Autonomous copper refining at Olympic Dam
Autonomous copper refining at Olympic Dam
BHP (ASX: BHP) is driving safety in copper refining at its Olympic Dam refinery in South Australia with a fully enclosed and automated robotic cathode stripping machine.Cathode stripping is a crucial step in the copper refining process, involving the removal of thin sheets of nearly pure copper (known as cathode) from large metal plates after refining.BHP’s original cathode stripping machine required frequent manual intervention, exposing operators to potential hazards including crush injuries, line-of-fire incidents and physical strain. Beyond safety concerns, the physically demanding nature of the work also limited participation, hampering efforts to build a more inclusive workforce.To address these challenges, a team of frontline workers and engineers from the refinery collaborated with project partners to develop and implement a safer and more inclusive approach.The team developed a fully enclosed and automated robotic cathode stripping machine, which uses precision automation to strip and process cathodes autonomously, to eliminate operator exposure to potential hazardous conditions — improving equipment reliability and reducing downtime caused by copper jams.Introducing an automated solution has also expanded the pool of candidates for operator roles, contributing to making Olympic Dam operations more inclusive, with women being strongly represented among qualified operators.The project won the Safety, Security and Emergency Management category at BHP’s 2025 Health, Safety, Environment and Community Awards for its reflection of the company’s culture of continuous improvement and collaboration — where frontline teams, engineers and partners come together to deliver solutions that make a tangible difference to how the company operates.
