Mining the future: How the circular economy is transforming tailings into treasure

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Introduction

In the age of sustainability, the mining industry is undergoing a quiet but significant transformation. Traditionally seen as a linear process – extract, process, discard – mining is now being reimagined through the lens of the circular economy. At the heart of this transformation lies an unlikely hero: mining tailings and by-products.

These once-overlooked residues are now being repurposed into valuable resources across various industries, including construction, agriculture, and battery production, transforming waste into wealth and reducing the environmental footprint of mining.

Mine Tailings – Overview and Management in Australia - Global Road Technology.

What are tailings and by-products?

Tailings are the leftover materials after valuable minerals (e.g. coal, copper, lithium, gold etc.) have been extracted from ore. They often contain a mix of crushed rock, water, and trace amounts of minerals. By-products, on the other hand, are secondary materials produced during the refining of primary metals, such as sulphuric acid from copper smelting, or gypsum from phosphate mining.

Generally, these materials are stored in extensive tailings dams or discarded, posing numerous environmental risks. Today, however, improved technology and innovations are unlocking their hidden potential. This has allowed for re-extraction from tailings, increasing profits and improving environmental outcomes (e.g. Fulcram Metals reprocessing using Extrakt technology in Canadian Gold Mines).

Building a greener world: Tailings in construction

The construction sector is emerging as one of the most promising outlets for repurposed tailings, thanks to the material’s mineral content and structural properties.

Researchers and industry partners are finding ways to incorporate tailings into a range of building products that not only perform well but also reduce the need for virgin resources. These include:

Cement and concrete: Tailings rich in silica and alumina can partially replace traditional cement ingredients, reducing CO₂ emissions from cement production.
Bricks and tiles: Tailings can be moulded and fired into durable bricks, offering a low-cost, eco-friendly alternative to clay-based products.
Road base and aggregates: Crushed tailings can serve as a stable base for roads and infrastructure, especially in remote mining regions.

This approach not only diverts waste from landfills but also reduces the demand for virgin construction materials.

Turning mine waste into value – sustainable strategies for modern mines

Case study one: Tailings-based concrete materials in South Africa

A study presented at the 6th International Conference on Concrete Repair, Rehabilitation and Retrofitting (ICCRRR 2022) explored the use of gold mine tailings as a partial replacement for fine aggregates in concrete. Researchers found that incorporating tailings into concrete mixes can improve specific mechanical properties, such as compressive strength and durability, while reducing reliance on natural sand. The tailings were chemically stable and met engineering standards, making them suitable for use in construction applications like bricks, tiles, and structural concrete.

Cultivating sustainability: Tailings in agriculture and rehabilitation

Beyond the built environment, tailings and by-products are also proving their worth in the natural environment.

With appropriate treatment and testing, some waste materials from mining can be repurposed to enhance soil health, facilitate land rehabilitation, and contribute to sustainable agricultural practices. Examples include:

Phosphates and potash residues: By-products of rare earth mining can be processed into nutrient-rich fertilisers, supporting food security.
Biochar and biomass residues: Some mining operations generate organic waste that can be converted into biochar, which enhances soil fertility, improves water retention, and increases carbon sequestration.
Lime and gypsum: By-products like lime (from gold mining) and gypsum (from phosphate mining) can correct soil acidity and improve structure.

With proper treatment and monitoring, these materials can enhance soil productivity while reducing the environmental burden of mining.

Case study two: BHP’s copper tailings transformed into bio-mineral fertilisers

BHP, in collaboration with America’s Tailings Inc. and Advancing Materials Processing Inc., has developed a method to convert copper tailings into bio-mineral fertilisers using slurry leaching and bio-digestion with organic waste. This process produces soil amendments and liquid fertilisers that enhance crop growth and soil health, aligning with circular economy goals.

Case study three: University of Newcastle and Thiess tailings to topsoil study

A recent University of Newcastle (UON) study (2025), conducted in collaboration with Thiess at a Hunter Valley mine, found that the tailings on site had a silt-like or silt-loam-like soil structure due to their high carbon content. The study suggests that incorporating these tailings into sandy soils could be both economically and environmentally beneficial. However, further research is needed to ensure carbon is available to plants and to determine the most effective tailings-to-soil ratio for optimal plant growth in mine-site rehabilitation.

The importance of mine rehabilitation - Mining Magazine Australia

Powering the future: By-products in battery production

The clean energy revolution is driving massive demand for battery materials – and mine tailings are increasingly being recognised as a secondary source of these critical inputs.

Instead of developing new deposits, companies are turning to the remnants of past operations to extract residual value, especially for metals needed in lithium-ion batteries and electric vehicle components. These include:

Cobalt and nickel: Often found in low concentrations in tailings from copper and nickel mines, these can be extracted using advanced hydrometallurgical techniques.
Lithium: Some tailings from spodumene and clay-based lithium mining still contain recoverable lithium, which can be reprocessed.
Manganese and graphite: By-products from steel and coal mining can be refined into battery-grade materials.
Rare Earth Minerals (REM): Cerium (Ce), Lanthanum (La), Neodymium (Nd), Praseodymium (Pr), and others found in some mine tailings (e.g. Bowen Basin – see Case Study Four) are critical in green technologies such as magnets, high-performance motors, electronics, and batteries.

This approach not only supports the clean energy transition but also reduces the need for new mining operations.

Case study four: Bowen Basin realisation of metallurgical coal tailings

The Bowen Basin in Queensland plans to recover REM from metallurgical coal tailings by mapping tailings compositions across multiple sites and using advanced processing technologies within shared, multi-mine recovery facilities. This system-wide approach could unlock up to $4.7 billion annually in value from materials such as REM, titanium, and sulphides, while also improving environmental outcomes and supporting circular economy goals.

Case study five: Cobalt recovery from tailings (Democratic Republic of Congo)

In the Democratic Republic of Congo, companies like Chemaf are reprocessing copper-cobalt tailings to extract residual cobalt. This cobalt is then refined and used in the production of lithium-ion batteries, supporting the global shift to electric vehicles.

Challenges and the road ahead

Despite its potential, transitioning to a circular economy in the mining industry presents significant challenges.

Extracting value from tailings is technically complex and may require significant investment in infrastructure and innovation. Regulatory frameworks also need to adapt, and the business case must be strong enough to sustain long-term change. Key challenges include:

• Technical complexity: Extracting value from tailings requires advanced processing technologies.

• Regulatory hurdles: Environmental and safety regulations must evolve to support reuse while protecting ecosystems.

• Economic viability: Market demand and commodity prices influence the feasibility of repurposing efforts.

However, with increasing sustainability pressures and a wave of innovation, momentum is building.

Final thoughts: Mining the past to power the future

As we stand at the crossroads of innovation and sustainability, the mining industry is proving that the end of extraction doesn’t mean the end of value. Legacy tailings, once dismissed as waste, are now being reimagined as resource banks – thanks to breakthroughs in processing technologies and a growing commitment to environmental stewardship.

The circular economy is reshaping the mining industry, turning tailings and by-products into valuable inputs for other sectors. By embracing this model, mining companies can reduce waste, lower emissions, and contribute to a more sustainable and resilient global economy.

Australia is at the forefront of this transformation. From BHP’s Olympic Dam tailings to Bowen Basin’s metallurgical coal tailings, companies are recovering valuable resources. These efforts not only unlock economic potential but also improve rehabilitation outcomes, reduce environmental risks, and align with circular economy principles.

By reprocessing tailings, we’re not only cleaning up the past – we’re also building a cleaner, more resilient future. The circular economy doesn’t have to be a distant ideal. By changing how we view mining waste, we also change how we mine, manage, and regenerate.

Curious about what circular economy thinking could mean for your site?

Contact Atlantech today to explore sustainable geological, mining, and environmental solutions tailored to your operation. Please email us at info@atlantech.com.au or phone 1300 682 616 within Australia or +61 2 7259 2804 internationally.