Ore Sand: A Circular Economy Solution to the Mine Tailings and Global Sand Sustainability Crises
Ore-sand is a manufactured sand produced as a by-product of metal ore mining that has the potential to drastically reduce mine wastes and the demand for natural sand.
Implementation Period
2019-present
Stakeholders and Partners
The University of Queensland; The University of Geneva; Federal University of Minas Gerais; Vale S.A. Mining Company
Themes
- Waste reduction
- Consumer behavioural changes
How this initiative contributes to zero waste.
Vale, with the support of its partners has implemented a circular economy initiative to hazardous reduce tailings waste production by adding mineral processing at its Brucutu iron-ore mining to extract ore-sand by-products for use in the local construction sector. Around 1 million tonnes of tailings has been reduced as a result of the initiative to date, with transformative implications for the global mining sector.
The approach reduces the environmental and social risks of traditional mining activities, such as habitat destruction and water pollution, while also addressing the growing demand for construction materials in a sustainable manner.
The approach reduces the environmental and social risks of traditional mining activities, such as habitat destruction and water pollution, while also addressing the growing demand for construction materials in a sustainable manner.
How this initiative contributes to the relevant SDGs associated targets.
Goal 12 (Target 12.2, 12.5, 12.6):
Target 12.2: The initiative promotes efficient natural resource use, and reduces the demand for new mineral extraction.
Target 12.5: Ore-sand minimizes waste by efficiently using the minerals present in the ore.
Target 12.6: Though not its primary aim, the initiative fosters sustainability by mine waste management, indirectly promoting sustainable practices.
Target 12.2: The initiative promotes efficient natural resource use, and reduces the demand for new mineral extraction.
Target 12.5: Ore-sand minimizes waste by efficiently using the minerals present in the ore.
Target 12.6: Though not its primary aim, the initiative fosters sustainability by mine waste management, indirectly promoting sustainable practices.
Goal 13 (Target 13.1):
The initiative indirectly strengthens resilience to climate-related hazards by mitigating environmental impacts of mining, reducing factors contributing to climate change.
The initiative indirectly strengthens resilience to climate-related hazards by mitigating environmental impacts of mining, reducing factors contributing to climate change.
Goal 6 (Target 6.3 and 6.6):
While not its main focus, the initiative helps improve water quality and protect water-related ecosystems by reducing pollution and habitat destruction from tailings storage facilities.
While not its main focus, the initiative helps improve water quality and protect water-related ecosystems by reducing pollution and habitat destruction from tailings storage facilities.
Goal 9
Ore-sand is a source of sustainable construction materials for infrastructure development.
Ore-sand is a source of sustainable construction materials for infrastructure development.
The aim of the initiative is to investigate whether by-products of mineral ores, with favourable mineralogical and physicochemical characteristics, can be a viable and sustainable source of substitute aggregate material for construction and other industries, and reduce the rising demand for sand extracted from the natural environment.
Relevant background of Minas Gerais, Brazil: Brazil's mining history, coupled with its dense population and high demand for construction materials, underscores the need for sustainable resource management. Minas Gerais, a populous state with significant mining activity, is a prime candidate for this initiative. Recent iron ore tailings dams disasters in 2015 and 2019 Minas Gerais have spurred investment in circular economy strategies, highlighting the urgency of innovative mine waste management.
Challenges and opportunities: By producing ore-sand materials the initiative aims to reduce tailings volume and meet sand demand sustainably, addressing environmental concerns and enhancing social acceptance of mining activities.
Choice of approach: The initiative demonstrates a commitment to addressing multiple sustainability issues by exploring the potential of sand by-products to manage tailings and meet sand demand sustainably.
Actions and Implementation
The case study represents a wide range of actions over a multi-year period.
The initial concept was advanced trough experimentation, pilot production and full-scale implementation at Vale's Brucutu mine in Minas Gerais. A range of studies were undertaken to advance and verify the work with University partners. The case study was featured in UNEP's Sand and Sustainability report in 2022. Full-scale implementation has been demonstrated with major mine waste reductions and use of ore-sand in road-building, brick making and concrete applications.
The initial concept was advanced trough experimentation, pilot production and full-scale implementation at Vale's Brucutu mine in Minas Gerais. A range of studies were undertaken to advance and verify the work with University partners. The case study was featured in UNEP's Sand and Sustainability report in 2022. Full-scale implementation has been demonstrated with major mine waste reductions and use of ore-sand in road-building, brick making and concrete applications.
Outcomes and Impacts
For details of outcomes and impacts see here:
https://miningmagazine.com.au/is-ore-sand-the-solution-circular-economy-to-the-mining-industrys-waste-problem/#:~:text=One solution to reduce mine,rock piles or tailings dams.
https://vale.com/w/vale-innovates-by-producing-sustainable-sand-for-the-market-reducing-the-volume-of-tailings-disposed-in-dams
https://vale.com/w/vale-launches-company-to-develop-sustainable-sand-business-2
https://miningmagazine.com.au/is-ore-sand-the-solution-circular-economy-to-the-mining-industrys-waste-problem/#:~:text=One solution to reduce mine,rock piles or tailings dams.
https://vale.com/w/vale-innovates-by-producing-sustainable-sand-for-the-market-reducing-the-volume-of-tailings-disposed-in-dams
https://vale.com/w/vale-launches-company-to-develop-sustainable-sand-business-2
Replicability and Scalability
Analysis has been undertaken to identify and model the global replicability of the initiative with major global reduction of mine tailings possible. The University of Queensland has also worked with other mining partners (e.g. Newmont) to demonstrate the applicability to other ore body types and improve the properties of the sand. The initiative is scaling up both through the University of Queensland and Vale's spin off company Agera.
Inclusive and Innovative
The initiative involves collaboration between mining company, universities, and government agencies. Mining companies play a key role in implementing the initiative, while government agencies provide regulatory oversight and support. Universities are engaged through consultations and research.
Innovation Methods include:
1. Relative advantages: the degree to which ore-sands are considered better than the
preceding product, technology, concept or approach by key stakeholders in the context of
market conditions.
2. Compatibility: the degree to which an innovation is perceived as being consistent with
existing organizational goals, current or future technical and legal constraints, values, past
experiences, and needs of the potential adopters and broader social goals.
3. Complexity: the degree to which an innovation is considered as difficult to understand and
use.
4. Trialability: the degree to which new ideas or innovations can be experimented for a limited
time ahead of making larger commitments.
5. Observability: the degree to which the results of an innovation become clearly visible to
decision makers and stakeholders within organizations and in industry sectors.
1. Relative advantages: the degree to which ore-sands are considered better than the
preceding product, technology, concept or approach by key stakeholders in the context of
market conditions.
2. Compatibility: the degree to which an innovation is perceived as being consistent with
existing organizational goals, current or future technical and legal constraints, values, past
experiences, and needs of the potential adopters and broader social goals.
3. Complexity: the degree to which an innovation is considered as difficult to understand and
use.
4. Trialability: the degree to which new ideas or innovations can be experimented for a limited
time ahead of making larger commitments.
5. Observability: the degree to which the results of an innovation become clearly visible to
decision makers and stakeholders within organizations and in industry sectors.
Accountability and sustainability
Life cycle assessment and other types of analysis have been performed to ensure sustainability. Full and independent sampling and characterisation has been performed.
See major study on Vale ore-sand here: https://smi.uq.edu.au/files/83107/FinalReport_OreSand_v1.pdf
See study on Newmont (Newcrest) ore-sand here: https://espace.library.uq.edu.au/view/UQ:96249f6
Budget and Resources Allocation
A full analysis of the costs of the multi-million dollar, multi-year initiative can be calculated at later phases.
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