MissionZero mine: Shaping the future of sustainable mineral processing

The following is a summary of the Robert E. Murray Innovation Lecture on “Sustainable Copper Mining Flowsheets and the MissionZero Mine” presented as part of the keynote session on Feb. 23, 2026 during the MINEXCHANGE 2026 SME Annual Conference & Expo in Salt Lake City, UT. Unprecedented challenge As the world accelerates its transition to renewable energy, the appetite for critical minerals such as copper, lithium, nickel, rare earths and graphite has never been greater. Forecasts suggest that global mineral demand will double by 2050, driven by the proliferation of electric vehicles, renewable power infrastructure and digital technologies. This surge presents not only an immense opportunity but also an unprecedented challenge. In a world where every ton of ore processed and every liter of water used is scrutinized, how can mining deliver more with less, while meeting tightening environmental and social expectations? Traditional mining methods, developed for an era of abundant, high-grade ore and looser regulations, are struggling to meet today’s demands. Declining ore grades, volatile markets and the imperative to shrink environmental footprints have rendered traditional mineral processing practices unsustainable. The sector thus finds itself at a decisive juncture, caught between the need to fuel the green economy, defense and artificial intelligence (AI) infrastructure, without compromising the planet’s future. Balancing these competing demands requires a paradigm shift in technologies and processes. FLS has responded to this challenge with MissionZero: an ambitious, holistic initiative to develop flowsheets for the future of mineral processing. This systemic approach aligns operational excellence with environmental responsibility. Integrating innovative technologies, digital intelligence and commodity-specific process designs, it offers mining professionals a roadmap to meet both production targets and sustainability goals. At the center of this approach is the belief that a more sustainable mining requires more than incremental improvement; it demands a fundamental shift in how we extract, process and manage resources. By developing tailored flowsheets for copper, gold, lithium and tailings reprocessing, FLS aims to set a new standard for efficiency, circularity and environmental stewardship. The message is clear. We must achieve more with less: less energy, less water, less waste. Commodity-specific solutions No two mines are alike. Whether extracting copper in Chile, lithium in Australia, or reprocessing legacy tailings in North America, each operation faces unique geological, regulatory and logistical constraints. By developing bespoke flowsheets, FLS can address these differences while delivering on the company’s aim of zero-waste and zero-emissions mineral processing: Copper flowsheets prioritize energy efficiency and water recycling, integrating high-pressure grinding and advanced flotation to maximize recovery and minimize tailings. Lithium flowsheets emphasize pyrometallurgical innovation, reducing the carbon footprint of battery-grade lithium while managing water use and waste streams. For gold and nickel, combining gravity separation, fine grinding and advanced thickening optimizes yield and minimizes environmental risk. Tailings reprocessing unlocks value from legacy waste, recovering minerals and reducing liabilities through bulk ore sorting, REFLUX classification and circular water management. Energy-efficient mineral processing Comminution, the process of crushing and grinding ore, remains the largest energy consumer in a mineral processing plant, accounting for up to 3 percent of global electricity use. As ore grades decline and mineralogy becomes more complex, the load on comminution circuits is likely to increase as more ore is processed to maintain (let alone increase) the supply of critical minerals. The need for energy-efficient grinding solutions, such as high-pressure grinding rolls (HPGR), vertical roller mills (VRM), the FLS Tower Mill (FTM) and Eccentric Roll Crusher (ERC), has thus never been more urgent. These technologies are integral components of more sustainable flowsheets, enabling operations to meet stringent energy targets while maintaining or improving throughput and recovery. Energy savings also extend beyond comminution. FLS’s reimagined flowsheets incorporate advanced ore sorting technologies to optimize recovery, reduce plant footprint and minimize reagent use. Bulk and particle ore sorting, rail running conveyors, coarseAIR coarse particle flotation, and the REFLUX Flotation Cell (RFC) work together, where applicable, to deliver higher throughput, lower energy consumption and a more compact plant footprint. These advances shift mineral processing from incremental improvement to transformational change, driving toward zero waste, zero energy waste and zero water waste. Water stewardship as a competitive advantage Water scarcity and environmental regulation are reshaping the mining landscape. In many regions, access to water is as important as access to ore. Progressive approaches to mineral processing thus place water stewardship at the strategic heart of operations, transforming water from a constraint into a competitive advantage. Advanced thickening and filtration, including the AFP2525 filter press and innovative thickener designs, enable near-zero liquid discharge and accelerate solids settling, improving water recovery and supporting closed-loop process water systems. Meanwhile, FLS’s EcoTails and EcoPaste technologies blend filtered tailings with waste rock, creating stable, environmentally secure landforms, reducing the risk of catastrophic failure and supporting progressive rehabilitation and land reuse. As water recovery rates rise to meet the growing water challenge, managing the chemistry of recycled process water will become increasingly essential for plant efficiency and environmental compliance, while advanced monitoring and acid mine water treatment systems will help maintain water quality across closed-loop circuits. Last, but not least, dry grinding technologies, such as VRM and advanced HPGR systems, represent the next frontier in copper processing. Breaking the link between mineral processing and water consumption could enable future copper flowsheets that eliminate or significantly reduce water use in comminution. Reimagining tailings as a resource Historically, tailings have been a costly liability, posing environmental risks and challenging management. Forward-thinking approaches flip this narrative, framing tailings as a resource of unlocked value. while reducing long-term risks. Innovative technologies such as the REFLUX and GradePro classifiers integrate real-time grade control, enabling efficient recovery of minerals from legacy tailings and ensuring economic returns. Ore sorting applied to tailings could further enhance recovery rates and reduce the volume of material requiring disposal. By transforming tailings management from a cost center to a profit center, circular flowsheets evaluate both economic viability and sustainability outcomes. Processing critical minerals with lower environmental impact The electrification revolution hinges on the availability of battery-grade lithium and high purity copper, yet refining both is energy intensive and presents significant environmental challenges. Tailored innovations address these complexities, including the FLS Lithium Pyro Island for lithium and alternative copper flowsheets. Hard-rock lithium processing requires high-temperature conversion of spodumene into lithium sulfate. Optimized preheaters and coolers recover and reuse heat in the conversion plant, reducing energy consumption. Meanwhile, the introduction of multiple hearth furnaces enables recycling of the lime used in the conversion process, reducing the carbon dioxide (CO2)-intensive production of fresh lime. Lime slaking and the use of alternative fuels further reduce the CO2 intensity of hard-rock lithium production.In optimized copper flowsheets, high-pressure grinding and advanced flotation are integrated for energy efficiency and water recycling, maximizing recovery while minimizing tailings and environmental impact. The digital backbone Products and flowsheet innovation are only part of the story. The digital backbone, comprising AI driven tools, advanced process control and digital twins, brings intelligence, adaptability and resilience to mining operations. For example, FLS’s LoadIQ advanced process control software and digital twins enable mines to respond dynamically to changing conditions, serving as key enablers of zero-waste, zero-emissions and zero-water waste mineral processing. From concept to commercial reality This MissionZero approach to sustainable mining has not gone unnoticed. The initiative was recently awarded the Robert E. Murray Innovation Award by the Society for Mining, Metallurgy & Exploration, recognizing its systemic approach to innovation and its framework for adopting new technologies across the mining industry. This accolade underscores the role of holistic thinking as a catalyst for industry transformation. Mining is entering a new era. This new age will be defined by the need to deliver more value with fewer resources, to operate with transparency, and to leave a positive legacy. Through commodity-specific flowsheets, energy-efficient technologies, advanced water management, circular tailings solutions and digital intelligence, the industry can meet this challenge. Importantly, this vision has now moved beyond concept to commercial reality. The first commercial sales of the RFC, ERC and HPGR FTM combination in wet grinding circuits mark a significant milestone, demonstrating that the industry is recognizing the potential of innovations to deliver practical, implementable solutions for today’s operations. By prioritizing energy efficiency, water recycling and digital innovation in commodity-specific flowsheets, FLS offers a robust framework for mining operations to achieve their water, energy and nature ambitions. Many of these advances are operational today, supported by ongoing innovation and commercial deployments. However, the destination has not yet been reached. As we move forward, collaboration will be central to success, as it has already been. The development and deployment of REFLUX and coarseAir technologies are just one example. Only through partnerships among mining operators, universities, engineering firms and technology providers can the industry ensure that solutions are grounded in real-world challenges, deliver measurable results and achieve a more sustainable future for mining.

MissionZero mine: Shaping the future of sustainable mineral processing

Authored by: Lucy England

To view the past issues of the UCA magazine you must be a member of SME/UCA.

Get your SME Foundation VIP Access Conference Pass to MINEXCHANGE 2027

“Check the box” and help support the SME Foundation

The Art and Science of the Flowsheet

Get your SME Foundation VIP Access Conference Pass to MINEXCHANGE 2027

“Check the box” and help support the SME Foundation

The Art and Science of the Flowsheet

To view the past issues of the UCA magazine you must be a member of SME/UCA.

How a simple equation delivers breakthrough understanding of grinding circuits

How Western miners can win Africa’s critical minerals race

Related Articles

Get your SME Foundation VIP Access Conference Pass to MINEXCHANGE 2027

“Check the box” and help support the SME Foundation

The Art and Science of the Flowsheet

UCA Division officer nominations

Get your SME Foundation VIP Access Conference Pass to MINEXCHANGE 2027

“Check the box” and help support the SME Foundation

The Art and Science of the Flowsheet

Get your SME Foundation VIP Access Conference Pass to MINEXCHANGE 2027

“Check the box” and help support the SME Foundation

The Art and Science of the Flowsheet

Use Single Sign On