Digitizing Tailings Dam Monitoring with Krucial CONNECT

The Global Tailings Management Institute: 

In the wake of disasters like the 2019 Brumadinho tailings dam failure, resulting in the deaths of 272 people and unprecedented environmental damage, increasingly stringent regulations have been drafted to ensure that tailings facilities globally remain safe and secure. 

Last month, The Global Tailings Management Institute (GTMI) was formed, an independent body which will oversee the implementation and consolidation of the Global Industry Standard on Tailings Management (GISTM) across the globe.  

Headquartered in South Africa, the GTMI aims to ensure that tailings facilities are independently audited and certified against the GISTM by qualified third-party assessors with the end goal of achieving zero risk from tailings dams to people and the environment.  

How does Continuous Monitoring come into Play? 

Principle 7 of the GISTM requires that operators of tailings facilities must “Design, implement and operate” comprehensive monitoring programs which should be in effect across a tailings dams entire lifecycle. Operators must set clear performance objectives that should be integrated into the monitoring programmes, with key parameters such as water levels, structural movement and pore pressure being monitored as close to real-time as possible. Data must then be analyzed and presented, with the acknowledgement of any deviations from the dams expected performance. 

Issues for Operators: 

While these requirements are vital in ensuring the long-term integrity of tailings dams, operators are likely to struggle to meet these monitoring standards. To integrate near-real-time monitoring programmes, tailings dam operators will need to leverage modern industrial technologies like IIoT smart sensors and automated reporting systems. 

To do this, stable connectivity and power is needed to ensure that smart sensors can continuously collect data on key parameters and transmit this data in regular intervals to an operator's device. More often than not, tailings dams are located in remote areas with limited access to terrestrial communications infrastructure, meaning that cellular is not a standalone connectivity option for an operator to meet the monitoring requirement of the GISTM.  

While there are a number of satellite options on the market that bypass the reliance on terrestrial communications, many of these are not tailored for the needs of IIoT monitoring programs, leading to expensive data costs and investment in additional hardware. 

The replacement of legacy systems will also be an issue for operators. Older monitoring systems may use proprietary protocols, outdated hardware, or incompatible data formats, making integration with modern IIoT sensors and platforms difficult.  

Scaling the monitoring programme as it is updated across a dam’s lifecycle is also difficult. Expanding legacy systems to support additional sensors, predictive analytics, or AI-driven insights is a complex and expensive process without an IIoT infrastructure that can easily integrate these technologies. 

The solution, Digitizing Tailings Management with Krucial CONNECT: 

Krucial CONNECT has been purpose built to support the integration of digital solutions anywhere on Earth, no matter the environmental conditions.  

Through IoT networks supported by robust hybrid satellite/cellular connectivity with multi backhaul options, users stay connected to data no matter the situation. If cellular fails, Krucial CONNECT automatically switches to its primary satellite communications, and in the rare case primary satellite fails, secondary satellite kicks in. This digital-first approach supported by robust hybrid connectivity eliminates blind spots, allowing for pre-emptive action in the risk of failure.  

Alongside this robust connectivity, Krucial CONNECT has numerous benefits which together facilitate the adoption of a digital-first strategy for tailings management: 

These include: 

• Drop-in functionality: With set up in hours rather than days, Krucial CONNECT skips the lengthy installation process of traditional connectivity solutions. 

• Durability: Krucial’s hardware is rated IP68 and UL50E for durability, meaning it can withstand the harshest environmental conditions. 

• Open Architecure: Through our secure open-API, Krucial CONNECT easily integrates with any data application or AI such as digital twinning technology. 

• Sensor Agnostic: LoRaWAN-Enabled, Krucial CONNECT can integrate 100’s of geotechnical sensors at once within a range of 15km meaning a single system can control remote monitoring of a full site.  

• Off-grid capable: Krucial CONNECT can be powered off-grid with in-built renewable energy options meaning there is no limit to where data can be collected. 

What this means for operators and regulatory bodies: 

Deploying robust digital monitoring solutions, like Krucial CONNECT, gives tailings dam operators access to the data they need to help drive operations and support compliance for these new standards set out by the GISTM. 

Krucial CONNECT’s scalability means it can adopt to the different monitoring requirements set out by the GTMI and operators alike. Smart sensors such as piezometers, inclinometers, extensometers and strain gauges as well as a range of environmental sensors and weather stations can be integrated into one system, with data transmitted and stored in Krucial’s cloud system. 

From here, data can then be securely transferred to the users chosen applications, which can include systems that can automatically process and send data to regulatory bodies. Furthermore, with Krucial CONNECT’s whole site coverage and ability to integrate 100s of sensors comes the possibility of digital twins for tailings dams.  

A digital twin is essentially a digital replica of an entire site, providing continuous insights which can allow an operator to pinpoint exactly where action is required. In the case of an issue with a dams structural integrity, an operator would have pre-emptive insights into exactly where on the dam this is, what variable has deviated from the norm, and what actions need to be taken to mitigate this risk. 

Conclusion: 

As tailings dam operators face increasing pressures to adopt continuous monitoring strategies, digitization is essential. Krucial CONNECT provides a secure and sustainable infrastructure for the adoption of the best IIoT, automating complex monitoring projects with ease. No matter the coverage of terrestrial communications infrastructure, no matter the power supply, operators can rest assured that critical data flows will never stop.