In the global copper resources recycling system, copper scrap recycling has accounted for more
than 35% of refined copper supply. Compared with primary smelting, recycled copper production
consumes 65% less energy, reduces carbon emissions by 85%, and the metal recovery rate can
reach 98.5%. In this paper, from the classification of raw materials, process routes, economic
model of three dimensions, in-depth deconstruction of copper scrap recycling technology
core and business logic.
Copper scrap resource classification and pretreatment standards
1. Raw material classification system
Class 1 copper scrap: bare copper (cables, pipes) with copper content > 99%, direct casting.
Class 2 copper scrap: alloy waste (brass, bronze) needs to be analyzed and sorted after composition analysis.
Class 3 copper scrap: copper-containing electronic waste (PCB boards, motors) with a copper content of 5-40%.
2. Intelligent pretreatment technology
Eddy current sorter realizes 95% separation efficiency between metal and non-metal
X-ray fluorescence spectrometer (XRF) detects the composition online.
Crushing system controls the particle size of materials at 10-50mm.
Recycled Copper Smelting Process Technology Matrix
1. Pyro-refining route
Process flow:
Scrap copper → reflector furnace smelting (1200℃) → oxidation and removal of impurities → insert tree reduction → anode plate casting
Technical parameters:
Natural gas consumption≤40m³/ton copper
Slag copper content＜0.5%
Purity of anode plate 99.0-99.5%.
2. Electrolytic refining enhanced program
Process upgrading:
Adopting permanent stainless steel cathode to replace the traditional starting pole piece
Electrolyte additives (gelatin + thiourea) to improve the density of cathode.
Current density increased to 300A/m², cycle time shortened to 12 days.
Output index:
Grade A copper purity ≥99.994
DC power consumption per ton of copper＜220kWh
Anode slime yield 0.2-0.5%.
3. Innovative application of hydrometallurgy
Ammonia leaching-extraction process:
Applicable to low-grade waste with copper content of 1-5%
Leaching rate of 92%, extractant recycling 2000 times
The purity of copper electrowinning reaches 99.95%.
Economic modeling analysis of recycled copper production
1. Investment return calculation
Construction period: 12-18 months
Gross profit of copper processing per ton: 2,800-3,500 RMB
Dynamic payback period: 3.2-4.5 years
Environmental Benefits and Carbon Emission Reduction Path
1. Pollution control technology
Dioxin prevention and control: Quench tower + activated carbon injection + bag filter three-stage purification
Wastewater recycling: Membrane separation technology realizes water reuse rate >90%.
Noise control: sound insulation of smelting workshop ≥35dB(A)
2. Carbon footprint management
Emission reduction of CO₂ 4.2 tons per ton of recycled copper
Waste heat boiler system recovers thermal energy of 3.6GJ/tonne
Photovoltaic energy storage covers 30% of the power demand in the plant.
Industry Technology Trends
1. Intelligent upgrading
Automatic sorting of copper scrap based on machine vision (recognition accuracy of 0.1mm)
Digital twin melting furnace realizes real-time optimization of process parameters
Blockchain traceability system to track the life cycle of raw materials
2. Low-carbon process breakthrough
Hydrogen reduction replaces coke for copper refining
Low-temperature molten salt electrolysis technology reduces energy consumption by 40 percent
Bioleaching treatment of e-waste
Industrial Value Orientation
Recycled copper industry has constructed a “city mine” resource system, freeing the copper industry from
absolute dependence on primary mines. Driven by technological upgrades, the production cost of recycled
copper is 18-25% lower than that of virgin copper, and the amount of tailings generated is reduced by 97%.
With the implementation of the global carbon tariff mechanism, the low-carbon attribute of recycled
copper is being transformed into a competitive advantage in international trade, driving the industry
to 20 million tons/year production capacity scale of high-speed development.