Hmmm, I don't know where your getting your information but Freeport is definitely NOT losing money in Arizona and the ore grades are not declining. I work for them in Morenci so I know how much we make and what we mine.
And Grasberg is pretty much going to take two years to get back up to full production now that they are underground working a HUGE block cave operation.
Freeport officially lost 72 million dollars from its operations in the last 3 months, that number is probably much larger as all companies under report their losses. Next time they report that number is going to rise even more as the price of copper has fallen.
Grades at all mines decline over time. Average grade at all mines in around the year 2000 was 1.2%, today it is 0.55%. Copper grades at Morenci are at 0.17%, which is extremely low for a copper mine, currently the mine is processing ores with higher grades. The mine produces some Mo, so that helps a little. When large scale operations first started ores were 2%. And in 2005 around 0.6% for comparison.
A mine to be profitable needs to have ore grades of at least 0.3% to 0.4%. Depending on the location specific operating costs that number can vary. Freeports mines are all under 0.45%. Morrenci is at 0.17%+, Bagdad 0.32%, Sierrita 0.23%, Safford 0.45%, Miami is no longer producing. Grades at SA are not much better. That is not sustainable.
Grasberg was the cash cow, but now the government has taken its share. And as you have pointed out it is not going to ramp up production for at least 2 years.
Freeport has been bankrupt for some time now and they have been able to finance them-self and keep going trough debt. The company has 10 billion dollars of debt. They dont have the money to buy a new profitable mine and to develop one from scratch takes 10 years at least and anywhere from 2Bn to 10Bn dollars. For some time now it has been under consideration that some larger mining company take Freeport trough M&A. But no one wants to acquire them. Freeport operations aside from Grasberg are unprofitable or make very little money.