BHP has partnered with Microsoft to apply advanced AI and high-performance computing to one of mining’s biggest technical challenges: improving copper recovery from existing ore bodies. The collaboration has already screened more than half a million molecules in the search for new leaching solutions that could help unlock future copper supply.
As copper demand continues to rise, mining companies are increasingly focused on extracting more value from existing resources.
BHP has unveiled the results of a collaboration with Microsoft and Prescience Insilico aimed at accelerating the discovery of advanced copper leaching solutions, using artificial intelligence and high-performance computing to tackle a challenge that has traditionally relied on years of laboratory testing.
Copper leaching plays a critical role in recovering metal from ore, but identifying new compounds capable of improving recovery rates has historically been a slow and resource-intensive process. With millions of potential molecules available for testing, conventional trial-and-error methods can take decades to produce viable results.
The collaboration leverages Microsoft Discovery, a platform designed to accelerate scientific research and development through advanced computing and specialised AI agents.
Working together, the teams screened more than 500,000 molecules that could potentially improve copper extraction performance. The project involved tens of thousands of quantum chemistry calculations and simulations before narrowing the field to a shortlist of candidate molecules now undergoing laboratory testing in Australia.
Importantly, the computational models were built using real operational data from BHP’s copper assets, ensuring potential solutions are relevant to actual mining and processing conditions rather than theoretical laboratory environments.
“As the first mining partner on Microsoft Discovery, BHP is leading the way in exploring how advanced computing and scientific capabilities can help tackle complex industry challenges,” said Aseem Datar, Corporate Vice President, Product Innovation for Microsoft Discovery.
The initiative forms part of BHP’s broader strategy to support future copper production growth as grades decline and new deposits become increasingly difficult and expensive to develop.
BHP Vice President Innovation Jessica Farrell said the technology has the potential to help address one of the industry’s most pressing challenges.
“As copper demand grows and new deposits become harder and more expensive to develop, improving recovery from existing ores is a critical lever to help meet future supply needs.
“This partnership has given our technical experts the tools they need to narrow an almost infinite field of possibilities down to a small number of options that could one day be deployed in our global copper operations.
“Those candidates are being tested against the realities of our ore bodies and operating constraints, so we are solving for what can actually work in practice.
“This shows how technology and human expertise can be applied together to solve complex, real-world challenges.”
Beyond improving copper recovery, the project is also targeting broader sustainability and operational benefits.
According to BHP, candidate molecules are being evaluated for their potential to reduce toxicity, lower environmental impacts and improve process efficiency while supporting lower-cost production.
The approach reflects a growing trend across the mining sector, where AI-enabled technologies are increasingly being deployed to optimise resource recovery, improve processing performance and support more sustainable operations.
The project was supported through BHP Invent, the company’s global innovation platform focused on connecting emerging technologies with operational challenges across mining, processing, leaching and tailings management.
Through its Open House program, BHP continues to work with external innovators and technology partners to identify solutions capable of improving productivity, sustainability and resource recovery across its global operations.
