be connected through the Internet and offers a powerful means of connectivity and data transmission via cloud storage and computers to implement statistical and probabilistic data analysis algorithms [42][43][44].…”

“…Considering these causes, it is important to note that the generation of mine tailings worldwide increases every year due to the increasing demand for the metals necessary to decarbonize the economy through the development of digital age information, the implementation of electromobility, and the use of renewable energies to address the global threat of climate change [13,14]. Society in general and governments worldwide demand sustainable development to leave a better world for future generations and reduce their ecological footprint.…”