BHP Taps RF Heat Tech to Decarbonize Global Mining Operations

CALGARY, Alberta – December 04, 2025 – A new partnership between global mining giant BHP and Canadian clean-tech firm Acceleware Ltd. is poised to test whether radio waves can solve some of the mining industry’s most energy-intensive problems. The collaboration, announced today, will launch two paid feasibility studies to assess if Acceleware’s electromagnetic (EM) heating technology can make mineral processing cleaner, cheaper, and more efficient.

This move signals a potentially transformative shift for an industry under immense pressure to decarbonize. By exploring novel applications for iron ore drying and copper extraction, BHP is betting on an innovative technology that promises to electrify and streamline processes traditionally reliant on fossil fuels. For Acceleware, a small-cap company known for its work in heavy oil, this validation from a market leader could unlock a vast new frontier in critical minerals.

The Science of Greener Heat

At the heart of the initiative is Acceleware’s EM Powered Heat platform, a technology that uses radio frequency (RF) energy to heat materials from the inside out. Unlike conventional methods that burn fuel to generate external heat which is then transferred—an often inefficient process—Acceleware's system directly couples RF energy to the target material at a molecular level.

The company's proprietary Clean Tech Inverter (CTI) is the engine behind this process, converting electricity into RF energy with a reported 98% efficiency. This direct, targeted heating is claimed to use 40% to 60% less energy than legacy industrial heating methods. When powered by renewable electricity, the system can dramatically reduce or even eliminate direct greenhouse gas emissions, a critical goal for hard-to-abate sectors like mining.

While the technology is now being aimed at minerals, its roots are in the energy sector. Acceleware developed its patented RF XL technology to enhance heavy oil recovery, promising a method that required no fresh water and produced near-zero GHG emissions compared to traditional steam-based extraction. With a portfolio of 28 granted patents and a field-proven technology, the company is now leveraging that expertise to pivot towards the burgeoning critical minerals market.

"Both studies are new and exciting opportunities to demonstrate how our EM Powered Heat technology can transform minerals processing," said Geoff Clark, Acceleware's Chief Executive Officer, in a statement. "These innovations align with our strategy to deliver cost-efficient process heat solutions that increase production for the mining sector."

Targeting Two Critical Processes

The two feasibility studies target distinct but equally challenging areas of mineral processing. The first will tackle moisture in iron ore from Australia's Pilbara region, one of the world's most important sources of the mineral. Excess moisture in iron ore fines can cause caking and create significant processing plant delays. Traditional drying involves massive rotary dryers that consume vast amounts of energy to blow hot air over the ore. Acceleware's study will explore using RF energy to directly and efficiently drive out that moisture, potentially smoothing out production bottlenecks and slashing energy consumption.

The second study ventures into the world of copper production in Chile, focusing on a process known as heap leaching. This method, used to extract metals like copper, gold, and nickel from low-grade ores, involves trickling an acidic solution over a massive pile, or "heap," of crushed ore. While more cost-effective than smelting, its efficiency can be limited by ambient temperatures. Research suggests that gently heating the heap can significantly accelerate the chemical reactions and improve copper yields.

The global market for copper produced via heap leaching is estimated at a staggering US$41 billion annually, making even marginal improvements highly valuable. Acceleware will assess the viability of using its RF technology to elevate and maintain the heap's temperature, either by heating the ore directly, the leaching solution, or a combination of both. This could boost production without a corresponding increase in the environmental footprint.

A Strategic Play for a Sustainable Future

BHP's involvement is being driven by its 'Think & Act Differently' (TAD) program, a global innovation initiative designed to fast-track new technologies that enhance efficiency and sustainability. For a mining behemoth like BHP, which has already made public commitments to decarbonization by signing renewable power agreements for its copper mines, partnering with agile tech firms is a key strategy for future-proofing its operations.

The collaboration isn't entirely out of the blue. BHP is a member of the International Minerals Innovation Institute (IMII), a consortium with which Acceleware previously completed a successful project validating RF energy for drying potash. This prior success likely put Acceleware on BHP’s radar, demonstrating the technology's potential and paving the way for these more ambitious studies in iron and copper. By funding these feasibility studies, BHP is not just exploring a new tool; it is actively scouting and nurturing solutions that align with its long-term goals of reducing its carbon intensity and securing resilient supply chains for minerals essential to the global energy transition.

For Acceleware, this partnership represents a pivotal moment. The Calgary-based company has been navigating a strategic shift from a research-focused entity to a commercial enterprise, recently raising $1 million in a private placement to fund its growth. While its RF XL technology for heavy oil remains a core focus, the validation from BHP opens the door to a massive diversification opportunity. Success in these studies could establish EM heating as a go-to platform technology for decarbonizing a wide range of industrial processes, moving Acceleware from the fringes of the oil patch to the center of the clean-tech revolution in mining. As the world demands more minerals for electrification and renewable energy infrastructure, the pressure to produce them sustainably will only intensify, placing technologies like Acceleware’s directly in the spotlight.