Building a safer future in tailings management: progress, challenges, and opportunities

Previn Pillay, Founder and CEO, Pyromin Consulting

In January 2019, Brazil’s state of Minas Gerais witnessed the country’s worst industrial accident, a shocking collapse that reverberated across the globe. The failure of Vale S.A.'s Córrego do Feijão tailings dam released over 11.7 million cubic metres of toxic sludge, claiming 272 lives and decimating Brumadinho's landscape and ecosystem. The tragic event underscored a harsh truth about tailings management: it is far more than an operational responsibility but a moral and ethical obligation. Each of us in the industry bears a shared responsibility to ensure that such disasters do not happen again.

More than simply meeting regulatory requirements, responsible tailings management now rightly mandates an intense focus on engaging the communities that neighbour our operations.

Dr David Williams, Professor of Geotechnical Engineering at The University of Queensland, who played a crucial role in the Brumadinho investigation, has seen both the successes and the failures of tailings management over his four decades in the field. “Tailings management isn’t just a technical issue; it’s a moral imperative,” he stresses. Dr. Williams’ call for accountability isn’t merely a critique; it’s a challenge for us to lead with responsibility and integrity. This article explores the steps we’ve taken, the challenges that remain, and the innovations on the horizon that redefine tailings management for a more resilient future.

Charting new paths towards safer mining

The Brumadinho disaster catalysed a shift in industry standards, leading to the development of the Global Industry Standard on Tailings Management (GISTM), launched by the ICMM and the UNEP in 2020. GISTM introduced enforceable guidelines for tailings facility design, operations and closure, focusing on transparency and community engagement. Today, the ICMM reports that 75% of high-risk tailings facilities operated by its members are aligned with GISTM, with full compliance expected by 2025.

In 2019, the Australian National Committee on Large Dams (ANCOLD) updated its guidelines on tailing management to reflect Brumadinho’s bitter lessons. ANCOLD now emphasises a ‘whole-of-life’ approach, considering tailings facilities not as fixed assets but ongoing responsibilities requiring regular inspection, monitoring, and adaptation.

Companies like BHP and Rio Tinto have incorporated ANCOLD’s standards into their tailings management strategies, aligning them with ESG commitments to demonstrate their dedication to sustainability. Yet, compliance with standards alone is scant motivation for the industry to sleep peacefully at night. More deliberate action is still warranted.

Post-Brumadinho, the Brazilian government responded by banning the construction of upstream tailings dams (commonly associated with structural risks) and mandated the decommissioning of existing ones by 2027. Chile and Peru also introduced stricter regulations, requiring mining companies to invest in safer technologies like dry stacking or filtered tailings. This regulatory evolution reflects an industry slowly but surely redefining what accountability means. However, regulatory frameworks are only part of the solution. Regardless of local mandates, mining companies must go above and beyond, treating tailings management as if every facility were in its backyard.

Harnessing technology for a safer tomorrow

Technology is transforming tailings management from a reactive process to a predictive and proactive one. However, each new tool unveils a complex basket of opportunities and challenges:

• Real-Time Monitoring Systems: The use of IoT sensors, satellite imaging and drones has revolutionised real-time monitoring, providing detailed insights into the stability of tailings dams. Vale, for instance, now monitors over 200 data points at each of its high-risk sites, tracking critical metrics like soil movement and pore water pressure. These systems allow operators to detect early warning signs, empowering them to act before an incident occurs. However, the annual cost of maintaining these systems can range from $200,000 to $1 million per facility, depending on the size and scope of the monitoring. In remote regions, connectivity issues can hinder effectiveness, and a shortage of skilled personnel can lead to misinterpretation of data, underscoring the need for continuous investment in technology and training.

• Dry Stacking: By removing water content from tailings, dry stacking reduces the risk of dam failure and mitigates water use—a key advantage in arid regions. Newmont’s Peñasquito mine in Mexico, where dry stacking has been implemented, has become a model for safe and efficient tailings storage. However, SRK Consulting estimates that dry stacking can cost up to 40% more than conventional tailings storage methods, primarily due to dewatering infrastructure and additional land requirements. While costly, the long-term benefits of risk reduction and environmental resilience make it an attractive option for companies willing to invest in safety and sustainability.

• AI and Predictive Analytics: At Teck Resources’ Canadian operations, AIdriven models analyse decades of data to predict potential failure points, giving operators an invaluable tool for risk mitigation. AI can identify patterns in the data, spotting subtle changes that could signal instability long before a human operator might even notice. Yet the effectiveness of these systems relies on the quality and quantity of data inputs and how they are interpreted. AI implementation remains a challenge for smaller operations, which may lack access to robust datasets. Moreover, data security is a growing concern, as AI models must be protected from cyber threats to ensure the integrity of their insights.

The Aitik Incident – a wake-up call for water management

In May 2020, Sweden’s Aitik tailings facility experienced a partial dam failure following a hefty rainfall season. While no injuries occurred, the breach led to significant contamination of nearby water sources. Investigations revealed that the heavy rainfall and insufficient drainage control increased water pressure within the tailings and compromised the dam’s structural integrity. Despite the facility’s advanced design, extreme weather events driven by climate change exposed hidden vulnerabilities.

Boliden, the company operating Aitik, responded by upgrading drainage systems, reinforcing dam structures, and introducing stricter water management protocols. This incident underscores the critical importance of adaptive water management as climate change heralds more intense and unpredictable weather. Investing in drainage control, flood barriers, and robust monitoring systems is paramount for mining companies to ensure tailings facilities can withstand the new climate realities.

Building lasting trust

In 2021, the BBC reported that the communities hit by the Brumadinho disaster would receive a $7 billion payout from Vale. We must contrast this with the human toll from the frontlines. "My husband left home for work in the morning, said 'God be with you', as he always did. But he never returned". A few days after the incident, Shirley Gonçalves recounted her husband’s words to the BBC.

Her stark words served as a wake-up call to anyone who even briefly entertained the thought that the payout was reparations for the damage. More than simply meeting regulatory requirements, responsible tailings management now rightly mandates an intense focus on engaging the communities that neighbour our operations. Mining companies must actively involve local stakeholders, ensuring their voices are heard and concerns addressed.

Barrick Gold established advisory boards across several of its operations in North America and Africa, inviting community representatives to meet regularly with company leaders. These boards discuss tailings management, environmental monitoring, and emergency preparedness.

In Tanzania, Barrick’s North Mara Gold Mine hosts open days where community members can tour the facilities, learn about tailings management practices, and provide direct feedback to the company. Initiatives like this nurture transparency, turning local stakeholders into informed partners rather than passive observers.

Best practices in community engagement include establishing accessible feedback channels, conducting emergency preparedness workshops, and publicly sharing safety data and incident reports. The adage ‘Show. Don’t Tell.’ takes centre stage regarding transparency and community welfare. Careful management of the social license to operate contributes to a legacy of ethical stewardship.

Emerging trends and innovations

Emerging technologies and innovative practices are shaping the future of tailings management. Carbon Capture, Utilisation, and Storage (CCUS) is one such development, with companies like Rio Tinto exploring the potential to mineralise CO₂ within tailings. This approach could align tailings management with global decarbonisation goals, transforming waste into a long-term carbon sink. Although still in its infancy, CCUS offers the potential for mining operations to contribute to climate solutions, turning an environmental liability into a climate asset.

Another exciting prospect is the integration of renewable energy sources into tailings operations. Solar panels and wind turbines could power tailings facilities, reducing their carbon footprint and operational costs. Additionally, as AI technology evolves, predictive analytics will likely become a standard across high-risk facilities by 2026. These systems will offer real-time insights and enhance operators’ ability to respond to emerging threats, making tailings management safer, more efficient, and more sustainable.

The road to safer tailings management is ongoing, and the stakes couldn’t be higher. Leading companies have made tremendous strides, but mammoth work is still ahead. By embracing global standards, investing in cutting-edge technology, and fostering genuine relationships with our communities, we can set a new standard for responsible mining. Let’s ensure that the lessons of Brumadinho are remembered and honoured through our actions.

In the words of Theodore Roosevelt, “The nation behaves well if it treats the natural resources as assets which it must turn over to the next generation increased, and not impaired, in value.” 