Driving circularity: Supporting the circular economy through effective tyre management

A typical mining tyre has a diameter of 63 inches, costs over US$40,000[2], weighs some five tonnes and contains about 27% of both steel and natural rubber, two valuable commodities that are currently being stockpiled or buried as waste on many mines. Not only are these two commodities high in demand but natural rubber production also faces challenges due to deforestation and climate change.

In 2023, Tyre Stewardship Australia (TSA), a voluntary industry-led product stewardship organisation, found that across Australia an estimated 245,000 tonnes of waste Off the Road Tyres, rubber conveyor belts and tracks are generated each year, with the mining industry accounting for 80% of the volume. Yet less than 2% of Off the Road Tyres used in mining are recovered[3].

Circularity can be an important approach to meeting the demand required for the energy transition while limiting waste production and its impacts on the environment. Through the development of new and innovative approaches, tyre waste and associated environmental impacts can be reduced and new value unlocked. But close collaboration between industry, local communities and stakeholders is key for circular strategies to succeed.

ICMM members are actively working with tyre manufacturers to implement robust circularity strategies across their operations, fostering innovation and collaboration to support the recycling and reuse of  tyres, as outlined in the following case studies.

Repurposing tyres to build sustainable roads

Often, end-of-life products that contain rubber are wasted and sent to landfills due to associated logistics and recycling costs and limited available technology options. In Australia, however, recycled rubber from old tyres are being used to improve the resilience of roads.

When tyres reach their end-of-life, they can be processed into rubber crumb, small granules made from rubber. The rubber crumb is then mixed with a binder and asphalt to form a new road product that increases the service life of the road by up to two times as long, whilst minimising the need and cost of maintenance and materials. The new road product helps reduce road noise, increase resistance to moisture, reduce deformation from heavy traffic, and is therefore cost-effective[4].

Alcoa Australia is one of the companies embracing the circularity of tyres. In 2024, the company announced its collaboration with Tyrecycle, a national tyre recycling company, to recycle old mining tyres from its Western Australian mines. Tyrecycle is processing Alcoa’s mining tyres into crumb rubber at Tyrecycle’s East Rockingham facility which opened in 2024.

Rio Tinto is also actively working to recycle end-of-life tyres across a number of mine sites in Australia. During the closure of its Argyle mine in Western Australia, the company reprocessed roughly 800 tonnes of end-of-life tyres to build more resilient road surfaces[5]. Not only did this initiative help reduce waste and its negative environmental impacts but it also benefited local governments and communities by improving the quality of local infrastructure. It also unlocked new commercial opportunities and fostered job creation. 

Extending the life span of tyres through retreading

Circularity means more than just recycling; it’s also about tackling waste production at its source. Extending the lifespan of tyres is a great example of how circularity practices help reduce waste production.

In Chile, Codelco seeks to extend the lifespan of its tyres through preventative maintenance processes and regular replacement of the tyre tread. To achieve this, Codelco works with Bailac and Kal Tire, companies specialised in tyre management and maintenance.

Tyre treads are the patterned rubber on a tyre that makes contact with a road and provides grip during operation. However, due to friction, they are often the first part of a tyre to wear, causing the entire tyre to go to waste. Replacing the tyre tread is an effective way to extend the lifespan of the tyre, helping to not only reduce waste but also reduce the need for fresh materials.

This initiative covers Codelco’s operational sites and seeks to generate substantial savings by reducing the purchase of new tyres, while also mitigating environmental impacts and both logistic and disposal costs.

Not only does this initiative reduce costs, but it also considerably improves performance at mine sites. Data already shows an increase in operational efficiency of the tyres, measured in hours of usage, by an additional 25 per cent to 50 per cent[6], extending the average 6000-hour tyre lifespan by about 2000 hours.

Through this approach to tyre management, Codelco is driving circularity by reducing waste and enhancing its operational effectiveness, ultimately driving value capture and retention across the organisation.

ICMM members and Michelin: Industry collaboration to recycle tyres

Michelin, a leader in tyre manufacturing and engineering, is shredding and cutting end-of-life mining tyres to support a recycling ecosystem in South America. As part of the Michelin Better Mining initiative, Michelin opened its first mining recycling plant in Antofagasta, Chile, in late 2024. The mining recycling plant is currently processing tyres from BHP, Antofagasta Minerals and Codelco mines.

The facility specialises in cutting and shredding giant mining tyres into rubber chips, small pieces of shredded or ground rubber. These rubber chips are then processed into micronised rubber powder, an ultra-fine, high-quality powder which is directly used to manufacture new tyres and other products. Micronised rubber powder is a sustainable, cost-effective material that helps reduce the environmental impact of tyre waste and cuts down on the use of virgin rubber.

With the aim of recycling 2,200 63-inch mining tyres each year, this plant will help repurpose a considerable waste stream from mining tyres into new products and unlocking new value from end-of-life tyres. The opening of this facility supports the development of a broader tyre recycling ecosystem across South America, reducing the need for virgin tyre materials, retaining value, and ultimately driving increased process circularity for the mining industry.

Notes

[1] Benchmark Source (2022), More than 300 new mines required to meet battery demand by 2035

[2] Tyre Stewardship Australia (2020), Mining Industry: Off the Road Used Tyre Analysis

[3] Tyre Stewardship Australia (2023), Tipping the Balance: The business case for a circular economy for Australia’s off-the-road tyres, conveyors, and tracks

[4] Tyre Stewardship Australia (2024), The Benefits of Surfacing Roads with Tyre Derived Crumb Rubber

[5]  Tyre Stewardship Australia (2024), Tipping the balance for mine restoration and waste recycling

[6] ICMM (2024), Tools for Circularity