BHP has removed a long-standing safety risk in copper refining at its Olympic Dam Production Refinery by using automation to eliminate operator exposure to a high-hazard task.
Cathode stripping is a critical step in the copper refining process, involving the removal of thin sheets of nearly pure copper from large metal plates after refining. At Olympic Dam, the original cathode stripping machine required frequent manual intervention, placing operators in close proximity to potential hazards and exposing them to risks including crush injuries, line-of-fire incidents and significant physical strain.
Beyond these risk considerations, the demanding nature of the task also restricted who could safely carry out the role, creating barriers to participation and limiting workforce diversity.
To address these challenges, BHP brought together frontline workers, engineers and project partners to redesign the process. The result is a fully enclosed, automated robotic cathode stripping machine that strips and processes cathodes autonomously using precision automation.
By removing the need for hands-on intervention, the system eliminates operator exposure to hazardous conditions and removes risk at its source. The automation has also improved equipment reliability and reduced downtime caused by copper jams.
The safety improvement has delivered broader workforce benefits. With the physical demands of the role removed, the pool of potential operators has expanded. Females are now strongly represented among qualified operators at the Olympic Dam Production Refinery, supporting BHP’s focus on inclusion alongside safety performance.
“By removing risk at its source and embracing innovative technology, the project – which won the Safety, Security and Emergency Management category in our 2025 Health, Safety, Environment and Community Awards – exemplifies our commitment to reducing risk, preventing harm and strengthening our emergency response,” BHP said in a statement.
“The project also reflects our culture of continuous improvement and collaboration, where frontline teams, engineers and partners come together to deliver solutions that make a tangible difference to how we operate.”
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