BHP, a global resources company focused on sustainable mining and innovation, and Eriez, a leader in advanced mineral processing solutions, have announced the successful commissioning of a HydroFloat coarse particle flotation (CPF) plant at BHP’s Carrapateena mine. This milestone marks a significant step forward in sustainable, high-efficiency mineral recovery for the global mining industry.

Delivered through close collaboration between BHP, Eriez, VOLPRO Pty Ltd, and Paradocs Metallurgy, the project integrated HydroFloat technology into the existing processing circuit. From installation through commissioning and optimisation, the teams met performance targets on an accelerated schedule and within budget.

HydroFloat CPF recovers coarse, high-value particles that conventional flotation often loses to tailings, boosting metal recovery and plant throughput while supporting more sustainable operations and improved tailings management. At Carrapateena, the technology will:

• Increase overall ore throughput to around 20,000 tonnes per day

• Reduce power consumption by enabling a coarser grind size

• Improve overall metal recovery

Anna Wiley, Asset President, BHP Copper South Australia, said: “We are making great progress in building our South Australian copper province. This is a massive achievement for our team and a significant step forward for our Copper SA operations. The HydroFloat is a compelling example of the smart technology, innovative thinking, and investment in productivity that will carry our business forward in South Australia. As a first-of-its-kind for BHP, this breakthrough will substantially increase Carrapateena’s processing capacity while maintaining recovery.”

Jose Concha, Global Director of Mining Products at Eriez, added: “BHP’s focus on innovation and operational excellence was critical to the success of this project. The trust, transparency, and teamwork with the Carrapateena operations team, VOLPRO Pty Ltd, and Paradocs Metallurgy have raised the bar for future HydroFloat deployments.”

The plant is fully operational and delivering results in line with expectations, paving the way for wider adoption of HydroFloat CPF in base and precious metals processing. Eriez, BHP, and partners will continue to refine the technology and CPF flowsheets, share insights, and assess opportunities to expand HydroFloat applications across other operations.

About BHP
BHP is a global resources company producing essential commodities, including iron ore, copper, and nickel, with operations across Australia and the Americas. Guided by its purpose to bring people and resources together to build a better world, BHP is committed to safety, sustainability, innovation, and long-term value creation.

About Copper South Australia
BHP’s Copper SA asset is a world-class copper province in the far north of South Australia, comprising three underground mines—Olympic Dam, Prominent Hill, and Carrapateena—that feed a centralised smelter and refinery at Olympic Dam. There is also an exploration project at Oak Dam, which could become a future fourth mine. Copper SA has a workforce of around 8,000 people, including contractors, and produced approximately 316,000 tonnes of copper last year. With global copper demand projected to grow by 70% by 2050, driven by population growth, rising living standards, and the energy transition, South Australia—home to two-thirds of Australia’s copper resources—stands to benefit significantly.