Weir Minerals Upgrades Tailings Monitoring at Glencore Zinc Refinery

Industry Milestone: Weir Minerals Completes Tailings Safety Upgrade at Kamoto

Weir Minerals has completed a significant upgrade to the tailings storage facility (TSF) monitoring system at Glencore‘s Kamoto zinc refinery—one of the world’s largest zinc processing operations. The project involved deploying Weir‘s Weir Sense® digital platform, which provides real-time monitoring of water levels, pore pressure, and settlement data across the tailings impoundment. The system integrates AI-driven early warning algorithms that can identify major risk events up to 72 hours in advance, with a detection accuracy exceeding 90% . It also supports mobile remote inspection and automated report generation, reducing the need for physical site visits and enabling faster response to changing conditions. The upgrade comes as global mining tailings safety standards tighten, particularly with the implementation of the Global Industry Standard on Tailings Management (GISTM) 2024, which mandates more rigorous monitoring, emergency preparedness, and community engagement requirements for tailings facilities worldwide. While such advanced digital safety systems represent a significant step forward for the mining industry, OCP Mechanical Company recognises that reliable, well-engineered crushing and screening equipment remains the foundation of safe and efficient mineral processing. With over 40 years of manufacturing experience, we supply high-performance jaw crushers, cone crushers, impact crushers, and complete crushing and screening plants engineered for durability and operational reliability. Our direct factory model eliminates intermediaries, delivering factory-direct pricing and responsive technical support.

Weir Sense® Platform: Real-Time Intelligence for Tailings Management

The Weir Sense® platform represents a comprehensive approach to tailings monitoring, combining sensor networks, data analytics, and cloud-based visualisation into a single integrated system. At the Kamoto refinery, the platform collects continuous data on water levels, pore pressure, and settlement—three critical parameters that determine tailings dam stability. This data feeds into AI-driven models that analyse trends and identify anomalies that may indicate developing risks. When a potential issue is detected, the system generates automated alerts and provides operators with actionable recommendations for response. The mobile remote inspection capability allows engineers to access real-time data and video feeds from anywhere, reducing the need for on-site visits and enabling faster decision-making. Automated report generation ensures compliance with regulatory requirements and provides a clear audit trail for internal and external stakeholders. According to Weir Minerals, the system has demonstrated the ability to identify major risk events 72 hours in advance with over 90% accuracy—a significant improvement over traditional manual monitoring methods, which typically provide only hours of warning. For mining operations managing tailings facilities, this capability translates to more time for evacuation, mitigation, and communication with affected communities.

GISTM 2024: A New Standard for Tailings Safety

The Global Industry Standard on Tailings Management (GISTM), updated in 2024, represents the most comprehensive set of requirements ever developed for tailings facility safety. The standard mandates that operators implement independent review, emergency preparedness plans, community engagement programmes, and real-time monitoring systems for all facilities with potential for significant consequences. It also requires that tailings facilities be managed by accountable executives and that performance data be publicly disclosed on an annual basis. The GISTM was developed in response to several high-profile tailings dam failures in recent years, including the 2019 Brumadinho disaster in Brazil, which resulted in over 270 deaths and widespread environmental damage. Since its initial release in 2020, the standard has been adopted by major mining companies, investors, and regulators worldwide. For operators of tailings facilities, compliance requires investment in monitoring technology, emergency response systems, and organisational governance. The Kamoto refinery upgrade demonstrates how digital platforms like Weir Sense® can help operators meet these requirements while improving operational efficiency and reducing risk exposure.

From Hardware Supplier to Tailings Lifecycle Service Provider

The Kamoto project reflects Weir Minerals‘ strategic evolution from a traditional equipment supplier to a tailings lifecycle management service provider. By combining hardware—valves, pumps, hydrocyclones—with digital monitoring and analytics, the company aims to support customers across the entire tailings lifecycle: from initial design and construction through operation, closure, and post-closure monitoring. This integrated approach is increasingly relevant as mining companies face mounting pressure from regulators, investors, and communities to demonstrate responsible tailings management. The tailings management market is growing rapidly, driven by regulatory compliance requirements, risk reduction imperatives, and the adoption of digital technologies that enable more proactive management. For equipment suppliers, this trend creates opportunities to differentiate through service capability rather than hardware specifications alone. However, not every operation requires the scale or investment associated with these comprehensive digital platforms. OCP Mechanical Company remains focused on delivering reliable, cost-effective crushing and screening equipment for the mid-tier market, with configurations matched to specific feed characteristics and production targets. Our direct factory model eliminates distributor margins, passing the savings directly to you. All price information provided is for reference only; final quotes depend on equipment configuration, shipping terms, optional features, and current exchange rates.

Why Equipment Reliability Matters for Safe Tailings Management

While digital monitoring systems are essential for tailings safety, they are only one part of a comprehensive risk management strategy. The reliability of the crushing and screening equipment that feeds the tailings facility directly affects the stability of the entire operation. Unplanned crusher downtime can disrupt material flow, affect downstream processing, and create operational variability that complicates tailings management. In contrast, reliable crushing equipment enables consistent throughput, predictable tailings generation, and more stable water balance management. OCP Mechanical Company‘s jaw crushers, cone crushers, impact crushers, and VSI crushers are engineered for continuous operation in demanding mining environments, with robust construction and wear-resistant components that extend service intervals. Our equipment supports the stable, predictable operation that effective tailings management requires. Our engineering team works closely with each customer to design custom crushing plants that match specific site conditions, feed characteristics, and production targets. Product specifications are continuously updated; please consult our online customer service for the latest technical parameters tailored to your application.

OCP Mechanical Company: Factory-Direct Crushing Solutions for Global Mining

With over 40 years of manufacturing experience and exports to more than 180 countries and regions worldwide, OCP Mechanical Company brings proven expertise to the global mining industry. Our product range includes jaw crushers, cone crushers, impact crushers, VSI crushers, vibrating screens, feeders, and complete crushing and screening plants—all brand-new and built to rigorous quality standards. We understand the specific requirements of mining operations processing complex ores: equipment must handle abrasive materials, deliver consistent product sizing for downstream processes, and withstand continuous operation in remote and demanding environments. As a direct factory manufacturer, we eliminate distributor margins, passing the savings directly to you. This is particularly valuable in the mining sector, where every dollar of capital expenditure must be justified against long-term operational returns. All price information provided is for reference only; final quotes depend on equipment configuration, shipping terms, optional features, and current exchange rates. Our engineering team works closely with each customer to design custom crushing plants that match specific site conditions, feed characteristics, and production targets. Product specifications are continuously updated; please consult our online customer service for the latest technical parameters tailored to your application.

Complete Crushing Solutions and After-Sales Support

A crushing plant is most effective when integrated into a complete processing line designed for efficiency and reliability. OCP Mechanical Company supplies complete crushing and screening plants that include vibrating feeders, primary jaw crushers, secondary cone crushers or impact crushers, and vibrating screens for classification. Every component is matched to your capacity requirements, preventing bottlenecks and ensuring smooth continuous operation across multiple shifts. Our after-sales support includes remote diagnostics, spare parts delivery, and wear-part prediction services to minimise downtime and extend equipment life. With the global mining industry continuing to expand—driven by demand for base metals, precious metals, and critical minerals—ensuring your crushing plant remains operational is essential to capitalising on market opportunities. Our team is available to assist with installation supervision, commissioning, and ongoing operational questions. With a 40-year track record of reliability and customer satisfaction, we have built lasting relationships with clients across the globe—relationships based on trust, performance, and mutual success.

Your Next Step: Get a Custom Quote for Your Crushing Circuit

Weir‘s tailings monitoring upgrade at the Kamoto zinc refinery reflects the mining industry‘s growing focus on safety, sustainability, and digital integration. However, the foundation of any successful mining operation remains reliable, high-performance crushing and screening equipment. OCP Mechanical Company offers factory-direct, high-quality crushing and screening solutions engineered for durability, energy efficiency, and low total cost of ownership—all at competitive prices. Our online customer service is available 24 hours a day, seven days a week, to provide free consultations, updated price references, and equipment selection guidance. Click the chat button now to discuss your project with a specialist—we are ready to help you build a more efficient and profitable processing operation.