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The Life Cycle of Copper, Its Co-Products and By-Products

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The Life Cycle of Copper, Its Co-Products and By-Products Mining, Minerals and Sustainable Development January 2002 No. 24 The Life Cycle of Copper, its Co-Products and By-Products Robert U. Ayres, Leslie W. Ayres and Ingrid Råde This report was commissioned by the MMSD project of IIED. It remains the sole Copyright © 2002 IIED and WBCSD. All rights reserved responsibility of the author(s) and does not necessarily reflect the views of the Mining, Minerals and MMSD project, Assurance Group or Sponsors Group, or those of IIED or WBCSD. Sustainable Development is a project of the International Institute for Environment and Development (IIED). The project was made possible by the support of the World Business Council for Sustainable Development (WBCSD). IIED is a company limited by guarantee and incorporated in England. Reg No. 2188452. VAT Reg. No. GB 440 4948 50. Registered Charity No. 800066 THE LIFE CYCLE OF COPPER, ITS CO-PRODUCTS AND BYPRODUCTS Robert U. Ayres and Leslie W. Ayres Center for the Management of Environmental Resources INSEAD, Boulevard de Constance F-77305 Fontainebleau Cedex France and Ingrid Råde Physical Resource Theory Department School of Physics Chalmers University of Technology Gothenburg Sweden With contributions from Roland Geyer Julia Hansson Donald Rogich Johan Rootzén Benjamin Warr R. U. Ayres et al The life cycle of copper, its co-products and byproducts ii CHAPTER 1. INTRODUCTION ..............................................1 1.1. The life cycle perspective ...........................................1 1.2. Historical background ..............................................5 1.3. Geology of copper .................................................7 1.4. Geology of lead and zinc ..........................................10 CHAPTER 2. COPPER: SOURCES AND SUPPLY ..............................12 2.1. Physical properties and chemistry ...................................12 2.2. Copper production ...............................................13 2.3. Process technology ...............................................13 2.3.1. Mining .................................................14 2.3.2. Beneficiation ............................................15 2.3.3. Leaching ................................................17 2.3.4. Cementation and solvent extraction (SX) ......................17 2.3.5. Roasting, and smelting .....................................18 2.3.6. Converting: .............................................20 2.3.7. Electrowinning (EW) ......................................20 2.3.8. Fire refining and electrolytic refining .........................21 2.3.9. Future trends in primary processing ..........................21 2.4. Exergy and exergy flows ..........................................22 2.5. Sulfur recovery ..................................................24 2.6. Production-related wastes and emissions ..............................26 2.6.1. Mining wastes ...........................................26 2.6.2. Beneficiation wastes ......................................27 2.6.3. Leaching (acid) wastes .....................................28 2.6.4. Smelting wastes ..........................................28 2.6.5. Wastes from finishing operations ............................30 2.6.6. Recycling (secondary recovery) wastes ........................31 2.6.7. Toxic releases ...........................................31 2.6.8. Global estimates of airborne emissions ........................31 2.7. Optimal extraction/production ......................................32 CHAPTER 3. COPPER: DEMAND AND DISPOSITION .........................34 3.1. Consumption patterns and trends ....................................34 3.2. Accumulation of copper stocks in the anthroposphere ....................38 3.4. Dissipative uses and losses of copper .................................43 3.5. The future of demand for copper ....................................45 CHAPTER 4: LEAD, ZINC AND OTHER BY-PRODUCT METALS ................53 4.1. Context ........................................................53 4.2. Physical properties and chemistry of lead and zinc ......................53 4.3. Lead process technology ...........................................54 4.3.1. Ore mining and beneficiation ...............................55 4.3.2. Sintering ................................................55 4.3.3. Smelting ................................................55 4.3.4. Drossing and final refining .................................56 R. U. Ayres et al The life cycle of copper, its co-products and byproducts iii 4.3.5. Exergy and exergy flows ...................................56 4.4. Lead sources and uses .............................................56 4.5. Zinc processing ..................................................59 4.5.1. Ore mining and beneficiation ...............................59 4.5.2. Roasting and sintering .....................................59 4.5.3. Smelting ................................................59 4.5.4. Exergy and exergy flows ...................................60 4.5.5. Recycling old zinc scrap ...................................60 4.6. Zinc sources and uses .............................................60 4.7. Lead and zinc wastes and emissions ..................................63 4.8. Other by-product metals ...........................................66 4.8.1. Antimony ...............................................66 4.8.2. Arsenic .................................................66 4.8.3. Bismuth ................................................68 4.8.4. Cadmium ...............................................69 4.8.5. Germanium .............................................71 4.8.6. Gold ...................................................72 4.8.7. Indium .................................................72 4.8.8. Rhenium ................................................73 4.8.9. Selenium ...............................................73 4.8.10. Silver .................................................73 4.8.11. Sulfur .................................................74 4.8.12. Tellurium ..............................................77 4.8.13.Thallium ...............................................77 CHAPTER 5. THE FUTURE OF RECYCLING .................................78 5.1. Background .....................................................78 5.2. Recovery and recycling of copper from old scrap .......................80 5.3. Recovery and recycling of electronic scrap ............................83 5.4. Copper as a contaminant of recycled steel .............................85 5.5. Copper recycling wastes and emissions ...............................86 5.6. Recovery and recycling of lead .....................................86 5.7. Recovery and recycling of zinc .....................................87 5.8. Recovery and recycling of byproduct metals ...........................88 5.8.1. Antimony ...............................................88 5.8.2. Arsenic .................................................88 5.8.3. Cadmium ...............................................88 5.8.4. Germanium .............................................89 5.8.5. Gold ...................................................89 5.8.6. Indium .................................................89 5.8.7. Selenium ...............................................89 5.8.8. Silver ..................................................90 5.8.9. Tellurium ...............................................90 5.9. Further comments on losses and potential recoverability ..................90 CHAPTER 6. CONCLUSIONS AND QUESTIONS ..............................92 6.1. Introduction .....................................................92 6.2. Copper availability ...............................................92 R. U. Ayres et al The life cycle of copper, its co-products and byproducts iv 6.3. Copper demand: the coming electrification of the global energy system ......94 6.4. Lead, zinc and by-product metals availability and uses ...................94 6.5. Concentration, reduction and refining technology .......................95 6.6. Sulfur recovery and acidification ....................................95 6.7. Copper, lead and zinc recycling .....................................96 6.8. Emissions and accumulation of copper and zinc in agricultural soils - probably a non-problem ..................................................97 6.9. Accumulation of arsenic, cadmium and other toxic byproduct metals in the terrestrial environment..........................................98 6.10. The `toxic time bomb’ problem ....................................99 REFERENCES ..........................................................101 APPENDIX A: THE EXERGY CONCEPT....................................113 A1. Definition and description of exergy calculations ......................113 A2. Exergy as a tool for resource and waste accounting.....................115 A3. Composition of mixtures, including fuels.............................116 APPENDIX B: GLOBAL COPPER MODEL...................................119 B1. Introduction ....................................................119 B2. A model of the global copper system ................................119 B3. Calibration of the model..........................................121 B4. Copper consumption scenarios .....................................122 B5. Copper system scenarios ..........................................124 APPENDIX C: BACKGROUND DATA ......................................125 C1: Ore minerals and materials........................................125 C2: Glossary ......................................................126
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