BHP Applying AI To Help Understand Operations In New Ways

MELBOURNE – Johan van Jaarsveld, Chief Technical Officer of BHP Group Ltd., said, “AI is no longer a future concept for BHP. Our focus is on applying it in practical, governed ways that support our teams in achieving safer, more productive and more reliable outcomes. Artificial intelligence is increasingly shaping how BHP operates, as we look for practical ways to improve safety, reliability and performance while helping meet rising demand for critical minerals. From supporting teams to identify new mineral deposits, to running large processing plants and transport networks, AI is moving beyond experimentation and becoming part of day-to-day operations across BHP’s global portfolio.
Demand for copper and other critical minerals continues to grow, driven by electrification, the energy transition, and the rapid expansion of data centres and digital infrastructure. Copper is a foundational material for this growth – essential to power generation, transmission and cooling, and increasingly critical to the data centres that underpin artificial intelligence and the digital economy.
At the same time, bringing new supply online often involves long development timeframes, complex operating environments and significant execution risk. Projects can take many years to progress from discovery to production, and operating conditions become more challenging as ore bodies are deeper, more variable and harder to access.
In this context, emerging technologies, including AI, are increasingly being used at BHP to help teams manage variability, anticipate issues earlier and support more consistent performance across large, interconnected operations.
Across BHP, artificial intelligence is being applied in practical ways along the mining value chain – from helping us find resources, to supporting processing plant operations, to improving reliability across large, interconnected systems. These applications are designed to help teams manage complexity and variability in operations that run continuously and at scale.”
In exploration, AI and advanced analytics are being used to help geoscientists analyse large volumes of geological data more efficiently. By reviewing decades of historical information alongside new data, these tools can help teams identify areas of interest earlier and with greater confidence. This supports better decision-making and can help reduce exploration risk, while decisions on where and how to invest remain with people. One of the biggest challenges in mining is natural variability, particularly changes in the type and hardness of ore, which can affect how smoothly material moves through a processing plant.
AI is also being used to support reliability across mining and transport systems, where even short disruptions can have a significant impact. For example, computer-vision systems are used at operations in Chile and Western Australia to help detect issues such as spillage, oversized material or foreign objects on conveyors, crushers and rail loading systems. Using existing camera infrastructure, these tools can alert teams early and, in some cases, trigger pre-programmed automatic responses to help prevent equipment damage and avoid unplanned downtime. This helps keep material moving safely and consistently, while reducing the need for teams to work in higher-risk situations.
AI is also supporting safety outcomes for our teams on the frontline. For example, a voice-to-text mobile application allows employees to log hazards instantly while in the field. Reports are automatically geotagged and linked to historical incident data, providing rapid digital risk assessments that help teams respond sooner and prioritise controls.
Looking ahead
BHP has been applying AI and advanced analytics across its operations for several years, with use increasing as data quality, platforms and internal capability have improved. As this work continues, teams across the business are identifying further opportunities where AI can support day-to-day operations, sharing what works and extending proven approaches where appropriate, supported by strong governance and clear accountability.
“AI is helping us understand our operations in new ways and act earlier, with greater confidence. What excites us is the scale of opportunity ahead as we continue to apply these tools responsibly – learning, improving and expanding what’s possible across our operations,” said Jaarsveld.