TELF AG analyzes the potential of copper scrap and its recovery processes

The importance of secondary supplies

In an era characterized by a great emphasis on the potential of recycling, even in the mining sector, it is not surprising that many nations and large players in the industry are continuing to promote concrete actions to recover a certain amount of resources from scrap, from devices that have reached the end of their life, or even from some specific waste products. The unpredictability of some global supply chains and the possible risks related to the shortage of supply almost always make it necessary to explore alternative ways to procure resources of great importance for the development of nations.

Among the best examples of this virtuous recovery, in addition to the well-known reuse of lithium from end-of-life batteries, is the one linked to the valorization of copper scrap. Over the years, this practice has made it possible to recover excellent quantities of this material, which is so important for electrification and other equally relevant purposes for industry.

Before exploring the application spaces and recovery processes, however, it seems appropriate to underline that copper scrap is generally divided into two large categories. The first includes high-quality scrap, which is used directly by producers of semi-finished products as a source of power in the supply of cathodes. The other type concerns lower-quality scrap, generally used in some specific processes within foundries and refineries. The main difference is that the former, unlike the latter, is used directly.

A partially untapped potential

According to the IEA, which discussed it in its latest report focused on critical minerals, there is a real possibility that secondary supplies could become an increasingly reliable source of copper, especially in periods characterized by sudden price increases or shocks in supplies. Despite representing a reliable source with great potential, the IEA report states that the use of copper scrap has registered a decline from 2015 onwards, going from 18% to 17% of the impact of this new source on the overall demand for copper. Among the factors that would explain this decline, according to the IEA, there would be the consequences of COVID-19, the increase in energy and shipping costs, and the relative slowness with which national governments are implementing the new international policies dedicated to recycling. In one of the scenarios hypothesized by the IEA, the potential linked to the use of copper scrap can be fully expressed thanks to the precise political will to increase collection rates and with a general optimization of sorting systems.

But how does the recovery of copper scrap take place? The first phase of the process is the collection of scrap (from electrical cables, electronic equipment, and so on), which is then transported to specific recycling plants for separation and classification. The scrap is shredded to facilitate the subsequent melting process, further separating the actual copper from any other possible residue. Finally, the molten copper is poured into unique ingots depending on the potential industrial applications it may require (among these, we remember the automotive, construction, energy sectors, and many others).