Project highlights
- Region: West Africa
- Industry Sector: Mining and Minerals
- Commodity: Gold
- Project: In-Pit Tailings Storage Facility (IPTSF)
- Scope: Detail Design and Multidisciplinary Engineering
- Services: Process, Civil, Mechanical, Hydraulic and Geotechnical Engineering
- Duration: 24 months
- Project Value: $TBC
Project details
Introduction/Overview:
CEMS delivered the detailed design for an innovative In-Pit Tailings Storage Facility (IPTSF) for a major gold mining operation in West Africa. Faced with limited remaining capacity in the existing tailings storage facility, the project sought to repurpose a depleted open pit into a sustainable, long-term tailings storage solution.
The project represents a modern approach to tailings management, maximising the value of existing mine infrastructure while significantly reducing the environmental footprint and capital expenditure associated with conventional embankment-style tailings facilities. Through the integration of advanced water recovery systems, engineered containment measures and operational flexibility, the IPTSF solution provides a safe and efficient alternative for long-term tailings deposition.
The Solve:
CEMS developed a comprehensive design encompassing tailings transport, water recovery and environmental management systems to support the conversion of the exhausted open pit into an operational In-Pit Tailings Storage Facility.
The design incorporated two new tailings pump sets and upgraded HDPE pipeline infrastructure to transport slurry to the pit. Flexible deposition points were incorporated to optimise tailings distribution and promote the migration of decant water to the deeper sections of the pit for efficient recovery.
A multi-stage decant collection system was designed to maximise water recovery and recycling back to the processing plant. The system included skid-mounted decant pumps, a booster station, flow control valves and standby pumping capacity to ensure operational reliability.
To maintain process performance and cyanide concentrations, a dedicated dilution system was incorporated to allow controlled mixing and return of process water. In addition, a geomembrane-lined event pond and trench system were designed to safely manage excess slurry and decant water, providing controlled containment and return to the process circuit.
Recognising the importance of long-term performance, the design incorporated detailed geotechnical investigations, including Cone Penetrometer Testing (CPT), together with provisions for ongoing monitoring of deposition behaviour, water recovery efficiency and tailings solids levels.
The resulting solution delivered:
- Increased tailings storage capacity without the need for new embankment construction.
- Significant reductions in capital costs and environmental impact.
- Improved water recovery and reduced freshwater demand.
- Enhanced long-term stability and reduced post-closure liabilities.
- A flexible and sustainable tailings management strategy aligned with modern mining practices.
Conclusion:
The IPTSF project demonstrates CEMS’ ability to develop innovative and sustainable solutions for complex tailings management challenges across Africa. By transforming a mined-out pit into a fully integrated tailings storage facility, the project maximises existing assets, improves water stewardship and reduces environmental impacts while maintaining operational efficiency.
Combining geotechnical expertise, hydraulic design, process engineering and practical operational considerations, CEMS delivered a resilient and future-focused solution that showcases the next generation of tailings management for the African gold mining industry.
