Brownfield mining operations in Zambia, including Kalumbila, Kansanshi, and Lumwana, generate significant waste, categorized into off-spec products, process-related materials, and indirect waste. Off-spec products that fail to meet required specifications can be minimized through continuous improvement frameworks like ISO 9000. Process-related waste, such as scrap metals, used lubricants, and worn-out conveyor belts, can be reclassified as by-products if viable markets are identified. Indirect waste, including obsolete equipment, furniture, and electronic waste, should be managed through structured collection systems that prioritize reuse and repurposing before disposal. Understanding these waste streams is critical for developing circular economy solutions that enhance sustainability, particularly in addressing the growing challenge of used tyres.
Mining firms in Zambia are increasingly facing challenges in managing end-of-life (EOL) Off-The-Road (OTR) tyres, particularly in brownfield mines. Kalumbila, Kansanshi, and Lumwana have stockpiled thousands of these tyres, creating environmental issues and storage constraints. With limited recycling options currently available, innovations are required to address this challenge. Composed of synthetic rubber, steel, and textile reinforcements, OTR tyres take decades to degrade. If improperly managed, they can leach harmful chemicals such as polycyclic aromatic hydrocarbons (PAHs) and heavy metals into the soil and water, leading to severe environmental risks. Their large size contributes to rapid accumulation at mining sites, consuming valuable land, creating fire hazards, and serving as breeding grounds for disease-carrying pests. Zambia also lacks adequate processing facilities and infrastructure to recycle these tyres effectively. Unlike smaller vehicle tyres, OTR tyres require specialized equipment for material recovery, and the absence of local circular economy solutions has led to prolonged stockpiling.
The EU-funded GreenTech4CE project has highlighted the scale of this issue, with FQM Kansanshi Mine in Solwezi alone having stockpiled over 7,500 OTR tyres. Similar challenges exist at Kalumbila and Lumwana, where continued mining operations exacerbate the problem. Globally, mining firms are among the largest consumers of these tyres, and international regulations are pushing for sustainable disposal and recycling solutions. However, Zambian mines have been slow to implement solutions due to technological and logistical barriers, making it difficult to safely dispose of or repurpose the waste.
The growing accumulation of OTR tyres presents an opportunity for Zambian SMEs, technology providers, and investors to develop scalable solutions that promote circular economy practices. Pyrolysis technology offers a potentially viable approach, converting waste tyres into fuel oils, synthetic gas, recovered carbon black (rCB), and steel. Conducted in an oxygen-free environment at high temperatures, this process has been successfully implemented in mining operations in Australia and South Africa. The outputs, including heavy fuel oil for industrial use and recovered carbon black for tire manufacturing and coatings, present valuable economic opportunities.
Another approach is mechanical shredding, which transforms OTR tyres into rubber granules or crumb rubber that can be repurposed for road surfacing, playgrounds, sports fields, and railway track stabilization. Devulcanization, a more resource-intensive solution, breaks down sulfur bonds in vulcanized rubber, allowing the material to be reintegrated into new tire production and various industrial applications.
To implement these solutions effectively, regulatory frameworks and investment mechanisms must be strengthened. Clear pathways for obtaining Zambia Environmental Management Agency (ZEMA) approvals and Energy Regulation Board (ERB) licensing for energy recovery projects are essential. Ppartnerships between mining firms, technology providers, and SMEs can facilitate the co-financing of recycling plants. Introducing incentives, such as duty-free importation of recycling equipment, rebates for recycled content, alongside access to green financing options like green bonds, will further encourage investment. Additionally, regional market expansion opportunities in countries like DR Congo and Botswana could unlock significant revenue potential, positioning Zambia as a leader in circular economy solutions for waste tyres.
The stockpiling of end-of-life OTR tyres in Zambia is both a challenge and an opportunity. Investing in sustainable solutions such as pyrolysis, mechanical recycling, and rubber reclamation can transform this waste issue into a circular economy success story. By taking proactive steps, SMEs, policymakers, and investors can align Zambia’s mining sector with global sustainability goals while unlocking long-term economic benefits.
