WORLD PROSPECTS
Freeport Bagdad AHS ramps up & ASARCO Ray begins journey
Copper miner ASARCO recently paved the way for the future of mining at its Ray copper mine in Arizona with the launch of its new autonomous haulage system, adding 11 new 327-ton payload Cat 794 diesel-electric drive autonomous haul trucks to the fleet.
In a statement shared in May with Arizona’ s CopperArea. com, ASARCO said that together with Caterpillar and its dealer, Empire Cat, it is proud to be embarking on a transformative journey at its Ray Mine operations with the introduction of Caterpillar’ s autonomous haulage system( AHS), Cat ® MineStar™ Command for hauling.
It is making history as one of the first mines in the US to be fully autonomous using MineStar Command for hauling after Freeport’ s Bagdad copper operation, which began the conversion of its Cat 256-ton payload mechanical drive 793D trucks to autonomy in January with haul truck 230, with the main rollout having started in March. It is also working with Empire Cat and expects to have its entire fleet of 33 haul trucks driverless by the end of 2025, which will be responsible for more than 95 % of Bagdad’ s total haulage needs.
There, four autonomous trucks were initially operated in a pushback dedicated to autonomous haulage only, followed by a larger pushback being dedicated to autonomous haulage. In May, a new autonomous command centre started running, operating 24 / 7 to provide real-time visibility and control that enhances safety, efficiency and communication. Also by May, the autonomous fleet had expanded to 15 trucks and moved more than 3 Mt of material.
Back to ASARCO’ s Ray mine, where Michelle Lammers, ASARCO Operations Director, said in a statement:“ This groundbreaking initiative marks another milestone in our journey towards safer, more efficient and sustainable mining operations. By embracing innovation, we are setting new standards for the industry while creating valuable opportunities for our workforce.”
It added that this significant technological investment will be integrating 11 new Cat
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794 autonomous haul trucks into one of the USA’ s largest copper mining operations, charting a pathway to a safe and sustainable future for the Ray mine. As copper remains a critical mineral for the US, this deployment“ positions ASARCO ahead of the curve in modernisation”. It also aligns with the company’ s long-term vision to double its capacity, an ambition that reinforces ASARCO’ s strategic growth and its vital role in securing the nation’ s mineral supply. The AHS project“ demonstrates ASARCO’ s vision for the future of mining and our commitment to future proofing our workforce – one that embraces technology to improve productivity while further developing the exceptional talent within our organisation”.
The deployment of round-the-clock autonomous haulage technology is anticipated to enable production efficiency, equipment utilisation and operational reliability. Most importantly, it will enhance workplace safety, creating a more secure operation for ASARCO’ s valued workforce.“ Transforming our operation creates compelling career advancement opportunities for all our current team members for developing expertise in digital systems and autonomous technology – positioning ASARCO as an attractive destination for digitally skilled professionals looking to build careers at the intersection of technology and mining innovation.”
Marc Cameron, Senior Vice President of Sales, Services & Technology at Caterpillar, said:“ We are proud to support ASARCO’ s journey with the integration of Cat MineStar Command for hauling at Ray Mine. This highlights our collaboration and ASARCO’ s commitment to leveraging advanced technology to optimise mining processes for operational excellence.” www. asarco. com; www. cat. com / mining
Mesabi Metallics bringing autonomous Komatsu 980E fleet to Iron Range
Mesabi Metallics Company LLC has announced a major $ 110 million purchase of an entirely new fleet of mining equipment from global heavy equipment leader Komatsu, through Mesabi Metallics’ partnership with Road Machinery & Supplies Co, a Minnesota-based distributor of construction and mining equipment with offices in Virginia, Minnesota.
The purchase includes a fleet of Komatsu 980E-5 haul trucks. Featuring the FrontRunner Autonomous Haulage System, these state-of-the-art machines are some of the largest mining trucks in the world, and Mesabi Metallics will be the only mine in Minnesota to operate them. Mesabi Metallics, located in Nashwauk, Minnesota, is on track to complete construction of its mine, beneficiation plant and pellet plant for the production of Direct Reduction grade pellets in the March quarter of 2026.
The new fleet marks a major step forward in Mesabi Metallics’ commitment to safety, efficiency and environmental responsibility. The ultra-class 400-ton trucks are engineered to deliver maximum payloads with best-in-class fuel efficiency and industry-leading safety features. The statement added:“ Komatsu’ s electric drive ultra-class trucks are trusted at some of the world’ s largest and most productive mining sites, but this is their first deployment at a Minnesota iron ore operation – solidifying Mesabi Metallics’ role as a leader in mining modernisation.”
Mesabi Metallics’ haul trucks from Komatsu will be fully equipped to operate autonomously, increasing health and safety on site by minimising the number of people required around mining equipment; limiting mining equipment to specific, predetermined paths; and limiting haul-truck accidents due to driver fatigue or error.
Autonomous haulage capabilities also improve fuel efficiency, reducing environmental impact, and will increase cost efficiency. Mesabi Metallics will form a committee to evaluate the implementation of autonomous haulage and plans to operate the trucks autonomously as soon as feasible, while maintaining the total number of jobs on site.
Joe Broking, President & CEO of Mesabi Metallics, said:“ This investment isn’ t just about a dollar amount – it’ s about setting a new standard for how iron ore mining is done. By deploying a fleet of 400-ton autonomous haul trucks, we are building the safest, most efficient and most environmentally sustainable mining operation anywhere on the continent. This investment keeps us on track to complete the project by the first quarter of 2026, creating hundreds of family-sustaining jobs and boosting the regional economy while reinforcing Minnesota’ s Iron Range as the centre for innovation and reliability in iron mining.”
John Ward, Senior Vice President for Mining and Company Stores at Komatsu North America, said:“ We’ re proud to partner with Mesabi Metallics and provide a fleet
International Mining | AUGUST 2025