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United States

Safford Mine

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Categories

Summary

Mine TypeOpen Pit
StatusActive
Commodities
  • Copper
  • Gold
  • Silver
  • Molybdenum
Mining Method
  • Truck & Shovel / Loader
Production Start2007
Mine Life2050
SnapshotThe Safford mine is a zero-discharge facility and one of the most environmentally advanced copper mines ever built.

The Safford mine includes three copper deposits. In recent years, Lone Star has been the only Safford deposit actively being mined.

In early 2026, limited mining production resumed in the San Juan deposit.

Freeport continues to advance pre-feasibility studies in the Safford/Lone Star district to define a potential significant expansion opportunity and expects to complete these studies during 2026.

A new acid transload facility is under study to improve logistics and reduce costs, leveraging rail access. Construction could begin mid-2026, pending regulatory approvals.

Owners

SourceSource
CompanyInterestOwnership
Freeport-McMoRan Inc. 100 % Indirect
Freeport-McMoRan Safford Inc. (operator) 100 % Direct
Freeport-McMoRan owns 100% of the Safford mine through its wholly-owned subsidiary Freeport-McMoRan Safford Inc.

Contractors

ContractorContractDescriptionRef. DateSource
Arizona Public Service Company Power supply The Safford operation’s electrical power is primarily sourced from Arizona Public Service Company. Dec 31, 2025
Luna Energy Power supply The Safford operation’s electrical power is primarily sourced from the Luna Energy facility. Dec 31, 2025
Tucson Electric Power Company Power supply The Safford operation’s electrical power is primarily sourced from Tucson Electric Power Company. Dec 31, 2025

Deposit type

  • Porphyry

Summary:

The Safford mine includes three copper deposits that have oxide mineralization overlaying primary copper sulfide mineralization. The predominant oxide copper minerals are chrysocolla and copper-bearing iron oxides with the predominant copper sulfide material being chalcopyrite.

Reserves at December 31, 2025

Mineral reserves Cut-off grade are 0.17% CuEq for Crushed Leach and 0.12% CuEq for ROM Leach.

Mineral resources Cut-off grades are 0.08% CuEq for Leaching and 0.12% CuEq for Milling.
CategoryOre TypeTonnage CommodityGradeRecoverable Metal
Proven Heap leach 513 Mt Copper 0.45 %
Proven ROM leach 194 Mt Copper 0.31 %
Probable Heap leach 138 Mt Copper 0.41 %
Probable ROM leach 79 Mt Copper 0.26 %
Proven & Probable Heap leach 651 Mt Copper 0.44 % 4.7 B lbs
Proven & Probable ROM leach 273 Mt Copper 0.3 % 0.6 B lbs
Proven & Probable Stockpiles 535 Mt Copper 0.43 % 0.2 B lbs
Measured ROM leach 444 Mt Copper 0.28 %
Measured Milling 1,829 Mt Copper 0.36 %
Measured Milling 1,829 Mt Gold 0.02 g/t
Measured Milling 1,829 Mt Silver 1.14 g/t
Measured Milling 1,829 Mt Molybdenum 0.01 %
Indicated ROM leach 480 Mt Copper 0.28 %
Indicated Milling 2,141 Mt Copper 0.3 %
Indicated Milling 2,141 Mt Gold 0.01 g/t
Indicated Milling 2,141 Mt Silver 0.93 g/t
Indicated Milling 2,141 Mt Molybdenum 0.01 %
Inferred ROM leach 280 Mt Copper 0.26 %
Inferred Milling 648 Mt Copper 0.23 %
Inferred Milling 648 Mt Gold 0.01 g/t
Inferred Milling 648 Mt Silver 0.84 g/t

Mining Methods

  • Truck & Shovel / Loader

Summary:

Safford mine is an open-pit copper mining complex that has been in operation since 2007.

In recent years (as of 2025), Lone Star has been the only Safford deposit actively being mined. In early 2026, limited mining production resumed in the San Juan deposit.

The available mining fleet consists of haul trucks loaded by electric shovels, which are capable of moving an average of 435,000 metric tons of material per day.

The highest bench elevation is 1,783 meters above sea level and the ultimate pit bottom is expected to have an elevation of 716 meters above sea level.

Operations Update (as of Q4 2025)
Construction and commissioning of fine ore stockpile facility are complete (adding 65,000- ton surge capacity), improving operational resilience.

Lone Star Stockpile
Phase two of the Lone Star leach stockpile was completed in spring 2025, supporting production plans.

Heavy Mobile Equipment

HME TypeModelSizeQuantityRef. DateSource
Shovel - EV P&H 4100 57 m3 9 Dec 31, 2025
Truck (haul) 235 t 59 Dec 31, 2025
Truck (haul) Caterpillar 777F Dec 31, 2024
Truck (haul) Caterpillar 793B 240 tons Dec 31, 2024
EV - Electric

Comminution

Crushers and Mills

Milling equipment has not been reported.

Processing

  • Sulfuric acid (reagent)
  • Crush-and-stack plant
  • Acid plant
  • Heap leach
  • Solvent Extraction & Electrowinning

Summary:

Safford is a leach operation that consists of a SX/EW facility with a capacity of approximately 320 million pounds of copper cathode per year from a 104,300 metric-ton-per-day crushing facility and a ROM leaching operation. The crushed ore is delivered to a leach pad by a series of overland and portable conveyors. A sulfur burner plant is also in operation at Safford, providing a cost-effective source of sulfuric acid used in SX/EW operations.

Sulfuric acid is used in the SX/EW process and is produced as a by-product of the smelting process at smelters and from sulfur burners at the Safford mine.

Operations Update (As of Q2 2025)
- Lone Star Phase II Leach Pad - completed and commissioned in late April 2025.
- Construction activities on Phase 2A will commence in the second half of 2025. This will increase the available footprint for ROM leaching stockpiles on the existing Safford leach pad, increasing overall production capacity for the site.

Production Milestone
As of Q4 2025, Safford achieved 'Tank House Max,' fully utilizing electrowinning rectifier capacity for maximum copper output, setting record daily and monthly production levels over summer 2025.

Acid Supply Strategy
As of Q4 2025, a new acid transload facility is under study to improve logistics and reduce costs, leveraging rail access. Construction could begin mid-2026, pending regulatory approvals.

Water Supply

Summary:

Safford operations water supply comes from groundwater wells in two distinct aquifers – the Fracture Zone aquifer and the Lower Basin Fill aquifer. Both of these aquifers are distinct and isolated from the Shallow Alluvial Aquifer which is adjacent to the Gila River.

Safford recycles approximately 93% of the water used each year on average. Examples of internal recycling within the processing facilities include: Use of in-pit dewatering for dust control on haul roads. Closing unneeded roadways, reducing or eliminating water usage for dust prevention.

Commodity Production

CommodityUnits20252024202320222021202020192018201720162015
Copper M lbs 287249245285265161110123150230202
All production numbers are expressed as cathode.

Operational metrics

Metrics20252024202320222021202020192018201720162015
Daily mining capacity 435,000 t408,000 t408,000 t408,000 t358,000 t358,000 t358,000 t340,000 t225,000 t225,000 t225,000 t
Daily milling capacity 104,300 t103,500 t103,500 t103,500 t103,500 t103,000 t103,000 t103,000 t103,000 t103,000 t103,000 t
Annual production capacity 320 M lbs of copper cathode320 M lbs of copper cathode305 M lbs of copper cathode305 M lbs of copper cathode305 M lbs of copper cathode285 M lbs of copper cathode240 M lbs of copper cathode240 M lbs of copper cathode240 M lbs of copper cathode240 M lbs of copper cathode240 M lbs of copper cathode

Production Costs

Commodity production costs have not been reported.

Personnel

Mine Management

Job TitleNameProfileRef. Date
Environmental Manager Mike Windsor LinkedIn Feb 18, 2026
Mine General Manager Vicki Seppala LinkedIn Feb 18, 2026
Project Manager Brian Payne LinkedIn Feb 18, 2026
Supply Chain Director James Seballos LinkedIn Feb 18, 2026
Supply Chain Manager Steven Sedillos LinkedIn Feb 18, 2026
Supply Chain Superintendent Fernando Díaz González LinkedIn Feb 18, 2026

Workforce

EmployeesContractorsTotal WorkforceYear
1,570 300 1,870 2025
1,575 2024
1,534 2023
1,466 2022
1,245 2021
1,215 2020
1,227 2019
1,000 2018
740 2017
700 2015

Aerial view: