In Port Hedland, Western Australia, a new tyre recycling plant has been opened, which can be viewed as a revolution in managing mining waste practices in the country. The plant marks the first special plant in Australia aimed at the processing of huge off-the-road mining tyres which used to be buried or stored. The leaders in the industry anticipate that this development will transform sustainable activities in the Australian mining industry as well as curb environmental issues that have continued to affect it over the decades.
Figure 1: Aerial view of Port Hedland’s harbor and mining infrastructure in Western Australia’s Pilbara region
Revolutionary Facility Opens in Mining Hub
In 2025, Tyrecycle started the specialised plant at Port Hedland, which was aimed at the centre of the busiest mining area in Australia. It has more than 30,000 tonnes of off the road mining tyres installed each year with special mine-to-processing services. Port Hedland is strategically located for accessing Pilbara mining activities, and this has made accessibility of these activities of great help in minimising transport expenses and logistics problems.
The facility operates under harsh weather conditions using purpose-built dome structures from DomeShelter Australia. These protective coverings shield specialised equipment and workers from extreme Pilbara climate conditions. Operations Manager Kane Goldsmith confirmed the structure enables safe processing operations in Australia’s most challenging industrial environment.
Figure 2: Tyrecycle’s specialised plant at Port Hedland
Mining Industry Faces Massive Tyre Waste Challenge
In Australia, it produces about 130,000 tonnes of off-road tyres every year with the mining sector producing 79 percent of the total production. Tyre mining is an activity that consumes a lot of resources since mining tyres weigh up to 3.8 tonnes and cost more than 50,000 units. They also produce tyres that are about 27 percent steel and 27 percent natural rubber thus producing good recovery opportunities.
The existing mining tyre recycling rates stand at a pathetic 10-14 percent in the country. The rest 86-90 percent are buried in mining sites or stockpiles that are in remote areas. The Pilbara region of Western Australia alone is producing mining tyre waste of 50, 000 tonnes per year, which shows the magnitude of environmental issues.
According to Tyre Stewardship Australia, in 2023-24 more than 100,000 tonnes of mining tyres were onsite buried. This is in spite of the increased environmental awareness and pressure to have a sustainable solution in waste management. The mining companies are well aware of the issue of disposal and have not had available recycling facilities around the areas of operation in the past.
Figure 3: Australian mining tyre waste statistics and recycling data
Environmental Impact Drives Industry Change
Stakeholders and regulatory bodies put pressure on mining companies to implement sustainable waste management. The current Environmental Social Governance requirements also require thorough waste stream management throughout the mining processes. Without a reliable system of disposing of used tyres, companies are exposed to reputational damage and issues of social licence.
Covered tyres pose long term environmental risks, such as fire risks and contamination of groundwater. The tyres dumped in the area gather rainwater that forms breeding areas of disease carrying mosquitoes and insects. Rubber compounds are non-biodegradable and therefore, buried tyres remain forever in the soil.
Studies have shown that the manufacturing of tyres produces a lot of greenhouse gases and the amount of CO2 equivalent per tyre is estimated to be between 1.5 and 2.5 tonnes. When recycling is done well, there is less emission of these emissions and valuable materials are recovered to be used in various industries.
Advanced Technology Enables Large-Scale Processing
The Port Hedland facility deploys cutting-edge T-Rex OTR tyre cutters, representing the first installation of this technology in Australia. These machines process tyres weighing up to seven tonnes, handling the extreme size requirements of mining equipment. The equipment specifically targets the density challenges posed by ultra-class mining tyres.
Processing begins with de-beading operations that remove steel bead wire from tyre structures. This separation enables efficient rubber recovery while isolating metal components for steel recycling. Advanced shredding equipment then reduces tyres into manageable pieces for transport and further processing.
The facility features space for second processing line installation, enabling capacity expansion to manage entire Pilbara regional tyre volumes. This future-proofing approach demonstrates commitment to long-term waste management solutions for expanding mining operations.
Figure 4: Mining tyre recycling process flow diagram
Products Create New Revenue Streams
Recycled mining tyres generate multiple valuable products across diverse industries. Processed materials travel to Tyrecycle’s East Rockingham facility near Perth for conversion into crumb rubber, tyre-derived fuel, and steel wire products. These outputs support road construction, manufacturing, and energy production sectors.
Breakdown of valuable products created from recycled mining tyres, showing diverse applications across multiple industries
Crumb rubber from mining tyres enhances road construction through improved asphalt mixes. Boral successfully demonstrated OTR-derived crumb rubber in Sunshine Coast Council road projects during 2024. The modified asphalt showed improved resistance to UV aging and cracking, extending pavement life up to two times conventional treatments.
Road construction applications consume approximately 40 percent of recycled tyre materials. Tyre-derived fuel provides lower-emission alternatives to coal in industrial processes, representing 25 percent of output volumes. Steel wire recovery accounts for 20 percent of materials, supporting construction and manufacturing industries.
Industry Leaders Champion Sustainable Practices
Tyrecycle Chief Executive Officer Jim Fairweather emphasised the facility’s role in transforming mining waste management. “These massive tyres are no longer seen as a disposal challenge but instead a resource for the achievement of better sustainable outcomes,” Fairweather stated. The company invested five years developing the Port Hedland facility specifically for mining industry needs.
Mining companies demonstrate increasing willingness to embrace sustainable tyre management solutions. “Mining companies recognise the importance of managing their waste streams responsibly, and we’re here to work alongside them to deliver more sustainable outcomes,” Fairweather confirmed. This industry collaboration drives adoption of recycling services across Pilbara operations.
Aerial view of Port Hedland’s harbor and mining infrastructure in Western Australia’s Pilbara region
Major mining corporations including Rio Tinto, BHP, and Alcoa actively participate in tyre recycling programmes. Alcoa Australia announced collaboration with Tyrecycle during 2024 to recycle mining tyres from Western Australian operations. Rio Tinto processed approximately 800 tonnes of end-of-life tyres during Argyle mine closure, creating resilient road surfaces for local communities.
Economic Benefits Support Business Case
The Australian tyre recycling market generated AUD 392.2 million revenue during 2024, with projections reaching AUD 518.3 million by 2030. This growth trajectory demonstrates strong economic foundations for expanded recycling infrastructure across mining regions. Market expansion creates employment opportunities while reducing waste management costs for mining operations.
Collection costs for OTR tyres from remote areas range between $474 to $600 per tonne. Direct disposal costs at mining operations reach up to $50 per tonne for lawful onsite management. These expenses exclude site preparation, long-term monitoring, and potential reputational costs associated with burial practices.
Recycling provides cost-effective alternatives while generating revenue from recovered materials. Steel recovery, rubber products, and fuel applications create multiple income streams from former waste materials. These economic incentives support business cases for sustainable waste management adoption across mining operations.
Figure 5: Environmental benefits of tyre recycling versus burial
Government Support Enables Industry Development
Both Western Australian and Commonwealth governments provided funding support through the Recycling Modernisation Fund for facility development. Government procurement policies promote recycled material utilisation in infrastructure projects, creating stable demand for tyre-derived products. Western Australia leads national efforts in rubber crumb utilisation across road network construction projects.
The Australian government invested AUD 57.1 million during 2023 to establish strategic partnerships supporting critical minerals processing. Additional AUD 40 million funding supports early-stage critical minerals projects advancing international partnerships. These investments demonstrate government commitment to sustainable mining practices and circular economy development.
Export regulations restrict whole tyre disposal overseas, creating domestic processing requirements. The Recycling and Waste Reduction Act 2020 and Export—Waste Tyres Rules 2021 mandate local processing solutions. These regulatory frameworks drive infrastructure development while supporting Australian recycling industry growth.
Figure 6: Circular economy model for mining tyre management
Facility Expansion Plans Target National Coverage
Tyrecycle plans to replicate the Port Hedland model across major Australian mining regions. Target areas include Queensland’s Bowen Basin, New South Wales’ Hunter Valley, and Western Australia’s southern Goldfields. This expansion strategy addresses regional tyre waste challenges while building national recycling infrastructure.
Future facility development considers conveyor belt recycling programmes alongside tyre processing. Mining operations generate substantial rubber conveyor belt waste requiring specialised processing solutions. Tyrecycle expects to launch conveyor belt recovery programmes within six to twelve months of tyre facility operations.
Industry collaboration drives technology advancement and processing efficiency improvements. Complete Tyre Solutions operates Australia’s first commercial facility capable of processing tyres from passenger vehicles to ultra-class mining tyres. This comprehensive approach maximises resource recovery while minimising processing costs across tyre categories.
Environmental Benefits Support Climate Goals
Mining industry greenhouse gas reduction strategies include comprehensive waste management improvements. Companies target net-zero emissions by 2050 with interim reduction goals of 30 percent by 2030. Sustainable tyre management contributes to these objectives through reduced disposal emissions and enhanced material recovery.
Recycled rubber applications in road construction provide carbon footprint reductions compared to conventional materials. Studies indicate proper tyre recycling eliminates significant greenhouse gas emissions associated with production and disposal. Energy recovery from tyre-derived fuel offers lower-emission alternatives to fossil fuel combustion in industrial processes.
Circular economy principles transform waste streams into valuable resources across mining supply chains. Advanced waste management practices support Environmental Social Governance requirements while delivering measurable environmental benefits. These outcomes align with international sustainability frameworks and Paris Agreement commitments.
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Technology Innovation Drives Processing Efficiency
Equipment manufacturers develop specialised machinery for mining tyre processing requirements. Eldan separation plants efficiently separate rubber, steel, and textile components from processed tyres. MT Rex by Salvadori and Super Wolverine systems downsize challenging tyre structures ensuring complete material repurposing.
Processing facilities achieve 100 percent material recovery rates through advanced separation technologies. Rubber components become crumb rubber and powder products supporting manufacturing applications. Steel wire recovery provides construction materials while textile fibres support industrial applications.
Innovation partnerships between equipment manufacturers and recycling operators drive technology advancement. These collaborations address specific challenges associated with ultra-class mining tyre processing. Continued development improves processing efficiency while reducing operational costs across recycling operations.
Industry Transformation Supports Sustainable Future
The Port Hedland facility represents a watershed moment for Australian mining waste management. Traditional burial practices face replacement by comprehensive recycling solutions generating economic and environmental benefits. This transformation supports mining industry sustainability goals while addressing community environmental concerns.
Mining companies increasingly recognise tyre recycling as essential operational practice rather than optional initiative. Regulatory pressure, stakeholder expectations, and economic benefits combine to drive adoption across industry operations. The success of Port Hedland facility demonstrates viability of sustainable waste management solutions in remote mining environments.
Figure 7: Timeline of mining tyre management transformation in Australia
Australia’s mining industry leadership in tyre recycling innovation positions the nation as a global example for sustainable resource management. Technology development, regulatory support, and industry collaboration create frameworks for international adoption. These achievements support Australia’s reputation for mining industry innovation and environmental stewardship.
The facility’s success will determine expansion opportunities across Australian mining regions. Early operational results indicate strong demand from Pilbara mining operations seeking sustainable waste management solutions. This foundation supports national infrastructure development addressing mining industry environmental challenges while creating economic opportunities through circular economy principles.
