The global pivot away from fossil fuels is creating unprecedented demand for copper and other critical minerals, but the mining industry faces a daunting challenge: falling ore grades, scarce new discoveries, and project timelines that can stretch over a decade. To bridge the gap, miners are reviving old waste, deploying advanced processing technologies, and turning to artificial intelligence.
Between 1910 and 2010, an estimated 100 million tonnes of copper were discarded into tailings ponds, according to Germany’s Fraunhofer Institute. These legacy deposits are now being seen as a resource. Rio Tinto has already extracted scandium and tellurium from waste streams, while Hudbay Minerals is evaluating re-mining opportunities at its closed Flin Flon mine in Canada. Australia’s Cobalt Blue Holdings is studying pyrite tailings as a potential sulphur source, and India’s Hindustan Zinc has committed $438 million to process 10 million tonnes of tailings per year at its Rampura Agucha mine.
At the same time, miners are working to reduce waste from new operations. Glencore’s ISAMill and Albion Process are enabling higher recovery rates with lower water use, while US bio-tech firm Allonnia has developed D-Solve, a microbial process that removes impurities like magnesium. At the Eagle nickel mine in the US, Allonnia is piloting a system that boosts nickel grades by 18% while cutting impurities by 40%.
Artificial intelligence is becoming a central driver of efficiency. BHP uses generative AI and digital twin technology at its Escondida copper mine in Chile to optimize blasting, blending, and mill performance. Freeport-McMoRan, working with McKinsey, trialed AI at its Baghdad mine in Arizona, achieving a 5–10% increase in copper production. Rolling this out across its US operations could add 90,000 tonnes of copper annually — equivalent to a new $1.5 billion processing plant, but without the decade-long construction timeline.
The push to reprocess waste, integrate bio-engineering, and apply AI represents a quiet revolution in one of the world’s oldest industries. If successful, it could transform mining from one of the planet’s most polluting activities into a cleaner, more efficient sector — ensuring that the energy transition has the metals it needs.