Freeport McMoRan's AI-Driven Autonomous Haulage Revolution

Freeport-McMoRan Copper & Gold Inc. has been working to increase haulage efficiency through its deployment of next-generation Autonomous Haulage (AHS) fleets. 

The company has an ongoing strategy that focuses on technological innovation and sustainable development, which is particularly vital amid growing economic, regulatory and environmental challenges.

Despite this, Freeport McMoRan is undertaking seven main innovations that are transforming its mines and establishing future resilience.

Making operational changes

Freeport McMoRan has core operations spread across the world, including Grasberg Mine in Indonesia, operations in Morenci and Bagdad, Arizona, as well as in South America. At each site, it works to evolve its mining practices, implementing advanced technology, sustainability and community engagement.

By investing in these innovations, Freeport McMoRan is making value-driven change that can reshape the mining industry and protect its own operational resilience.

Mines around the world are facing issues to meet demand, especially as volatility has resulted in supply chain fragmentation across global business. By investing in technology, mining companies like Freeport McMoRan are making advancements to streamline operations and ensure long-term savings. Due to rising labour costs and issues with human error, ultra-large-scale mining can experience a range of bottlenecks.

Through the addition of technology, including AI and automation, mining companies are seeing the benefits, with less error and heightened productivity.

All supply chain, sustainability, Scope 3 and net zero leaders should attend:

• Procurement and Supply Chain LIVE: The Net Zero Summit - QEII Centre, London, March 4-5
• Procurement and Supply Chain LIVE: The US Summit - Navy Pier, Chicago, April 21-22

Co-located with Sustainability LIVE, these events brings together CSCOs, CSOs and senior decision-makers at a moment when sustainability, supply chains and commercial performance are increasingly interconnected.

Tickets can be booked online today for The Net Zero Summit and The US Summit. Group discounts available.

Technological innovations

Three of Freeport's innovations are technology-based, demonstrating efficiency through advancements.

1. AI-Driven Autonomous Haulage Systems (AHS)

Across mines in Arizona and Indonesia, Freeport McMoRan is deploying next-generation autonomous trucks and loaders. These vehicles are powered by advanced AI, with the capabilities to optimise ore extraction, route planning and maintenance. Through these, there will be optimal speed and fuel management, resulting in reduced greenhouse gas emissions, enhanced safety and reduced human error, as well as continuous 24/7 operations. 

As a result, there will be an increase in annual output, with an estimated 18% increase in haulage efficiency and 22% decrease in accident rates. This will also introduce more higher-skilled tech jobs and improved worker safety.

2. Advanced Ore Sorting and Process Automation

Through the use of AI-powered sensors, X-Ray transmission and automated conveyers, Freeport is able to expand its metal recovery rates as well as reduce its energy and chemical consumption in extraction. As a result, there is a 20-25% increase in processing efficiency, lowered emissions and waste volumes and a boost in production output amid growing demand.

The smart sensors are able to streamline metal separation, with an anticipated 12% reduction in energy needed per tonne. For the wider community, this offers more local tech upskilling and stable job opportunities.

3. Digital Twin Modelling and Predictive Analytics

This approach integrates geological data, sensor feeds and AI simulation, allowing for a virtual modelling of the operation. This provides early fault detection and maintenance prediction, scenario testing for extraction optimisation, an anticipated reduced downtime of 30% and improved sustainability.

This will help avoid failures and resource wastage and can help other industries with its mining data insights.

Responsible actions

Four of the innovations Freeport McMoRan is implementing are ones which have a wider impact on the community and environment.

4. Real-Time Environmental Monitoring with IoT and Satellite Data

There has been an introduction of high-resolution satellite imagery and distributed sensors to provide continuous monitoring of air, water and soil quality around the mines. This enables the proactive management of environmental issues, transparency for compliance and community assurance due to real-time reporting portals. 

It is expected to help with proactive pollution mitigation and rea-time reporting compliance, as well as the added benefit of increasing transparency and trust with the surrounding communities. 

5. Integration of Renewable Energy (Solar and Wind) Across Mining Complexes

It has installed solar parks near its Grasberg and Morenci operations, as well as wind turbines in South America. As a result, it is reducing its reliance on fossil fuels, cutting operational emissions and ensuring a resilient energy supply. 

It is anticipated to have a 30% fossil fuel reduction and a 40% energy-related carbon cut. This will also save on water usage, will improve air quality and will develop long-term health benefits for the local community.

6. Water Management and Recycling Systems

Freeport has implemented a closed-loop water systems and advanced tailings management at it mines, which reduced total water withdrawal by up to 50%, minimises local water source contamination and improves community access to clean water. 

Freeport estimates this will result in a 15% decrease in remediation costs and will increase partnership opportunities for locals.

7. Community Engagement Platforms and Local Value Chains

Platforms are helping introduce direct engagement with local populations across Indonesia, Arizona and South America. This ensures the integration of community feedback into mine planning, promotion of local supplier development and training programmes and inclusive economic growth.

This is anticipated to develop more than 1,500 local jobs and supplier contracts every year. 

These investments are helping the company absorb price shocks, develop better communication across its supply chain and with the local community, as well as increase operational output.

By investing into its operations and making sustainable and technological advancements, Freeport McMoRan is building mining resilience and demonstrating how the mining industry can modernise to tackle ongoing bottleneck issues.