How is copper mined and processed? From the basics to exploration & refinement

Copper is one of the most important metals for modern society, powering everything from our homes and infrastructure to renewable energy technologies like electric vehicles and solar panels.

But how is copper mined and processed, and what makes it such a crucial mineral for the future?

We’ll take you through the entire lifecycle of copper, from its discovery beneath the earth to the final refined product that keeps the world running smoothly.

The importance of copper in today’s world

Copper has been used by humans for thousands of years, but its importance has never been greater than it is today.

As the backbone of modern technology and a cornerstone of the renewable energy transition, copper’s role in the global economy is only growing. Its unmatched electrical conductivity makes it essential for everything from power grids and electric vehicles to smartphones and wind turbines.

With the world shifting towards a more sustainable, electrified future, copper is key for building the infrastructure that supports clean energy systems.

And it’s not just about new applications – copper is a champion of sustainability, as it can be recycled endlessly without losing its essential properties.

This makes it a vital part of the circular economy, keeping resources in use and reducing waste.

In a world increasingly concerned with environmental responsibility, copper serves as a metal that combines durability, versatility, and sustainability – making it more critical now than ever.

Key uses of copper

• Electricity and power generation: Copper’s superior conductivity makes it the preferred metal for wiring in homes, power grids, and electronics.
• Green energy technologies: From wind turbines to electric vehicle batteries, copper is critical to the renewable energy revolution.
• Infrastructure: Copper is used in construction for plumbing, roofing, and electrical wiring due to its durability and resistance to corrosion.

Copper’s role in shaping a more sustainable future is huge, which you can learn more about in our blog, ‘What is copper used for?’. As demand for green energy solutions continues to rise, so does the need for a reliable and ethically sourced supply of copper .

But how do we source and extract copper in the very first place?

Stage 1: Finding Copper

Geologists use surveys, rock sampling, and advanced technology like satellite imagery and geophysical methods to locate copper deposits. Once potential sites are identified, exploratory drilling confirms the presence and size of the deposit.

Stage 2: Mining the copper deposit

Once a deposit has been discovered, the copper bearing rock will need to be mined. Mining can occur as an open pit or underground mine. The Elizabeth Creek project includes both open pit (Cattle Grid South, MG14 and Windabout) and underground mining (Emmie Bluff) operations.

Our mining techniques in action at Elizabeth Creek

At Coda Minerals, we are dedicated to ethical and sustainable mining at our Elizabeth Creek Project in South Australia. We prioritise minimising environmental disruption, respecting Indigenous rights, and fostering strong community engagement.

Our open-pit deposits will use a conventional pit-strip and staged mining method. At the Emmie Bluff underground deposit, we’ve adopted a mechanical cutting with battery-powered continuous miners mining method with grout packs for additional pillar recovery. This innovative approach reduces greenhouse gas emissions compared to traditional underground mining methods such as long-hole open stoping.

Stage 3: Crushing and Grinding

Once the ore is extracted, it will be crushed and then grinded.

• Crushing: Large pieces of ore are broken down into smaller pieces by heavy-duty crushers.
• Grinding: The crushed ore is ground into a fine powder, allowing the copper minerals to be separated more easily.

Stage 3: Concentration (Beneficiation)

• For sulphide ores, flotation is the primary method. The finely ground ore is mixed with water, chemicals, and air bubbles. Copper sulphide particles attach to the bubbles and float to the surface, creating a frothy layer that is skimmed off as a concentrate. There are multiple stages of this flotation process, otherwise known as ‘rougher’ and the ‘cleaner’ stages. This refinement results in a final product containing approximately 20–25% copper. This is the beneficiation method Elizabeth Creek will use in the first stage of the processing process.
• For oxide ores, flotation is less effective, and hydrometallurgical methods like leaching are typically used. The ore is treated with a dilute acid solution, dissolving the copper into a liquid phase. The copper-laden solution is then processed using solvent extraction and electrowinning (SX-EW) to recover copper metal.

Once the copper has been concentrated, it can be sold to the market in this primary form. MG14 and Cattle Grid South is currently planned to be sold as a concentrate. Alternatively, this product can be further refined via a hydrometallurgical process to create copper metal.

Stage 4(A): Selling as a concentrate

Selling as a Concentrate: At this stage, the copper concentrate, typically containing 20–25% copper, can be sold to smelters. This is common when mining companies don’t have their own smelting facilities or operate in regions where local smelting is impractical.

Smelting: Once concentrated, the copper is heated in a smelter to extract pure metal.  The smelting process involves heating the ore to high temperatures, separating the copper from other minerals and impurities through chemical reactions. The end result is blister copper, which contains around 98% pure copper.

Stage 4 (B): Downstream Processing

Hydrometallurgical processing refers to the use of aqueous chemical techniques to extract and refine copper into a final product. Hydrometallurgy is particularly suited for processing low-grade ores, complex ores, or ores containing impurities that are difficult to remove using traditional smelting methods. It is also an environmentally friendly alternative to pyrometallurgical methods, as it typically generates fewer emissions.

• Albion Process: This process uses ultrafine grinding followed by oxidative leaching. The fine particles increase the surface area, and an oxygen-enriched solution breaks down the ore, releasing copper into solution. It is energy-efficient and suitable for low-grade or refractory ores. This is the current process the Elizabeth Creek project uses.
• Pressure Oxidation (POX): This process involves subjecting the concentrate to high temperatures (around 200-250°C) and pressures in an autoclave with oxygen. The intense conditions oxidize the sulphides, freeing copper for subsequent leaching. POX is highly effective for refractory ores containing high levels of sulphur or impurities like arsenic.

Both methods produce a liquid with an exceptionally high copper content.

Solvent extraction and electrowinning (SX-EW)

The copper-rich solution is then processed using Solvent Extraction and Electrowinning (SX/EW) to extract the copper.

• Solvent Extraction (SX): The leach solution is mixed with an organic solvent that selectively binds with copper ions. This separates the copper from impurities.
• Electrowinning (EW): The copper-rich solution from SX is subjected to an electrical current, which causes pure copper to deposit onto cathodes. This produces high-purity copper (99.99%) without the need for smelting.

Sustainability and copper recycling

One of copper’s most remarkable qualities is its ability to be recycled endlessly without losing its essential properties.

This makes it a cornerstone of the circular economy, where resources are kept in use for as long as possible, minimising waste and reducing the need for new materials.

Copper recycling

Recycling copper is far more energy-efficient than mining new copper. It uses only 15% of the energy required to mine and process copper from ore.

In fact, nearly 80% of all copper ever mined is still in use today, either in its original form or as part of a recycled product. Around 30% of the annual copper supply comes from recycled sources, making it a key material for sustainability.

At Coda Minerals, we see copper recycling as a key component of our commitment to sustainability. By focusing on both the extraction of new copper and the promotion of recycling efforts, we can help ensure a stable and environmentally responsible supply of this vital mineral.

The role of renewable energy

At Coda Minerals, we are committed to reducing our carbon footprint at every stage of production.

Thanks to South Australia’s renewable energy grid, which boasts the world’s highest percentage of clean energy, we can power our refining operations more sustainably. This not only lowers our environmental impact but also aligns with our goal of ethical and future-forward copper production.

What is the future of copper mining?

The demand for copper is expected to rise sharply in the coming decades as the world transitions to a greener, more electrified economy.

Key drivers of copper demand include urbanisation, electrification, and renewable energy projects.

As cities expand and electrify, the need for copper in infrastructure, power grids, and electronics grows rapidly. The rise of electric vehicles (EVs) is especially significant, as EVs use significantly more copper than traditional cars, due to copper’s essential role in batteries, wiring, and charging infrastructure.

Copper’s unique properties—such as its high conductivity and recyclability—make it indispensable not only in electric vehicles but also in renewable energy technologies like wind turbines and solar panels, as well as energy-efficient buildings, supporting the global shift toward greener, more sustainable living.

Trends shaping the copper industry

• Green energy: The shift to renewable energy sources like wind, solar, and hydroelectric power requires significant amounts of copper for wiring, batteries, and generators.
• Electric vehicles (EVs): EVs use up to four times more copper than traditional combustion engine cars, making copper a critical resource for the transportation industry.
• Sustainability: Investors and consumers are demanding more sustainable mining practices, and companies that can meet these expectations will be well-positioned for long-term success.

Increasing demand

As we mentioned, copper plays a vital role in the global energy transition, particularly in clean energy technologies such as solar panels, wind turbines, and electric vehicles (EVs). Its superior conductivity makes it essential for transmitting electricity efficiently, making copper a critical component of the push towards greener, more sustainable energy systems.

However, the growing demand for copper is exacerbated by a global supply shortage, driven by under-exploration and declining ore quality.

Many of the world’s major copper mines, including the Escondida mine in Chile, are now facing peak production due to the diminishing quality of copper ore.

With fewer new sources being developed—particularly in key regions like Chile, the Democratic Republic of Congo (DRC), and Australia—the supply remains tight, creating significant challenges for meeting future demand.

Additionally, the average copper ore grade has declined significantly over time. To make lower-grade deposits economically viable, innovation in both mining and processing technologies is essential.

Exploration meets innovation: Coda’s answer to the copper supply shortage

The supply gap and declining copper grades underscore the urgent need for increased exploration and innovation in the mining industry.

At Coda Minerals, we are tackling these challenges head-on with our forward-thinking approach to exploration and a strong commitment to sustainability, ensuring we can meet the growing demand while minimising environmental impact.

By leveraging our unique position in South Australia, we have the ability to produce copper in a way that aligns with both market demand and environmental sustainability. With a focus on innovation, ethical practices, and community engagement, we are working towards shaping the future of copper mining for the better.

Empowering the energy transition: Join Coda Minerals in building a sustainable world

Copper is essential to our modern world, from powering cities to enabling the transition to renewable energy. But it’s not just about how copper is used—it’s about how it’s mined, processed, and refined.

At Coda Minerals, we are committed to doing things differently, with a focus on sustainability, ethical practices, and long-term thinking.

From our innovative exploration techniques at our Elizabeth Creek Project to our commitment to using South Australia’s renewable energy grid, we are leading the way in responsible copper mining.

And with copper’s endless recyclability, we see a future where this incredible mineral plays a central role in building a cleaner, more sustainable world.

So, if you’re looking to invest in a company that is not only shaping the future of copper but also the future of the planet, with a dedicated, Australia-based team leading the way, you should consider Coda Minerals. Let’s build a greener, more sustainable future together—powered by copper.