Grasberg Minerals District

Description: The Grasberg minerals district includes open-pit and underground mines.

Did You Know? PT Freeport Indonesia (PT-FI) commenced mining operations in 1972 and in 1988 discovered the Grasberg mine. Today, after significant production, the Grasberg mining district contains one of the world’s largest recoverable copper reserve and the largest gold reserve.

We have several projects in progress in the Grasberg minerals district related to the development of large-scale, long-lived, high-grade underground ore bodies located beneath and nearby the Grasberg open pit. In aggregate, these underground ore bodies are expected to ramp up over several years to process approximately 240,000 metric tons of ore per day (mtd) following the transition from the Grasberg open pit, currently anticipated to occur in late 2017. Development of the Grasberg Block Cave and Deep Mill Level Zone (DMLZ) is advancing to enable the DMLZ to commence production in late 2015 and the Grasberg Block Cave mine to commence production in early 2018. In addition to the near-term development projects in progress, we also have a long-term underground mine development project for the Kucing Liar ore body, which lies on the southern flank of and underneath the southern portion of the Grasberg open pit.

Location:  The remote highlands of the Sudirman Mountain Range in the province of Papua, Indonesia, which is on the western half of the island of New Guinea.

Ownership: 90.64% FCX (including 9.36% owned through our wholly owned subsidiary, PT Indocopper Investama); 9.36% the Government of Indonesia.

Mines, Processes and Facilities: The Grasberg minerals district currently has three mines in operation: the Grasberg open pit, the Deep Ore Zone (DOZ) underground mine and the Big Gossan underground mine.

Grasberg open pit. We began open-pit mining of the Grasberg ore body in 1990. Open-pit operations are expected to continue through late 2017.

Crushing and conveying systems are integral to the mine and provide the capacity to transport up to 150,000 mtd of ore to the mill and 75,000 mtd of overburden to the overburden stockpiles. The remaining overburden is moved by haul trucks.

DOZ underground mine. . The DOZ ore body lies vertically below the now depleted Intermediate Ore Zone. We began production from the DOZ ore body in 1989 using open stope mining methods, but suspended production in 1991 in favor of production from the Grasberg open pit. Production resumed in September 2000 and is expected to continue through 2020.

Using ore passes and chutes, load-haul-dump units transfer ore into haul trucks. The trucks dump into two gyratory crushers and the ore is then conveyed to the surface stockpiles for processing.

The success of the development of the DOZ, one of the world’s largest underground mines, provides confidence in the future development of PT-FI's large-scale undeveloped underground ore bodies.

Big Gossan underground mine. The Big Gossan mine lies underground and adjacent to the current mill site. It is a tabular, near-vertical ore body. Production from the Big Gossan mine began in fourth-quarter 2010 and is designed to ramp up to 7,000 mtd in 2018.

The Big Gossan mine utilizes a blasthole stoping method with delayed paste backfill. Stopes of varying sizes are mined and the ore dropped down passes to a truck haulage level. Trucks are chute loaded and transport the ore to a jaw crusher. The crushed ore is then hoisted vertically via a two-skip production shaft to a level where it is loaded onto a conveyor belt. The belt carries the ore to one of the main underground conveyors where it is transferred and carried to the surface mill stockpile for processing.

Description of Ore Bodies: The ore bodies are located within and around two main igneous intrusions, the Grasberg monzodiorite and the Ertsberg diorite. The host rocks of these ore bodies include both carbonate and clastic rocks that form the ridge crests and upper flanks of the Sudirman Range, and the igneous rocks of monzonitic to dioritic composition that intrude them. The igneous-hosted ore bodies (the Grasberg open pit and block cave, and portions of the DOZ block cave) occur as vein stockworks and disseminations of copper sulphides, dominated by chalcopyrite and, to a much lesser extent, bornite. The sedimentary-rock hosted ore bodies (portions of the DOZ and all of Big Gossan) occur as “magnetite-rich, calcium/magnesian skarn” replacements, whose location and orientation are strongly influenced by major faults and by the chemistry of the carbonate rocks along the margins of the intrusions.

The copper mineralization in these skarn deposits is dominated by chalcopyrite, but higher bornite concentrations are common. Moreover, gold occurs in significant concentrations in all of the district’s ore bodies. These gold concentrations usually occur as inclusions within the copper sulphide minerals, though, in some deposits, these concentrations can also be strongly associated with pyrite.

The Grasberg complex shown below illustrates the layout of the Grasberg/ Ertsberg minerals district reserves. The western side of the district is dominated by the Grasberg, with its massive open pit (final design shown) and block cave mineable reserves, and the Kucing Liar and Big Gossan ore bodies. The eastern side of the district is dominated by the Ertsberg East ore bodies, the DOZ and the DMLZ. The underground production and exploration access to these ore bodies is shown.