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Released January 24, 2025 | SUGAR LAND
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Researched by Industrial Info Resources (Sugar Land, Texas)--Amid upheavals in the global markets for energy and manufacturing, two things are certain: Copper demand remains strong and only will grow in coming years. To that end, copper miner Freeport-McMoRan Incorporated (NYSE:FCX) (Phoenix, Arizona) believes it is well-positioned for large-scale expansions at some of its most productive facilities, especially at both upstream and downstream assets in Arizona. Industrial Info is tracking more than $5 billion worth of active and proposed projects across the U.S. from Freeport, more than 70% of which is attributed to expansion projects.
Click on the image at right for a graph detailing Freeport's active and proposed projects in the U.S., by project type.
Freeport recently announced it had started pre-feasibility studies at its Lone Star Mine in Safford, Arizona, in response to a "significant expansion opportunity." As it put the finishing touches on a $300 million expansion of its copper oxide ore-handling and stacking system, as part of a larger overhaul and debottlenecking plan, Freeport kicked off studies of the large, heavily mineralized area to pursue further capacity additions. FCX expects to complete these studies by mid-2026.
The recently completed project expanded Lone Star's crushing facility and increased its feed rate for oxide ore from 95,000 to 120,000 tons per day, which is expected to boost copper production from 250 million to 300 million pounds per year. Subscribers to Industrial Info's Global Market Intelligence (GMI) Metals & Minerals Project and Plant databases can learn more from a detailed project report and plant profile.
Freeport said in its quarterly presentation that its Safford and Bagdad mines are "established, long-lived copper districts with opportunities to expand capacity." While the company hopes its upcoming efforts at Safford will add another 300 million to 400 million pounds per year of copper beginning in 2030s, it expects to make a decision by the end of the year on as much as $3.5 billion of proposed investment at its copper and molybdenum mine in Bagdad, Arizona.
The Bagdad mine currently produces 216 million pounds per year of copper, 11 million pounds per year of molybdenum and 9 million pounds per year of copper cathode. Freeport believes recent feasibility studies point to another 200 million to 250 million pounds per year of production at Bagdad, which could begin as early as 2029.
The company already is at work on several major projects at Bagdad, including the $65 million conversion of its haul trucks to a fully autonomous haulage system, which would use technology from Caterpillar Incorporated (NYSE:CAT) (Deerfield, Illinois) to improve safety and decrease operating costs, and the $170 million expansion of tailings management infrastructure. Subscribers can learn more about Bagdad from a detailed plant profile and read detailed reports on the haulage system and tailings management projects.
On the downstream side, Freeport is at work on a $50 million electric furnace addition at its Claypool Copper Smelter in Miami, Arizona, which processes 850,000 tons per year. The new matte-setting furnace from Metix, a subsidiary of SMS Group (Mönchengladbach, Germany), will replace an aging, obsolete model. The company also is considering a new hot electrostatic precipitator to better process gas particulate removal at the facility. Subscribers can read detailed project reports on the furnace and precipitator.
Freeport's capital expenditures (capex) totaled $4.8 billion in 2024, including $2.1 billion for major mining projects. The company expects capex will total about $5 billion in 2025, including $2.8 billion for major mining projects.
Subscribers to Industrial Info's GMI Project and Plant databases can click here for a full list of detailed reports for projects mentioned in this article, and click here for a full list of related plant profiles.
Subscribers can click here for a full list of detailed reports for active and planned projects across the U.S. from Freeport.
Industrial Info Resources (IIR) is the leading provider of industrial market intelligence. Since 1983, IIR has provided comprehensive research, news and analysis on the industrial process, manufacturing and energy related industries. IIR's Global Market Intelligence (GMI) platform helps companies identify and pursue trends across multiple markets with access to real, qualified and validated plant and project opportunities. Across the world, IIR is tracking more than 200,000 current and future projects worth $17.8 trillion (USD).
Click on the image at right for a graph detailing Freeport's active and proposed projects in the U.S., by project type.Freeport recently announced it had started pre-feasibility studies at its Lone Star Mine in Safford, Arizona, in response to a "significant expansion opportunity." As it put the finishing touches on a $300 million expansion of its copper oxide ore-handling and stacking system, as part of a larger overhaul and debottlenecking plan, Freeport kicked off studies of the large, heavily mineralized area to pursue further capacity additions. FCX expects to complete these studies by mid-2026.
The recently completed project expanded Lone Star's crushing facility and increased its feed rate for oxide ore from 95,000 to 120,000 tons per day, which is expected to boost copper production from 250 million to 300 million pounds per year. Subscribers to Industrial Info's Global Market Intelligence (GMI) Metals & Minerals Project and Plant databases can learn more from a detailed project report and plant profile.
Freeport said in its quarterly presentation that its Safford and Bagdad mines are "established, long-lived copper districts with opportunities to expand capacity." While the company hopes its upcoming efforts at Safford will add another 300 million to 400 million pounds per year of copper beginning in 2030s, it expects to make a decision by the end of the year on as much as $3.5 billion of proposed investment at its copper and molybdenum mine in Bagdad, Arizona.
The Bagdad mine currently produces 216 million pounds per year of copper, 11 million pounds per year of molybdenum and 9 million pounds per year of copper cathode. Freeport believes recent feasibility studies point to another 200 million to 250 million pounds per year of production at Bagdad, which could begin as early as 2029.
The company already is at work on several major projects at Bagdad, including the $65 million conversion of its haul trucks to a fully autonomous haulage system, which would use technology from Caterpillar Incorporated (NYSE:CAT) (Deerfield, Illinois) to improve safety and decrease operating costs, and the $170 million expansion of tailings management infrastructure. Subscribers can learn more about Bagdad from a detailed plant profile and read detailed reports on the haulage system and tailings management projects.
On the downstream side, Freeport is at work on a $50 million electric furnace addition at its Claypool Copper Smelter in Miami, Arizona, which processes 850,000 tons per year. The new matte-setting furnace from Metix, a subsidiary of SMS Group (Mönchengladbach, Germany), will replace an aging, obsolete model. The company also is considering a new hot electrostatic precipitator to better process gas particulate removal at the facility. Subscribers can read detailed project reports on the furnace and precipitator.
Freeport's capital expenditures (capex) totaled $4.8 billion in 2024, including $2.1 billion for major mining projects. The company expects capex will total about $5 billion in 2025, including $2.8 billion for major mining projects.
Subscribers to Industrial Info's GMI Project and Plant databases can click here for a full list of detailed reports for projects mentioned in this article, and click here for a full list of related plant profiles.
Subscribers can click here for a full list of detailed reports for active and planned projects across the U.S. from Freeport.
Industrial Info Resources (IIR) is the leading provider of industrial market intelligence. Since 1983, IIR has provided comprehensive research, news and analysis on the industrial process, manufacturing and energy related industries. IIR's Global Market Intelligence (GMI) platform helps companies identify and pursue trends across multiple markets with access to real, qualified and validated plant and project opportunities. Across the world, IIR is tracking more than 200,000 current and future projects worth $17.8 trillion (USD).
