INNOVATIVE design & development of RED MUD TAILING POND for Vedanta Aluminium

Garware Technical Fibres Ltd (GTFL) has pioneered the design and construction of high-performing waste containment facilities and tailing ponds across India for over 25 years. Guided by a core philosophy centred around best-in-class engineering, GTFL has completed approximately 250 projects nationwide, establishing itself as an industry leader in delivering efficient and sustainable geo-environmental solutions. This case study highlights GTFL’s ground breaking work for Vedanta Aluminium Ltd (VAL) in Odisha, focusing on the design and development of a red mud tailing pond facility. This ambitious project, spanning over 200 acres, demanded innovative approaches to expand the existing storage capacity and introduce stability measures that met the highest safety and environmental standards.

Project background

For VAL’s alumina refinery operations, efficient and sustainable red mud disposal is critical. VAL required a tailing pond that could not only manage large volumes of waste but also address complex challenges, including lateral expansion and an increase in facility height beyond 50 meters. GTFL was tasked with designing a solution that provided substantial storage, met stringent safety and regulatory standards, and minimized environmental impact. This project serves as a testament to GTFL’s capability in addressing highly technical and demanding geo-environmental projects.

Objectives

GTFL approached this project with four primary objectives:

•  Capacity augmentation: To scientifically augment capacity for safe red mud disposal and ensure seamless, uninterrupted production at VAL's refinery.

•   Structural stability: To design a structure that remains stable under extreme operational and weather conditions, securing both the facility and the surrounding environment.

• Infrastructure development: To develop auxiliary facilities that support smooth operation and water management, essential for efficient tailing pond functionality.

• Environmental compliance & sustainability: To ensure the facility adheres to global best practices in environmental safety, aligning with Vedanta's sustainability goals and regulatory requirements.

Scope of work: The project scope included property line marking, site preparation, grading, embankment construction, filter and toe drains, HDPE geomembrane and liner installations, catchment pond development, and rainwater and seepage management systems. GTFL also coordinated the diversion of natural storm drains and construction of access routes, facilitating safe and efficient vehicular movement on-site.

Project execution

Executing a large-scale tailing pond required expertise in geo-environmental engineering, geosynthetic applications, and regulatory compliance. GTFL collaborated with numerous stakeholders, including technical and safety teams from VAL, third-party consultants, local authorities, and environmental institutes like IIT, Odisha’s environmental department, and local communities. The project was divided into key phases, each meticulously planned to ensure success.

Design and regulatory compliance: GTFL held detailed consultations with VAL and Odisha’s environmental authorities, outlining the step-by-step requirements for tailing pond development. This collaborative planning ensured all legal and operational requirements were fully integrated into the design.

Survey, investigation, and design: The GTFL team conducted an exhaustive site survey to establish baseline data critical for accurate design and drawing development. This survey served as the foundation for determining site suitability and addressing specific project requirements.

Material selection: Leveraging its extensive experience, GTFL selected high-durability HDPE liners with both smooth and textured surfaces, along with non-woven geotextiles for robust lining systems. These materials were chosen for their resilience and long service life, ensuring minimal maintenance and optimal performance.

Execution and collaboration: GTFL’s Landfill and Lining (L&L) team—comprising surveyors, designers, project engineers, safety supervisors, and technicians—worked seamlessly with civil engineering partners to execute Phase I of the tailing pond, currently operational by Vedanta. Phases II and III are ongoing and progressing as planned.

Quality assurance: Rigorous quality checks were conducted throughout the project, adhering to design specifications and technical standards. These checks were crucial in ensuring compliance with environmental and safety requirements, thus eliminating risks of later-stage complications.

Stakeholder coordination: GTFL actively engaged with local authorities and community stakeholders, ensuring smooth project progression and fostering a positive relationship with the local community.

Key achievements

GTFL’s work on this project achieved several notable milestones:

First-of-its-kind execution: GTFL successfully completed its first large-scale tailing pond for the mining and metallurgical sector. This accomplishment establishes GTFL as a leader in the design and execution of large geo-environmental projects, showcasing its engineering prowess and dedication to innovation.

Enhanced safety standards: Building a structure capable of safely containing waste up to a height of 50 meters required advanced engineering and a steadfast commitment to quality. The project has enhanced confidence in GTFL’s capabilities and reinforced Vedanta’s trust in our ability to deliver under challenging conditions.

Environmental and regulatory compliance: The successful construction of this tailing pond has provided VAL with the necessary waste management capacity, helping the company maintain compliance with environmental regulations and supporting uninterrupted production at its alumina refinery.

The GTFL advantage

Through this project, GTFL has demonstrated its unmatched capability in delivering innovative, sustainable, and high-performance solutions for the mining and metallurgical industries. GTFL’s technical expertise, combined with its commitment to environmental stewardship, makes it a trusted partner for companies seeking to align operational goals with sustainable practices. GTFL’s tailing pond solutions incorporate advanced geosynthetics, precision engineering, and a dedication to customer success, reinforcing its reputation as a leader in India’s growing environmental infrastructure sector.

Looking ahead: A vision for sustainable growth

GTFL’s successful completion of the Vedanta tailing pond marks a pivotal achievement in its journey toward becoming a global leader in technical textiles and geo-environmental solutions. By consistently innovating and delivering projects that combine sustainability with customer-centric design, GTFL is well-positioned to address the evolving needs of India’s mining and industrial sectors. Our work at Vedanta highlights GTFL’s commitment to creating lasting value and its proactive approach in supporting the sustainable growth of India’s critical industries.

The Vedanta Aluminium Ltd tailing pond project serves as a compelling example of GTFL’s expertise in addressing complex engineering challenges. With a focus on customer success, environmental compliance, and long-term sustainability, GTFL has set new standards in geo-environmental engineering. As India’s industrial landscape continues to grow, GTFL remains dedicated to providing innovative solutions that meet the highest standards of safety, quality, and environmental responsibility. Through projects like these, GTFL reaffirms its vision to be at the forefront of technical textiles and environmental solutions, driving positive change and creating a legacy of responsible industrial development.

Ranjeet Dash     Vice President – Geosynthetics,Garware Technical Fibres Limited