Freeport McMoRan’s AI-Driven Autonomous Haulage Revolution
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[1].
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.
References
- ^ 22% decrease in accident rates (miningdigital.com)